Modular LED Luminaire Tray with Stepped Profile
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Tunnel lighting solutions require modular designs to accommodate varying tunnel geometries and lighting needs, ensuring safe and comfortable environments while minimizing installation complexity and total cost of ownership, but existing solutions lack the necessary modularity and efficiency in terms of mechanical design and light distribution.
Innovation Solution
A thin modular luminaire assembly comprising interconnectable modules with an electronic module and optical modules, where the optical module has a tray with a protrusion for electrical connectors and a stepped profile for mechanical connectors, allowing for flexible light distribution and easy assembly, reducing material usage and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the tray is made thin to reduce material usage and energy consumption, then the amount of material and energy used is reduced, but the tray may not have sufficient space to accommodate electrical connectors and mechanical interfaces
Solution Approach 1:
The patent introduces a stepped profile with multiple levels in the tray structure, utilizing vertical dimensionality to create separate zones for different components. The first level accommodates the optical plate and LED array, while the second level provides space for electrical connectors and mechanical interfaces, thereby maintaining a thin overall profile while accommodating all necessary components.
Solution Approach 2:
The electrical connectors and mechanical interfaces are integrated within the stepped profile structure of the tray itself, nesting these components within the existing tray geometry rather than adding separate housing structures. This nesting approach reduces overall complexity while maintaining functionality.
2Adaptability or versatility
If modular design is implemented to accommodate varying tunnel geometries and lighting needs, then adaptability is improved, but the device complexity increases due to multiple interconnectable modules
Solution Approach 1:
The tray structure is designed with universal features including electrical connectors, mechanical interfaces, and mounting provisions that are consistent across different module types. This universality allows various optical modules to be interchanged and combined with electronic modules in different configurations to meet diverse tunnel lighting requirements without increasing connection complexity.
3Device complexity
If the tray accommodates both optical components and electrical connectors within the same structure, then device complexity is reduced, but the precision of component placement and connection becomes more difficult
Solution Approach 1:
The tray is segmented into distinct zones through the stepped profile design, with separate areas for optical components, electrical connectors, and mechanical interfaces. This segmentation provides dedicated mounting locations for each component type, simplifying assembly and ensuring precise component placement while maintaining overall structural simplicity.
Data Source
AI summary
A plurality of interconnectable modules includes an electronic module and a first optical module. The first optical module includes a tray with a bottom surface and a side surface, a LED array provided on a printed circuit board disposed on the bottom surface, and an at least partially light-transmitting optical cover closing the tray. The electronic module includes a housing with a bottom wall and a sidewall, a LED driver circuitry for driving the LED array of the printed circuit board, and a door closing the housing. The side surface includes a first electrical connector and a first mechanical connector and the sidewall includes a second electrical connector and a second mechanical connector. The first and second electrical connectors are cooperating to electrically interconnect the electronic module to the first optical module, while the first and second mechanical connectors cooperate to mechanically secure them together.