Modular Lighting Fixture Segmentation and Sealing

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Solution Overview

Problem

Existing solid-state lighting fixtures face limitations in length and configuration due to shipping, storage, and installation constraints, and require protection from harsh environmental elements like moisture and dust, especially in industrial settings.

Innovation Solution

A modular lighting fixture design comprising sub-assemblies with trays, housing elements, and lenses, connected via a coupling with sealing elements to ensure moisture resistance and flexibility in configuration, allowing for easy assembly and extension to various lengths.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If solid-state lighting fixtures are made longer to accommodate various applications, then the adaptability and versatility are improved, but the shipping, storage, and installation constraints worsen

Engineering Contradiction:

Improveconfiguration flexibilityVSAvoidfixture length

Core Design Contradiction:

Adaptability or versatilityVSLength of moving object

Solution Approach 1:

The lighting fixture is divided into multiple modular sections that can be independently manufactured, shipped, and stored. Each section contains complete functional elements (housing, tray, lens, mounting brackets), allowing the fixture to be segmented into manageable units that overcome shipping and storage length constraints while maintaining configuration flexibility through assembly of different section combinations

Inventive Principle:

Principle #1Segmentation

2Ease of repair

If modular sections are connected via couplings, then the ease of assembly and repair is improved, but the device complexity increases

Engineering Contradiction:

Improveassembly simplicityVSAvoidcoupling mechanism complexity

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The coupling mechanism merges multiple functions into a single integrated component: it provides mechanical connection between sections, incorporates sealing elements for environmental protection, and includes mounting bracket attachment features. This consolidation reduces the number of separate parts and simplifies assembly while maintaining ease of repair through standardized coupling interfaces

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If sealed lens covers are used to protect from moisture and contaminants, then the reliability and durability are improved, but the manufacturing complexity increases

Engineering Contradiction:

ImproveweatherproofingVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sealing system uses a nested structure where the lens cover is positioned within the housing and sealed against it using integrated sealing elements. The seal is nested at the interface between the lens cover and housing, creating a protective barrier without requiring separate sealing components or complex assembly steps, thus maintaining ease of manufacture while achieving reliable weatherproofing

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS10240759B2Modular lighting fixture

Publication Date: 2019.03.26 MAXLITE

AI summary

An improved and modular lighting fixture that reduces shipping and storage requirements and costs, facilitates simple assembly and repair, and that is modularly configurable to provide flexibility when designing and installing lighting fixtures. The improved lighting fixture also reduces the adverse effect of external environmental factors such as moisture, dust, etc. by providing a seal that impedes ingress into the modular lighting fixture.