Modular Luminaire With Self-Aligning Connectors
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Solution Overview
Problem
Luminaires using light-emitting diodes (LEDs) on printed circuits are difficult to dismantle due to their long lifespan, making it challenging to replace or modify individual modules, such as defective LEDs or change the power or color temperature of lighting components.
Innovation Solution
A luminaire design featuring a modular structure with a support profile and electrical connector system that allows for easy mounting and replacement of lighting modules, where the electrical connection is established during assembly, enabling the exchange of modules without requiring extensive electrical knowledge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lighting modules with LEDs on printed circuits are designed with fixed installation, then reliability and lifespan are improved (20,000-50,000 hours), but ease of repair and adaptability deteriorate, making it difficult to replace defective modules or modify lighting specifications
Solution Approach 1:
The luminaire is divided into separate functional modules: a removable lighting module containing LEDs on a printed circuit board, and a fixed support structure with electrical connectors. This segmentation allows the lighting module to be independently replaced without affecting the overall luminaire structure, resolving the contradiction between long lifespan reliability and ease of repair.
Solution Approach 2:
The electrical connection system is designed to be dynamic rather than permanent. The lighting module can be dynamically connected and disconnected from the support structure through sliding contacts and spring-loaded connectors, enabling easy replacement while maintaining reliable electrical connection during operation.
2Stability of the object's composition
If lighting modules are permanently fixed in the luminaire, then structural stability is improved, but adaptability deteriorates, preventing replacement with modules of different power or color temperatures
Solution Approach 1:
The luminaire structure is segmented into a fixed support profile and a removable lighting module. The support profile contains electrical connectors that remain stationary, while the lighting module can be independently removed and replaced with different specifications, maintaining structural stability while enabling adaptability.
Solution Approach 2:
The support profile with its electrical connectors and mounting structure is designed as a universal interface that can accommodate different types of lighting modules with varying power ratings and color temperatures. This universal design allows the same support structure to work with multiple module variants, achieving both stability and versatility.
3Reliability
If electrical connectors are designed for permanent connection, then electrical reliability is improved, but ease of operation deteriorates, requiring extensive electrical knowledge for module replacement
Solution Approach 1:
The electrical connection system incorporates self-aligning and self-latching features. Spring-loaded contacts automatically engage with corresponding terminals when the lighting module is inserted, and sliding contacts automatically establish electrical connection during the sliding motion. This self-service mechanism eliminates the need for manual wiring or complex electrical operations, making module replacement simple while maintaining reliable electrical connection.
Solution Approach 2:
The electrical connectors are pre-positioned and pre-configured in the support profile before the lighting module is installed. Contact areas are预先 arranged to automatically align with the module's electrical terminals during insertion, so that electrical connection is established as part of the mechanical assembly process, requiring no separate electrical connection steps.
4Ease of manufacture
If the luminaire is designed as an integrated unit, then manufacturing simplicity is improved, but device complexity increases, making it difficult to replace individual components
Solution Approach 1:
The luminaire is manufactured as segmented components: a support profile with integrated electrical connectors, and separate lighting modules with printed circuit boards. This segmentation allows each component to be manufactured and tested independently, then assembled through simple mechanical insertion and sliding motions, reducing overall assembly complexity while maintaining manufacturing efficiency.
Data Source
Figure 1
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AI summary
The fixture (100) has a frame (200) and a lighting unit (150) incorporating a lighting module (400) equipped with electroluminescent components e.g. LEDs. The module is placed in a section support (300) i.e. curved structure element, so that the components illuminate a wafer directly or indirectly from a light diffuser (800). An electric connector (500) connects the module with an electrical supply, so that connection is established during assembly of the section in the frame or during the assembly of the module in a profile.