Telescoping Bracket for Junction Box in Retrofit Applications
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Solution Overview
Problem
Retrofitting lighting in existing buildings is challenging due to inaccessible joist cavities, and installing low-voltage lighting requires a transformer that must be hidden within the joist cavity while adhering to building codes, which can be difficult to achieve without compromising the ceiling panel.
Innovation Solution
A method and bracket system that allows for inserting a telescoping bracket between ceiling joists, wedging it in place for frictional support, and attaching a junction box to suspend it above the ceiling panel, enabling the installation of a luminaire without the junction box resting on the panel, and providing a mount for the junction box to ensure secure and code-compliant installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a transformer is laid on top of the ceiling panel in the joist cavity, then the installation is simple and expeditious, but building codes prohibit such installation and require the transformer not to touch the ceiling panel
Solution Approach 1:
The patent introduces a bracket as an intermediary component between the transformer and the ceiling panel. The bracket extends through the ceiling panel opening and is secured to the joists above, providing a mounting structure that holds the transformer in suspended position without direct contact with the ceiling panel, thus satisfying building code requirements while maintaining installation simplicity
Solution Approach 2:
The mounting system is segmented into distinct components: the ceiling panel opening, the bracket (which includes a mounting portion and a suspension portion), and the transformer. This segmentation allows each component to perform its specific function - the bracket separates the transformer from the ceiling panel while providing structural support through the joists
2Shape
If the joist cavity is covered by a ceiling panel, then the finished ceiling appearance is achieved, but access to the joist cavity is blocked making retrofit lighting installation difficult
Solution Approach 1:
The patent employs preliminary action by providing a bracket that is inserted and secured to the joists through the ceiling panel opening before the transformer is mounted. This preliminary installation of the bracket maintains the finished ceiling appearance while pre-establishing access and mounting capability for the transformer and associated lighting components
3Ease of manufacture
If the junction box is attached to rest on the ceiling panel, then the installation is simple, but building codes require the junction box to be suspended above the ceiling panel
Solution Approach 1:
The bracket serves as an intermediary mounting structure that suspends the junction box above the ceiling panel. The bracket extends through the ceiling panel opening and is secured to the joists, providing a support structure that holds the junction box in suspended position without direct contact with the ceiling panel, satisfying building code requirements while maintaining installation simplicity
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
Facilitates the installation of lighting fixtures in retrofit and new construction scenarios by providing a secure, friction-supported bracket system that maintains a clean finished look while adhering to building codes, allowing for efficient and accessible low-voltage lighting installations.
Implementation Method 1
The method further comprises wedging the bracket between the two joists at a height above the ceiling panel such that the bracket is supported above the ceiling panel by friction or interference between the ends of the bracket and the ceiling joists
Data Source
AI summary
A bracket facilitates retrofit installation of items in a joist cavity. For example, the bracket permits mounting of a junction box containing a transformer, for use with low-voltage luminaire. The bracket wedges between the joists and provides a mounting for the junction box so that the junction box does not rest on a ceiling panel fixed to the underside of the joist cavity.