Modular LED Luminaire Assembly with Universal Mounting Ring
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Solution Overview
Problem
Current LED luminaires have fixed structural components and limited flexibility in light emission direction, restricting the use of interchangeable components and increasing production, assembly, and warehousing costs, as well as limiting changes in color correlated temperature and light diffusion patterns.
Innovation Solution
A modular luminaire assembly with a universal mounting ring, non-conductive inner body, and adjustable components such as LED printed circuit boards, thermal plates, and décor bezels, allowing for customizable configurations and interchangeable parts to alter appearance and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed structural components are used in LED luminaires, then manufacturing and assembly are simplified, but flexibility in light emission direction and component interchangeability is reduced
Solution Approach 1:
The luminaire is divided into modular components including a mounting ring, inner body, light engine, diffuser, and décor trim. Each component can be independently manufactured, assembled, and replaced. The mounting ring segments the electrical splice compartment from the light-emitting components, enabling flexible reconfiguration while maintaining manufacturing efficiency through standardized interfaces.
Solution Approach 2:
The mounting ring serves multiple functions: providing structural support, enabling mechanical connection of components, facilitating electrical connections through the splice compartment, and allowing for component interchangeability. This universal component resolves the contradiction by maintaining manufacturing simplicity while enabling versatility through its multi-functional design.
2Stability of the object's composition
If fixed light emission direction is designed, then structural stability is improved, but ability to alter lighting patterns post-production is lost
Solution Approach 1:
The lighting system transitions from fixed to dynamic configuration. The light engine can be rotated or repositioned within the inner body, and the diffuser can be removed or replaced to alter light emission patterns. This dynamic capability maintains structural stability through the rigid mounting ring and inner body while enabling post-production flexibility in lighting patterns.
3Ease of manufacture
If interchangeable components are prohibited, then production costs are reduced, but additional costs for multiple fixed configurations must be incurred
Solution Approach 1:
Instead of producing multiple fixed-configured luminaires for different applications, a single universal luminaire design with interchangeable components serves multiple functions. The standardized mounting ring and inner body accommodate various light engines, diffusers, and décor trims, eliminating the need to warehouse multiple fixed configurations while reducing production costs through economies of scale.
4Manufacturing precision
If features are fixed during design and production, then quality control is simplified, but post-production modifications are restricted
Solution Approach 1:
The luminaire features are segmented into replaceable modules. The mounting ring and inner body maintain fixed, precisely-manufactured interfaces for quality control, while the light engine, diffuser, and décor trim are separate modules that can be replaced or modified post-production. This segmentation preserves manufacturing precision while enabling ease of repair and adaptation.
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
Enables cost-effective and sustainable modifications to LED luminaire designs, accommodating changes in light diffusion, color correlated temperature, and light engine types, while reducing production and assembly costs by allowing for flexible component arrangements and wireless control options.
Implementation Method 1
index a thermal plate for the driver and a thermal pan
Implementation Method 2
LED (light emitting diode) luminaires are used in lighting commercial, institutional, and residential buildings
Data Source
AI summary
A modular luminaire assembly comprising includes a mounting ring configured to be selectively coupled with a mounting surface, an inner housing defining a channel configured to receive the mounting ring, wherein the mounting ring is configured to be selectively coupled with the inner housing, a lighting assembly, one or more diffusers configured to direct light from the lighting assembly; and a retaining ring including a ring body defining an opening a plurality of flanges configured to snap engage with the inner housing, wherein the ring body is configured to at least partially support the one or more diffusers and the lighting assembly.