LED Conversion Panel with Hinge for Troffer Retrofit

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Solution Overview

Problem

Existing ceiling/overhead lighting fixtures configured for fluorescent bulbs are expensive and labor-intensive to modify for LED installations, and the conversion process often results in an aesthetically unpleasing outcome.

Innovation Solution

A system involving a mounting panel with hinge connection is used to cover the original components of the fluorescent fixture, allowing LED light strips and a power supply to be mounted on the panel, which obscures the ballast unit and bulb receptacles, maintaining the fixture's appearance while enabling easy access and installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If existing fluorescent fixtures are replaced with new LED fixtures, then lighting efficiency and energy savings are improved, but installation cost and labor requirements increase significantly

Engineering Contradiction:

Improveenergy efficiencyVSAvoidinstallation cost

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The LED conversion kit is designed to be universally compatible with standard fluorescent fixtures, allowing the same LED module to replace multiple different fluorescent bulb types (T8, T12, etc.). This multi-functionality eliminates the need for custom fixtures and reduces installation costs while maintaining energy efficiency improvements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The LED conversion kit is nested within the existing fluorescent fixture housing. The LED module, driver, and mounting components are contained within the original fixture boundaries, allowing the conversion to occur without replacing the entire fixture assembly. This nesting approach significantly reduces installation cost while achieving energy savings.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If components are removed from the fluorescent fixture during conversion, then LED installation is enabled, but aesthetic appearance deteriorates

Engineering Contradiction:

Improveconversion capabilityVSAvoidaesthetic appearance

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

Instead of removing components from the fixture to install LEDs, the approach is inverted: a complete LED conversion kit is installed within the existing fixture boundaries, and the original fluorescent components (ballast, reflectors, bulbs) are left in place but electrically isolated. This preserves the fixture's original appearance while enabling LED functionality.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The LED conversion kit acts as an intermediary system that mediates between the existing fluorescent fixture infrastructure and the desired LED lighting function. The kit includes its own mounting brackets, electrical connections, and housing that interface with the original fixture components without requiring their removal, thus maintaining aesthetic appearance while achieving conversion capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If traditional conversion methods are used, then LED functionality is achieved, but maintenance accessibility and customization options are reduced

Engineering Contradiction:

ImproveLED functionalityVSAvoidmaintenance accessibility

Core Design Contradiction:

Adaptability or versatilityVSEase of repair

Solution Approach 1:

The LED conversion kit is segmented into modular components: the LED light module, the driver power supply, and the mounting bracket system. This segmentation allows individual components to be accessed, removed, or replaced independently through the fixture opening, significantly improving maintenance accessibility compared to traditional enclosed conversions while maintaining full LED functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting bracket system incorporates dynamic adjustment capabilities, allowing the LED module to be positioned at different angles and depths within the fixture. This dynamic mounting approach enables both optimal lighting performance and easy access for maintenance, while also allowing customization of the lighting configuration to suit different application requirements.

Inventive Principle:

Principle #15Dynamics

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

This method allows for cost-effective and labor-efficient conversion of fluorescent fixtures to LED fixtures with minimal aesthetic impact, providing easy maintenance and customization options, and enabling dimming control.

Implementation Method 1

LED light strips are mounted on the panel that faces away from the troffer

Methodology Applied

Scientific EffectLight emitting diode: Light Emitting Diode

Implementation Method 2

A new panel is then mounted over the face of the troffer with a hinge connection

Methodology Applied

Scientific EffectHinge: Hinge

Data Source

PatentUS10288240B2System and method for covering a fluorescent ceiling fixture with a matrix of LED lights

Publication Date: 2019.05.14 HMIP LLC

AI summary

A system and method of converting a light fixture from a conventional light fixture to an LED light fixture. Originally, the light fixture has a troffer, a ballast unit, and bulb receptacles. The conversion is accomplished by mounting a panel over the face of the troffer that obscures the ballast unit and bulb receptacles. LED light strips are mounted to the panel. Likewise, an LED power supply is mounted to the panel. The panel is attached to the troffer with a hinge connection. In this manner, the panel can be rotated away from the troffer for easy access.