LED Troffer Door Assembly with Adjustable Hinges
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Solution Overview
Problem
The current method of retrofitting troffer light fixtures to replace fluorescent lamps with LED light bars is time-consuming and expensive, requiring the removal of non-essential electrical components and hardware for installation.
Innovation Solution
A troffer door assembly with a peripheral frame that functions as a heat sink, allowing direct affixation of LED light bars and adjustable hinge and latch members for alignment with existing slots, enabling retrofitting without removing internal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the current retrofitting method is used (removing non-essential electrical components and hardware), then LED light bars can be installed in troffer fixtures, but the retrofitting process becomes time-consuming and expensive
Solution Approach 1:
The invention divides the retrofitted fixture into separate functional modules: the existing troffer housing with its electrical components remains in place, while a new door assembly containing the LED light bar is installed as a separate unit. This segmentation allows the LED module to be pre-assembled and pre-tested, then quickly installed in the existing fixture without disrupting the original electrical system, thereby reducing retrofitting time and complexity
Solution Approach 2:
The door assembly acts as an intermediary component that bridges the existing troffer housing and the new LED light bar. Instead of directly installing the LED bar into the housing (which would require removing existing components), the door assembly serves as a mediator that holds the LED bar and interfaces with the existing fixture structure, simplifying the retrofitting process
2Strength
If LED light bars are directly affixed to the peripheral frame, then structural integrity is increased and heat removal is improved, but the frame must be designed to serve multiple functions
Solution Approach 1:
The peripheral frame is designed as a multi-functional component that simultaneously serves as the structural support for the door assembly, the heat sink for the LED light bar, and the mounting surface for the LED module. By integrating these multiple functions into a single frame structure, the invention increases structural integrity while avoiding the need for separate support structures, heat sinks, and mounting brackets, thereby managing device complexity through functional integration
3Ease of operation
If hinge and latch members are made adjustable along the frame, then alignment with existing slots is facilitated, but the frame structure becomes more complex
Solution Approach 1:
The hinge and latch members are designed with adjustable positions along the peripheral frame, allowing them to be dynamically repositioned to align with existing slots in the troffer housing during installation. This dynamic adjustability simplifies the alignment process and facilitates easier operation during retrofitting, while the adjustment mechanism is integrated into the frame design to minimize additional complexity
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 reduces the retrofitting time and cost by allowing LED light bars to be directly affixed to the peripheral frame, providing increased structural integrity and improved heat removal, enabling efficient conversion of troffer light fixtures to LED fixtures without removing non-essential components.
Implementation Method 1
the peripheral frame thereby functions as a heat sink in addition to the light bar support structure
Implementation Method 2
the support structure for the LED system is usually constructed to function as a heat sink and/or heat radiating member such that heat is conducted away from the LED system
Data Source
AI summary
A troffer door assembly has a frame assembly, a lens member and a light emitting diode (LED) assembly. The rigid brace member is affixed to the frame assembly such that the rigidity of the frame assembly is increased. Hinge members and latch members are positioned in exterior slots on the frame assembly such that the location of the hinge members and latch members can be adjusted. In this manner installed troffer light fixtures can be retrofitted by replacing the installed troffer door with the troffer door assembly as described.