Removable Illuminated Sign Insert with Integrated Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing illuminated signs face challenges in installation complexity, sagging issues due to weight, and the need for separate component replacement, leading to increased costs and reduced visibility.
Innovation Solution
A removable sign insert and mounting device system that simplifies installation by covering junction box components, using a canopy element to secure the sign to the wall or ceiling, and allows for separate housing of inner components, enhancing visibility and reducing installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complicated hanging structure with multiple parts is installed over the junction box to secure the sign, then the sign can be mounted securely, but the installation becomes difficult and time-consuming
Solution Approach 1:
The mounting device combines multiple functions (structural support, electrical connection, and junction box cover) into a single integrated unit. The housing frame integrates the mounting structure with the sign housing, eliminating the need for separate hanging components while maintaining secure attachment to the junction box
Solution Approach 2:
The mounting device is designed to perform multiple functions simultaneously: it provides mechanical support for the sign, establishes electrical connections through integrated wiring access, and covers the junction box for safety. This multi-functional design reduces the number of separate components needed
2Strength
If metal is used to make exit signs, then the signs are durable, but they become relatively heavy and tend to sag or pull from the ceiling or wall
Solution Approach 1:
The sign construction uses composite materials combining metal housing frame for structural strength with plastic or polymer components for the sign face and internal structures. This composite approach maintains durability while reducing overall weight compared to solid metal construction
Solution Approach 2:
The sign is divided into separate components: a metal housing frame for structural support, plastic cover plates for the sign face, and removable internal components. This segmentation allows the heavy metal frame to be minimized while maintaining overall strength through distributed structural elements
3Reliability
If the inner components are mounted directly to the housing frame, then the sign functions properly, but the entire sign must be replaced when components fail, increasing costs
Solution Approach 1:
The sign is segmented into a permanent housing frame and removable internal components. The housing frame remains installed while internal components (light sources, electronics, battery) can be independently removed and replaced, facilitating easier maintenance and repair
Solution Approach 2:
Internal components are extracted from direct permanent mounting to the housing frame and instead are mounted to removable panels or brackets. This allows components to be taken out and replaced without removing the entire sign from the ceiling or wall
4Reliability
If pipe fittings are used to bias the sign toward the ceiling or wall, then the junction box is covered, but the pipe fittings cast shadows that negatively impact visibility
Solution Approach 1:
The mounting structure is extracted from traditional pipe fittings that cast shadows and instead uses a canopy-style housing frame that covers the junction box from the front. This eliminates shadow-casting elements while maintaining coverage functionality
Solution Approach 2:
The housing frame acts as an intermediary structure that covers the junction box without creating shadow-casting protrusions. The design uses recessed mounting and smooth surfaces that do not interfere with light transmission to the sign legend
Data Source
AI summary
There is provided a sign insert that can house the inner components of a sign. The insert can be easily inserted into and removed from signs so that either of the sign housing or the sign insert with inner components can be salvaged and reused if the other becomes inoperable.