Modular LED Lighting Fixture with Plastic Housing

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Solution Overview

Problem

Existing lighting fixtures made of metal face challenges in creating complex shapes, increasing manufacturing costs and weight, and interfere with wireless communication signals, while incorporating sensors disrupts the aesthetic appearance and requires additional parts.

Innovation Solution

A modular lighting fixture with an elongate center support member, reflector panels, and light guides, formed through extrusion or molding processes, allowing for quick assembly without fasteners, and integrating wireless components and sensors seamlessly within a plastic structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal is used for housing and structural components, then strength and durability are improved, but manufacturing complexity and cost increase for complex shapes

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The lighting fixture is divided into modular components including a housing module, light source module, and control module that can be independently manufactured and assembled. This segmentation allows each module to be optimized separately, reducing overall manufacturing complexity while maintaining structural integrity through standardized connection interfaces

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs composite construction combining metal structural elements with non-metallic components such as plastic housings or coatings. This composite approach provides the necessary structural strength from metal components while reducing overall complexity and cost by using easier-to-manufacture materials for non-structural portions

Inventive Principle:

Principle #40Composite materials

2Strength

If metal is used for housing and structural components, then structural integrity is improved, but weight increases

Engineering Contradiction:

Improvestructural integrityVSAvoidfixture weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

By segmenting the fixture into modular components, only the essential structural elements require metal construction for strength, while other modules can use lighter materials. This reduces overall weight while maintaining structural integrity where needed

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The use of composite materials combines lightweight non-metallic components with selective metal reinforcement, achieving the required structural integrity with reduced overall weight compared to fully metal construction

Inventive Principle:

Principle #40Composite materials

3Strength

If metal structures are used, then structural strength is improved, but interference with wireless communication signals occurs

Engineering Contradiction:

Improvestructural strengthVSAvoidwireless signal interference

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Wireless communication components such as antennas and RF modules are extracted from the metal housing structure and placed in separate non-metallic modules or positioned in designated RF-transparent zones. This isolation eliminates signal interference while maintaining structural strength in the metal components

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The housing incorporates RF-transparent or RF-shielding composite materials that allow wireless signals to pass through without interference. These composite structures maintain structural integrity while enabling unimpeded wireless communication

Inventive Principle:

Principle #40Composite materials

4Adaptability or versatility

If sensors are incorporated into metal lighting fixtures, then functionality is improved, but additional parts and fasteners increase device complexity

Engineering Contradiction:

Improvesensor integrationVSAvoidnumber of parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Sensors are merged with the housing structure or integrated into module housings during the molding process, eliminating the need for separate mounting brackets, fasteners, and assembly steps. This integration reduces the total part count while maintaining sensor functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The modular housing structure is designed with universal mounting features and standardized interfaces that can accommodate various sensor types without requiring additional specialized parts. This multi-functionality reduces complexity by using the same mounting system for different sensor applications

Inventive Principle:

Principle #6Universality (Multi-functionality)

5Adaptability or versatility

If sensors are incorporated into metal lighting fixtures, then functionality is improved, but aesthetic appearance is disrupted

Engineering Contradiction:

Improvesensor integrationVSAvoidaesthetic appearance

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #3Local quality

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

The modular design reduces manufacturing complexity and weight, minimizes interference with wireless signals, and allows for aesthetically pleasing integration of sensors and wireless components, enhancing functionality and appearance.

Implementation Method 1

The light guide may have a curved cross-sectional shape in a plane perpendicular to a longitudinal direction of the center support member. At least one light emitting diode (LED) is disposed adjacent the first edge of the light guide, whereby light produced by the LED is directed through the light guide toward the second edge.

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentUS10274173B2Modular LED lighting fixture

Publication Date: 2019.04.30 LSI IND INC

AI summary

A modular lighting fixture includes an elongate center support member defining a channel. At least one reflector panel is coupled with the center support member and extends laterally outward therefrom. The lighting fixture further includes at least one light guide having a first edge and an oppositely disposed second edge. The first edge of the light guide is mechanically coupled with the center support member. The light guide may have a curved cross-sectional shape in a plane perpendicular to a longitudinal direction of the center support member. At least one light emitting diode (LED) is disposed adjacent the first edge of the light guide, whereby light produced by the LED is directed through the light guide toward the second edge.