Continuous-Run Light Panel Interlocks for Fast Fixture Joining
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Solution Overview
Problem
Existing LED lighting fixtures require complex and labor-intensive processes to form a continuous run, involving substantial disassembly and complicated mechanical and electrical connections, which is time-consuming and prone to damage components.
Innovation Solution
A lighting system with elongated light panels featuring integrated power connectors and end plates that allow for easy mechanical and electrical interconnection without disassembly, using interlocking end plates and fastening bars to secure the connection, and allowing for shared power and dimming control signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional LED lighting fixtures are connected end-to-end to form a continuous run, then a linear lighting solution is achieved, but the installation process becomes complicated and labor intensive requiring substantial disassembly
Solution Approach 1:
The lighting system is divided into modular linear fixtures that can be independently installed and then quickly connected through simple mechanical interfaces. Each fixture contains integrated electrical connectors that are pre-assembled, allowing the system to be segmented into manageable units without requiring disassembly during installation.
Solution Approach 2:
The patent combines mechanical support structure and electrical connection components into a single integrated assembly. The mechanical interface and electrical connectors are merged so that a single mechanical connection action simultaneously establishes both structural support and electrical continuity, eliminating the need for separate connection steps.
2Ease of manufacture
If end caps are removed and lenses are detached to connect fixtures, then electrical connectors become accessible, but the risk of component damage increases and installation time increases
Solution Approach 1:
The electrical connectors are pre-positioned and pre-assembled within the fixture housing during manufacturing. Access holes are pre-cut and positioned optimally to allow connector engagement without requiring any disassembly of protective components. This preliminary preparation eliminates the need for runtime disassembly and reduces the risk of damaging sensitive components.
3Adaptability or versatility
If multiple screws are loosened and re-tightened to access electrical connectors, then electrical connection is possible, but the installation process becomes time consuming
Solution Approach 1:
The electrical connectors are extracted from deep within the fixture and brought to accessible locations through strategically positioned access holes in the end caps. This extraction allows connectors to be engaged from the exterior without requiring the loosening or removal of multiple fastening screws, dramatically reducing installation time while maintaining connection reliability.
4Loss of time
If fixtures are designed with integrated power connectors and interlocking end plates, then installation is simplified, but the fixture design becomes more complex
Solution Approach 1:
The end plate design incorporates multiple functions: it provides mechanical support, enables interlocking between fixtures for structural stability, positions electrical connectors for automatic alignment, and includes access holes for connector engagement. This multi-functionality consolidates several components into one, reducing installation steps without proportionally increasing overall system complexity.
Data Source
AI summary
A continuous run lighting system includes first and second light panels each including first and second power connectors proximate their first and second ends. A first end plate closes the second end of the first light panel, and a second end plate closes a first end of the second light panel. A power connector near the first end of the second light panel can engage the power connector near the second end of the first light panel. The first and second end plates can be mechanically interlocked as by sliding a projecting screw head with a keyhole without disassembling either light panel. A narrowed channel of the keyhole has a ramped surface for engaging the screwhead, urging the first and second end plates toward each other. A fastener selectively slides within channels formed in the first and second light panels for spanning the adjoining ends thereof.