LED Driver Installation in Junction Box Plenum Space
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Solution Overview
Problem
Conventional LED drivers for higher wattage luminaires are too large to fit in standard wiring junction boxes and generate excessive heat, which cannot be properly dissipated, leading to potential failure and safety hazards.
Innovation Solution
An LED driver design that allows partial insertion through a knockout hole of a wiring junction box and into a plenum space, providing additional space for wiring and better heat dissipation by locating the driver in a larger air space rather than a confined junction box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional LED drivers are designed for higher wattage luminaires, then the driver size increases to handle higher power, but the driver becomes too large to fit into standard wiring junction boxes
Solution Approach 1:
The patent transitions the driver installation from a two-dimensional constraint (fitting within the junction box footprint) to a three-dimensional solution (extending into the plenum space above the ceiling). The driver housing is designed to protrude through the ceiling into the plenum area, effectively utilizing vertical space to accommodate larger driver volumes while maintaining compatibility with standard junction box openings.
2Power
If larger LED drivers are used for higher wattage luminaires, then more power can be delivered, but heat dissipation becomes insufficient within the confined junction box space
Solution Approach 1:
The patent extracts the heat-generating LED driver component from the confined junction box environment and relocates it to the plenum space above the ceiling. This separation removes the thermal management problem from the limited junction box space, allowing the driver to access the much larger plenum volume for effective heat dissipation through convection and radiation.
3Ease of operation
If the LED driver is placed within the wiring box, then wiring connections are simplified, but space for wiring connections is reduced and heat dissipation is compromised
Solution Approach 1:
The patent divides the installation space into two functional zones: the junction box area for electrical wiring connections and the plenum space for housing the LED driver. This segmentation allows wiring connections to be made within the junction box while the driver extends into the plenum, effectively separating the wiring function from the power conversion and heat generation functions.
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 the use of larger LED drivers for higher wattage luminaires while ensuring effective heat dissipation, reducing the risk of failure and safety hazards by utilizing the plenum space for heat management.
Implementation Method 1
better dissipation of heat generated by the higher wattage LED drivers because the LED driver is located in a larger air space provided by a wall or ceiling plenum space rather than confined within the conventional wiring box
Data Source
AI summary
Drivers (10) for a luminaire (12) are disclosed. The driver (10) includes a housing (13) designed to be capable of being inserted at least partially through an opening (18) formed by removing a knockout tab (18a) in a junction box (17) and into a plenum space that is not part of the splice compartment of the junction box. A plurality of components (11) for driving the luminaire (12) are locatable within the housing (13). An electrical connection (14) is provided to electrically coupling the plurality of components (11) to the luminaire (12). A method of installation for the drivers (10) is also disclosed.