Luminaire Driver Extraction in Hinge for Thermal and Sealing
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Solution Overview
Problem
Existing LED luminaires face challenges with water ingress due to hinge movement, heat management, and installation complexity, particularly when using shared or integrated driver units, which can lead to increased size, weight, and aesthetic issues, as well as safety concerns during installation.
Innovation Solution
A waterproof and thermally separated driver unit housed within a hollow hinge, combined with a rotatable bayonet-type connector and secondary mounting system, allowing for independent sealing and cooling of the LED panel and driver unit, and enabling easier installation without relying on cable support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a shared driver unit is used to power multiple LED light panels, then wiring complexity is reduced and low-voltage safety is improved, but the likelihood of human error increases due to dual wiring systems
Solution Approach 1:
The driver unit is extracted from the LED light panel and placed in a separate location, eliminating the need for dual wiring systems within the luminaire. This allows mains wiring to be separate from low-voltage LED wiring, reducing confusion and human error during installation and maintenance.
2Ease of operation
If a dedicated driver unit is provided for each LED light panel, then installation is simplified with only mains wiring present, but the size and weight of the luminaire increases
Solution Approach 1:
The driver unit is extracted from the LED light panel and mounted separately on the support structure. This maintains installation simplicity with only mains wiring needed at the luminaire, while eliminating the weight and size penalty of integrating the driver into each light panel.
Solution Approach 2:
The luminaire system is segmented into separate functional components: the LED light panel and the driver unit. This allows each component to be optimized independently - the light panel remains compact and lightweight, while the driver unit is positioned where it does not contribute to the luminaire's hanging weight.
3Device complexity
If the driver unit is co-located with the LED light panel, then integration is improved, but cooling considerations are complicated due to heat generation from both components
Solution Approach 1:
The driver unit is extracted from the LED light panel and positioned in a separate location with its own thermal management. This eliminates the need to design complex cooling solutions that must handle heat from both the driver and LEDs in a confined space, while still maintaining electrical integration through the hinge connection.
4Adaptability or versatility
If the hinge is designed to allow relative movement between LED panel and driver housing, then adjustability is improved, but sealing becomes difficult and water ingress risk increases
Solution Approach 1:
The driver unit is extracted to a separate housing that is not rigidly connected to the LED panel housing. The hinge connects the two housings but allows the driver housing to be positioned independently, maintaining water sealing integrity while preserving adjustability of the LED panel relative to the mount.
5Shape
If the luminaire is designed for second fix installation with cable entry through the mount, then cable concealment is improved, but the installer must support the luminaire with one hand during installation
Solution Approach 1:
The driver unit is extracted and mounted separately on the support structure before the LED light panel is installed. This allows the installer to secure the main weight of the luminaire to the mount with one hand, while the second hand is free to manipulate cables and complete the connection, maintaining the aesthetic cable routing through the mount.
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 configuration enhances water resistance, thermal management, and installation ease by providing a compact, aesthetically pleasing luminaire with improved cooling and reduced risk of water ingress, while allowing for hands-free installation and reduced cable visibility.
Implementation Method 1
a hinge providing a rotatable connection between the mount and the luminaire
Implementation Method 2
a light panel, comprising one or more LEDs
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
An LED luminaire (10) comprising: a main body portion (12) adapted, in use, to house an LED light panel (24); a mount (14) for securing, in use, the luminaire (10) to a surface; a driver unit (62); and a hinge (16, 42, 44) adapted to hingedly connect the main body portion (12) to the mount (14), wherein the hinge (16, 42, 44) comprises a, hollow interior volume for accommodating the driver unit (62), and wherein the driver unit (62) comprises a water-resistant housing.