Modular Lighting Apparatus with Tool-Free LED Module Replacement
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Solution Overview
Problem
Existing lighting fixtures in commercial buildings often have inaccessible attachment points and wires, making it difficult and costly to replace or upgrade lighting systems without disturbing the surrounding environment.
Innovation Solution
A modular lighting apparatus featuring a heat sink with a mechanical pad and electrical connector, and a light pod with a mounting ring, mechanical holder, and mating electrical connector, allowing for easy replacement of LED modules without disconnecting wires or using tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lighting fixtures are permanently installed with wires and holders, then the lighting system provides stable illumination, but the fixtures become difficult and costly to replace or upgrade due to inaccessible attachment points and electrical hazards
Solution Approach 1:
The lighting fixture is divided into separate modular components: a heat sink assembly with electrical connectors and a separate LED module with corresponding connectors. This segmentation allows the LED module to be replaced independently without disturbing the heat sink, mounting structure, or electrical wiring, thereby maintaining stable illumination while enabling easy repair and replacement.
2Ease of repair
If traditional LED fixtures are replaced by removing the holder within the heat sink, then the LED module can be replaced, but the process requires disconnecting and reconnecting wires with inline connectors, making it time-consuming and complex
Solution Approach 1:
The electrical connectors are pre-assembled and integrated into the heat sink assembly before the LED module is installed. The mounting structure is pre-configured with external mounting points. This preliminary preparation eliminates the need for on-site wire disconnection and reconnection, allowing the LED module to be quickly replaced by simply detaching and reattaching the pre-prepared components.
3Ease of repair
If the entire fixture including heat sink and optical assembly is disposed of at end of life, then replacement is simple, but waste is generated and replacement cost increases
Solution Approach 1:
The LED module is extracted as a separate replaceable component from the heat sink assembly, which remains in place. The electrical connectors and mounting structure are designed to retain the heat sink while allowing the LED module to be removed and replaced. This extraction approach enables replacement of only the faulty LED module rather than the entire fixture, reducing waste and replacement costs.
4Ease of repair
If modular design with releasable connections is implemented, then easy replacement is achieved, but the connection reliability and electrical contact stability may be compromised
Solution Approach 1:
The electrical connectors are merged with the heat sink assembly through integral construction or rigid mounting, creating a unified structure. The LED module connectors are similarly integrated. This merging ensures that when the modules are connected, the electrical contacts maintain stable and reliable connection while still allowing for easy separation and replacement of the LED module from the heat sink assembly.
Data Source
AI summary
Modular lighting apparatus and method of using whereby a heat sink is provided including a first mechanical pad and a first mating electrical connector; and a light pod is releasably secured to the heat sink, wherein the light pod further includes a mounting ring, a second mechanical pad or secondary circuit board, and a second mating electrical connector; wherein the second mating electrical connector of the light pod mates with the first mating electrical connector of the heat sink; and wherein the second mechanical pad or secondary circuit board of the light pod makes contact with the first mechanical pad of the heat sink when the light pod is removably secured to the heat sink; and wherein the mounting ring tightens and releasably secures the light pod to the heat sink. The light pod is replaced after use without the need for tools.