Integrated Lighting Module Driver Housing
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Solution Overview
Problem
Traditional recessed lighting systems are bulky and difficult to adjust due to separate mounting of drivers and light source modules, requiring additional hardware and complicating installation and maintenance.
Innovation Solution
A compact recessed lighting system with a unified casting housing both the light source module and driver, allowing for adjustment and installation within a standard junction box without a separate 'can' housing, using a junction box with moveable hangar holders and bars for positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If drivers and light source modules are mounted separately in traditional recessed lighting systems, then each component can be independently designed and manufactured, but the overall system becomes bulky and difficult to adjust, requiring additional mounting hardware and complicating installation and maintenance
Solution Approach 1:
The patent combines the driver and light source module into a single integrated housing unit. The driver is mounted directly within the same housing that contains the light source module, eliminating the need for separate mounting structures, additional hardware, and complex assembly procedures while maintaining independent design and manufacturing capabilities for each component
2Reliability
If separate mounting structures and additional hardware are used for drivers and light source modules, then components can be securely mounted, but installation and maintenance become more difficult and time-consuming
Solution Approach 1:
By integrating the driver and light source module into a single housing unit, the patent reduces the number of separate mounting operations required. The unified structure maintains secure mounting through a single integrated mounting interface, thereby simplifying installation and maintenance procedures while ensuring reliable component attachment
3Device complexity
If a unified housing integrates both driver and light source module, then system bulk is reduced and installation is simplified, but heat dissipation challenges may increase due to closer proximity of components
Solution Approach 1:
The patent applies different thermal management strategies to different regions within the housing. The housing structure incorporates localized heat dissipation features such as vents or heat sinks positioned specifically near the driver component, while maintaining the integrated structure. This allows effective heat management in critical areas without compromising the overall integration benefits
4Ease of manufacture
If integrated housing is used for driver and light source module, then costs are lowered and serviceability is enhanced, but compliance with building codes and regulations may become more challenging
Solution Approach 1:
The patent designs the integrated housing with universal mounting features and standardized dimensions that can adapt to various building code requirements and installation environments. The housing structure incorporates adjustable elements and compliant material selections that allow it to meet different regulatory standards while maintaining the cost benefits of integration
Data Source
AI summary
An integrated lighting module comprises a light emitting diode element, a driver, and a driver housing having first side walls and a first top that caps the first side walls to receive the driver. A heat sink module having an upper portion and a lower portion is configured for receiving the light emitting diode element and for transferring heat away from the light emitting diode element. An optical reflector is substantially conical in shape for reflecting and directing at least some light from the light emitting diode element. The light emitting diode element is disposed above a top-hole of the optical reflector. A holder is detachably coupled to the heat sink module to hold the at least one optical reflector.