LED Retrofit Kit with Adjustable Mounting Bracket for Fixture Compatibility
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing LED retrofit kits for fluorescent light fixtures are often incompatible with various sizes and configurations, requiring labor-intensive and costly installations that pose safety hazards due to asbestos concerns and exposed electrical wiring, deterring businesses and consumers from adopting LED solutions.
Innovation Solution
A retrofit kit comprising a light engine with foldable convenience tabs and hooks, and a mounting bracket with adjustable flanges and channel-centering slots, allowing for easy installation by a single worker and compatibility with different light fixture dimensions, including temporary hanging, support, and fully-installed positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a LED retrofit kit is designed to be compatible with various light fixture sizes and configurations, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The mounting bracket is designed with adjustable flanges that can be positioned at different locations and angles, allowing a single bracket design to accommodate multiple light fixture sizes and configurations. This universal design eliminates the need for multiple specialized brackets for different fixture types.
Solution Approach 2:
The mounting bracket incorporates movable and adjustable components, including flanges that can be repositioned along the bracket body and angled to match different fixture orientations. This dynamic adjustability enables the same bracket to adapt to various installation scenarios without requiring multiple fixed-design brackets.
2Ease of operation
If the light engine includes foldable convenience tabs and hooks for easy installation, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The light engine is divided into functional segments including foldable convenience tabs and hooks that can be independently manipulated during installation. These segmented features allow the installer to engage different parts of the mounting bracket in sequence, simplifying the installation process while adding minimal structural complexity.
Solution Approach 2:
The convenience tabs and hooks act as intermediary elements between the light engine and the mounting bracket. These features facilitate the connection process by providing dedicated engagement points that guide the installer through the mounting procedure, reducing the complexity of directly attaching the light engine to the bracket.
3Use of energy by moving object
If traditional fluorescent fixtures are replaced with LED fixtures requiring ceiling access, then the illumination efficiency is improved, but the safety hazards increase due to asbestos and exposed electrical wiring
Solution Approach 1:
The light engine is extracted as a separate, self-contained unit that can be installed within the existing fixture housing without requiring removal of the fixture from the ceiling. This extraction eliminates the need to access the ceiling cavity, thereby avoiding exposure to asbestos and hidden electrical wiring while still enabling the transition to LED technology.
Solution Approach 2:
The mounting bracket and light engine are designed to be pre-assembled or pre-configured within the fixture housing before ceiling installation. This preliminary preparation ensures that all electrical connections and mounting components are secured before the fixture is suspended from the ceiling, eliminating the need for workers to access hazardous ceiling areas during installation.
4Productivity
If a single worker can install the retrofit kit, then the labor requirements are reduced, but the installation stability decreases
Solution Approach 1:
The mounting bracket incorporates self-aligning and self-locking features that automatically guide and secure the light engine during installation by a single worker. The foldable convenience tabs and hooks are designed to engage with the bracket in a self-evident manner, providing inherent stability and correctness without requiring a second person to assist with alignment or verification.
Data Source
AI summary
A retrofit kit for a light fixture includes a light engine and a mounting bracket. In some aspects, a method of installing the retrofit kit in a light fixture includes installing a mounting bracket in a housing of the light fixture, and placing a light engine in a temporary hanging position. In the temporary hanging position, a hook of a first engine flange of the light engine rests on the mounting bracket and a second engine flange of the light engine opposite from the first engine flange is spaced apart from the mounting bracket.