Modular Sealed Luminaire Housing for Unified Direct-Indirect Lighting
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Solution Overview
Problem
Existing modular sets for luminaires require a large variety of components, leading to high manufacturing costs and inconsistent design and functionality across different applications, making them costly and difficult to maintain.
Innovation Solution
A modular set comprising a tubular housing, gear tray, light module, and end caps, allowing for a luminaire configuration with a vertical light emission direction and a bottom optical section that provides both direct and indirect illumination, enabling adaptation to various applications with a unified design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large variety of different components (housings, gear trays, light modules, optical elements) are used to adapt luminaires to specific application requirements, then adaptability is improved, but manufacturing costs and device complexity increase
Solution Approach 1:
The patent implements a universal modular luminaire system where a single standardized housing design can accommodate different light modules, optical elements, and configurations through standardized mounting interfaces. The housing includes universal mounting structures that allow various components to be installed in multiple positions and orientations, enabling the same housing to serve multiple application requirements without needing different housing variants.
Solution Approach 2:
The luminaire is divided into independent modular components (housing, gear tray, light module, optical elements, end caps) that can be separately selected, configured, and assembled. This segmentation allows customers to mix and match components from a standardized catalog to create customized luminaires for different applications, reducing the need for completely different housing designs for each application.
2Adaptability or versatility
If a large variety of different components are used to meet specific illumination requirements, then adaptability is improved, but manufacturing costs increase
Solution Approach 1:
The standardized housing design serves as a universal platform that can be manufactured in high volumes for multiple applications. By using the same housing, mounting structures, and fastening mechanisms across different luminaire configurations, the manufacturer achieves economies of scale in production, reducing per-unit costs while still allowing customization through component selection.
Solution Approach 2:
Multiple functional elements (mounting brackets, optical mounts, cable access points, ventilation structures) are integrated into the standardized housing design itself, eliminating the need for separate auxiliary components. This consolidation reduces the total number of parts that need to be manufactured and assembled, lowering manufacturing complexity and costs.
3Adaptability or versatility
If different types of luminaires with varying design and functional elements are used for different applications, then adaptability is improved, but installation and maintenance costs increase
Solution Approach 1:
The standardized housing and mounting structures across all luminaire types allow installation personnel to use the same tools, techniques, and procedures regardless of which specific luminaire model is being installed. Similarly, maintenance personnel can service different light modules and optical elements using common access points and mounting mechanisms, reducing training requirements and labor costs.
Solution Approach 2:
The modular design with standardized interfaces allows individual components (light modules, optical elements, end caps) to be easily removed, replaced, or upgraded without affecting the housing or other components. This enables quick component-level replacement during maintenance rather than requiring complete luminaire replacement or complex disassembly procedures.
4Device complexity
If a modular set with standardized components is used, then manufacturing costs and complexity are reduced, but adaptability to specific applications may be limited
Solution Approach 1:
The housing incorporates adjustable and reconfigurable mounting structures that allow the same physical housing to dynamically adapt to different configuration requirements. For example, mounting brackets can be repositioned along tracks, optical elements can be rotated or tilted to different angles, and cable access points can be configured in multiple positions, enabling a single standardized housing to meet varying spatial and functional requirements.
Solution Approach 2:
While the overall housing design is standardized, the system allows for localized customization through optional accessories, specialized end caps, or application-specific optical elements that can be attached to the standardized platform. This enables tailoring specific local features to application needs while maintaining the benefits of standardized core components.
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 set enables cost-effective and adaptable luminaire solutions with consistent design and functionality, providing both direct and indirect illumination, and reducing installation and maintenance costs.
Implementation Method 1
the light module being attached to the bottom side of the mounting panel and configured to emit light, wherein this light emanating from the light module is emitted to surroundings of the luminaire from the tubular housing
Implementation Method 2
a bottom optical section which is arranged below the fixing means and which forms said bottom end and at least partially surrounds said bottom side of the mounting panel
Data Source
Figure 1~2a
Figure 2b~2c
Figure 2d~2e
AI summary
The invention refers to a modular set for realising a luminaire, the set comprising a tubular housing (2), a gear tray (4), a light module (5) and at least two end caps (9). The tubular housing (2) comprises a fixing means (23) at its inner side, wherein in the operating state the gear tray (4) is fixed to the fixing means of the tubular housing (2) the bottom side of its mounting panel being arranged at a vertical distance from a bottom end of the inner side of the tubular housing (2), wherein the tubular housing (2) comprises a bottom optical section being arranged below the fixing means and forming said bottom end of its inner side and, in the operating state, surrounding at least partially the bottom side of the mounting panel and being configured to emit at least 5 %, in particular at least 10 % of the light intensity upwards and at least 70 % of the light intensity downwards, wherein in particular the tubular housing (2) comprises a top section and the bottom optical section, the top section and the bottom optical section together closely surround the tube axis and in particular being formed of different material, the bottom optical section being at least twice as large as the top section.