Single-Housing Recessed Lighting with Adjustable Brackets
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Solution Overview
Problem
Conventional recessed lighting systems require two separate housings, leading to size and cost issues, as well as limited adjustability, restricting installation locations and increasing installation complexity and cost.
Innovation Solution
A single-housing recessed lighting system with a housing assembly that includes adjustable brackets and a length-adjustable hanger bar, allowing for vertical and lateral adjustment, and a fire-rated housing with a removable access door, integrating the light emitting module, driver circuitry, and trim assembly within a single unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two separate housings (can and driver housing) are used in conventional recessed lighting systems, then the driver circuitry can be contained separately, but the system size increases and installability is restricted to larger, more open portions of the ceiling or wall
Solution Approach 1:
The patent combines the can housing and driver housing into a single integrated housing structure. The driver circuitry is mounted directly on the interior surface of the housing, eliminating the need for a separate driver housing. This merging reduces the overall system size and enables installation in locations with limited space and accessibility.
Solution Approach 2:
The single housing serves multiple functions: it contains the light source module, houses the driver circuitry, and provides structural support for the trim assembly. This multi-functionality eliminates the need for separate housings and reduces installation complexity.
2Ease of manufacture
If two separate housings are used, then the driver can be contained separately, but the complexity and cost of hardware and installation labor increase
Solution Approach 1:
By merging the can and driver housing into a single unit, the patent reduces the number of components that need to be manufactured, shipped, and assembled. This simplification reduces both hardware costs and installation labor costs.
Solution Approach 2:
While the housing is integrated, the patent maintains segmentation of functional modules (light source module, driver circuitry, trim assembly) that can be independently manufactured and then assembled into the single housing. This modular approach within a unified structure balances manufacturing efficiency with functional separation.
3Adaptability or versatility
If two separate housings are used, then the driver circuitry is contained, but adjustability is lost and installation locations are restricted
Solution Approach 1:
The patent incorporates adjustable brackets that allow the housing to be positioned at different angles and orientations. The trim assembly can also be adjusted to direct light in various directions. This dynamic adjustability enables installation in diverse locations and configurations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible installation in various ceiling or wall configurations, reduces hardware and labor costs, and improves illumination efficiency by allowing for better alignment and reduced packaging complexity.
Implementation Method 1
The light emitting module includes a light source mounted at a center of the circuit board
Implementation Method 2
The trim assembly includes a reflector
Data Source
AI summary
Recessed lighting systems are provided including a housing defining an interior cavity, a light emitting module positioned inside the interior cavity and including a heat sink, a circuit board stacked on the heat sink, a light source mounted at a center of the circuit board, driver circuitry for powering the light source, and a cover stacked on the circuit board including a channel for enclosing the driver circuitry and an opening defined such that the light source is not covered by the cover, and a trim assembly installed in the housing including a reflector, a trim having a light guide portion and a decorative trim extending from the light guide portion, and a plurality of interface elements extending from an exterior surface of the reflector or an exterior surface of the light guide portion, the interface elements configured to retain the trim assembly in the housing.