Plug-Together LED Modules With Spring-Biased Mounting
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Solution Overview
Problem
Existing LED light fixtures lack flexible positioning and orientation of individual LED modules, limiting their adaptability and ease of maintenance, as well as efficient heat transfer and electrical connectivity.
Innovation Solution
The design features LED modules mounted on a power system extrusion with opposing channels and a spring-biased mounting bracket for improved heat transfer, along with a plug-in mechanism for modules and connectors that facilitate flexible orientation and easy assembly/disassembly, enabling flexible positioning and orientation of LED modules and efficient electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If LED modules are fixed in position on the extrusion, then structural simplicity is maintained, but flexible positioning and orientation capability is lost
Solution Approach 1:
The lighting system is divided into modular LED modules that can be independently positioned and oriented on the extrusion. Each module is a self-contained unit that can be separately mounted, adjusted, and replaced, enabling flexible positioning without requiring complex integrated mounting systems.
Solution Approach 2:
The mounting mechanism incorporates adjustable and reconfigurable elements that allow LED modules to be dynamically repositioned along the extrusion and oriented in different directions. The system transitions from static fixed mounting to dynamic adjustable mounting, enabling flexible positioning while maintaining operational simplicity.
2Ease of operation
If modular plug-in components are used, then ease of assembly and maintenance is improved, but connection reliability may deteriorate
Solution Approach 1:
The electrical connector employs a nested design where the contact elements are housed within protective receptacles. The male connector inserts into the female connector with precise alignment features, creating a reliable nested connection that is both easy to assemble and maintain while ensuring consistent electrical contact and connection reliability.
Solution Approach 2:
The connector design incorporates self-aligning and self-latching features that automatically ensure proper connection when modules are plugged together. The mechanism performs its own alignment and securing functions without requiring additional tools or complex procedures, maintaining both ease of operation and connection reliability.
3Temperature
If spring-biased mounting brackets are used for heat transfer, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The spring-biased mounting bracket employs a self-regulating mechanism where the spring automatically applies optimal pressure to maintain thermal contact between the LED module and the extrusion. The spring compensates for thermal expansion, vibration, and assembly variations, ensuring consistent heat transfer efficiency without requiring complex control systems or adjustment mechanisms.
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 solution allows for flexible positioning and orientation of LED modules, enhances heat transfer, and simplifies electrical connections, reducing labor costs and improving reliability by eliminating the need for frequent disconnection and reconnection of wires during assembly and maintenance.
Implementation Method 1
attached to a spring biased mounting bracket which presses a surface of the driver module against an interior floor of the power system extrusion so as to improve heat transfer between the driver and the extrusion
Data Source
AI summary
An LED light fixture having adjacent interconnected light fixture modules, each comprising a power system extrusion, an LED light module body attachable to the power system extrusion, female and male end caps at opposite ends of each extrusion and respectively including a female electrical connector and a male electrical connector, a male electrical connector being configured to plug into the female electrical connector of an adjacent extrusion, and a power box component having a female electrical connector configured to plug into a male electrical connector of a male end cap.