Modular Power Supply with Integral Junction Box Mounting Extension
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Solution Overview
Problem
The installation of power supplies for solid state lighting systems is complicated due to the need to convert alternating current (AC) to direct current (DC) and requires cumbersome conduit and wire connections, especially when multiple supplies are connected to a single junction box.
Innovation Solution
A modular power supply design that allows easy mounting to standard junction boxes with integral extensions and end caps, enabling multiple power supplies to be connected to a single junction box without conduits, and featuring sealed wire connections for reliability in various orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional power supplies are installed using conduits and wire connections to junction boxes, then electrical power conversion from AC to DC is achieved, but the installation process becomes complicated and cumbersome
Solution Approach 1:
The power supply unit is merged with an integral mounting extension that directly attaches to the junction box, combining the electrical power conversion function with the mechanical mounting function into a single integrated component, thereby eliminating the need for separate conduit installations
Solution Approach 2:
The power supply design incorporates multiple functions: electrical power conversion from AC to DC, direct mounting to junction boxes via integral extensions, and sealed wire connections, allowing a single component to perform multiple tasks that previously required separate elements
2Power
If multiple power supplies are connected to a single junction box using conventional methods, then power conversion capacity is increased, but the installation complexity increases significantly
Solution Approach 1:
The system is segmented into multiple identical modular power supply units, each with its own integral mounting extension, allowing independent installation and connection to the junction box without interfering with other units, thereby simplifying multi-unit installations
3Adaptability or versatility
If power supplies are mounted to junction boxes without integral extensions, then mounting flexibility is reduced, but the power supply design becomes simpler
Solution Approach 1:
The mounting extension is pre-integrated into the power supply housing during manufacturing, with wire connections pre-sealed and positioned, so that during installation the unit can be directly attached to the junction box without requiring separate mounting operations or complex field assembly
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
This design simplifies the installation process, reduces space requirements, and allows multiple power supplies to be connected to a single junction box, providing a compact and reliable power solution for solid state lighting systems.
Implementation Method 1
The power source (primary source) at many commercial and residential locations, however, is typically in the range of 100-240 volts alternating current (AC). As a result, a power supply is needed to convert the primary AC source to the appropriate DC source to drive the SSL systems.
Data Source
AI summary
A modular power supply particularly adapted for mounting to standard junction boxes in a system to provide a solid state lighting system compatible power signal. One embodiment of a modular power supply for mounting to a junction box according to the present invention includes a housing holding internal electronic components and a first extension integral to the housing for mounting to a junction box. The extension has an opening to the interior of the housing with primary wires passing from the interior of the housing through the extension. The first extension is positioned so that the power supply is capable of being mounted to the mounting surface of a junction box when the power supply is at different orientations.