LED Lamp with Snap-Fit End Caps for Fluorescent Retrofit
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Solution Overview
Problem
The conversion from traditional fluorescent lighting to LED-based solid-state lighting systems is time-consuming and expensive, requiring the replacement of entire fixtures, and existing solutions do not easily integrate with existing infrastructure.
Innovation Solution
An LED lamp design that fits into standard fluorescent housings, using existing tombstone connectors to provide power, allowing for quick and easy conversion by replacing the fluorescent bulb with an LED lamp that includes an elongated optically transmissive enclosure with a support structure and snap-fit end caps for secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional fluorescent lighting systems are replaced with LED systems, then energy efficiency and durability are improved, but installation time and cost increase due to requiring complete fixture replacement
Solution Approach 1:
The LED lighting system is segmented into modular components: an LED module containing LEDs mounted on a circuit board, an enclosure housing the LED module, and end caps with electrical connectors. This modular design allows the LED lamp to be installed as a replaceable unit within existing fluorescent fixtures without replacing the entire fixture, thereby reducing installation time while maintaining energy efficiency benefits.
Solution Approach 2:
The LED lamp is designed with universal compatibility features including end caps with electrical connectors that interface with standard fluorescent fixture sockets, and an elongated enclosure that fits within existing fixture dimensions. This multi-functionality enables the LED lamp to replace fluorescent bulbs in various fixture types without requiring custom installation procedures, reducing both installation time and cost.
2Use of energy by moving object
If traditional fluorescent lighting systems are replaced with LED systems, then energy efficiency is improved, but installation complexity and cost increase due to requiring specialized tools and training
Solution Approach 1:
The LED lamp incorporates self-aligning and self-securing features: the end caps with electrical connectors automatically align with the fixture socket during insertion, and the enclosure includes mounting structures that secure the lamp in place without requiring additional fasteners or tools. This self-service design enables ordinary users to install the LED lamp without specialized training, maintaining energy efficiency while improving installation ease.
3Device complexity
If LED modules are secured within the enclosure using adhesive, then structural simplicity is improved, but thermal management capability deteriorates due to adhesive blocking heat dissipation
Solution Approach 1:
The enclosure is designed with differentiated local properties: the interior surface includes dedicated adhesive areas for securing the LED module, while other areas maintain thermal conductivity for heat dissipation. This local quality differentiation allows the adhesive to provide structural bonding without completely blocking thermal pathways, balancing structural simplicity with thermal management capability.
Solution Approach 2:
The enclosure utilizes composite material construction combining materials with different thermal and adhesive properties in specific regions. This allows certain areas to be optimized for bonding (adhesive-friendly) while other areas are optimized for heat transfer (thermally conductive), resolving the contradiction between structural simplicity and thermal management.
4Illumination intensity
If the enclosure is made completely optically transmissive, then light output is improved, but structural strength deteriorates
Solution Approach 1:
The enclosure is designed with differentiated optical properties in different regions: the portions of the enclosure that face outward and are intended to transmit light are made optically transmissive, while the portions that provide structural support and connection points (such as the ends and mounting areas) are made opaque or semi-transparent. This local quality differentiation maintains structural strength while maximizing light output through the necessary areas.
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 a seamless transition from fluorescent to LED lighting without specialized tools or training, maintaining similar light distribution patterns and energy efficiency while reducing installation time and costs.
Implementation Method 1
At least one LED is in the enclosure operable to emit light through the enclosure when energized through an electrical path
Implementation Method 2
The tang may comprise an angled camming surface that deforms the enclosure when the enclosure is inserted into the end cap
Data Source
AI summary
An LED lamp includes an elongated at least partially optically transmissive enclosure. The LEDs are mounted on an LED board. The enclosure has a support structure for supporting the LED board. The support structure is formed as one-piece with the enclosure and of an optical material. A pair of end caps are secured to the ends of the enclosure using a snap-fit connection. The end caps retain pins for connecting to a light fixture.