Replaceable LED Reflector Inserts for Independent Mounting
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Solution Overview
Problem
Existing LED light fixtures require time-consuming and costly processes to replace reflector attachments, which can damage components and disrupt the circuit board's connection to the mounting bracket, necessitating a more efficient method for changing light distribution and reflector inserts.
Innovation Solution
The design of LED light fixtures with replaceable reflector inserts that are removably attached to the housing, allowing for independent installation and removal without decoupling the circuit board from the mounting bracket, using brackets or direct attachment to the housing for simplified replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If reflector attachments are attached using the same fasteners as the circuit board to the mounting bracket, then device complexity is reduced, but replacing the reflector attachment becomes time-consuming and costly due to decoupling the circuit board from the mounting bracket
Solution Approach 1:
The reflector attachment is segmented from the circuit board assembly, allowing independent attachment and removal. The reflector attachment has its own separate mounting mechanism using distinct fasteners or attachment points on the housing, while the circuit board remains permanently mounted to the mounting bracket. This segmentation enables replacement of the reflector without disturbing the circuit board connection.
Solution Approach 2:
The reflector attachment is extracted as a separate replaceable component from the integrated assembly. Instead of being permanently fixed to the mounting bracket along with the circuit board, the reflector attachment is designed to be independently removable, allowing it to be taken out and replaced without affecting the circuit board's permanent attachment to the mounting bracket.
2Ease of repair
If reflector attachments are removed by decoupling the circuit board from the mounting bracket, then the reflector can be replaced, but damage may occur to the circuit board and other components
Solution Approach 1:
The system is segmented into two independent subsystems: the permanently mounted circuit board on the mounting bracket, and the separately attachable reflector attachment. This segmentation ensures that operations on the reflector (attachment or removal) do not mechanically affect the circuit board or its connection to the mounting bracket, thereby preserving component integrity and reliability.
Solution Approach 2:
The housing serves as an intermediary structure that provides separate mounting interfaces: the mounting bracket permanently secures the circuit board, while the housing provides independent attachment points for the reflector attachment. This intermediary structure allows the reflector to be replaced without transmitting mechanical forces or disturbances to the circuit board, preventing potential damage.
3Ease of manufacture
If a single piece reflector attachment extends on two sides of the circuit board, then manufacturing is simplified, but adaptability to change light distribution is reduced
Solution Approach 1:
The reflector system uses separate reflector attachments for each side, rather than a single piece spanning both sides. Each reflector attachment can be independently selected and configured to provide different light distribution patterns. This segmentation maintains manufacturing simplicity for each individual component while enabling flexibility in configuring different reflector combinations to achieve various light distribution requirements.
Solution Approach 2:
The reflector attachments are designed as universal, interchangeable components that can be attached to either side of the housing. Multiple types of reflector attachments with different optical characteristics can be used in the same fixture by simply changing which reflector attachments are installed on which sides, providing adaptability for different light distribution needs without requiring different fixture designs.
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 approach reduces installation and removal time and costs, enabling quick modification of light distribution during installation or manufacturing, and prevents damage to components by allowing reflector inserts to be replaced without affecting the LED board's attachment to the mounting bracket.
Implementation Method 1
a first reflector insert positioned adjacent to the circuit board on a first side of the circuit board. The first reflector insert is configured to reflect light from the LED.
Data Source
AI summary
A lighting fixture includes a housing and a circuit board having a light emitting diode (LED). The circuit board is attached to a mounting bracket that is positioned inside the housing. The lighting fixture further includes a first reflector insert positioned adjacent to the circuit board on a first side of the circuit board. The first reflector insert is configured to reflect light from the LED. The lighting fixture also includes a second reflector insert positioned adjacent to the circuit board on a second side of the circuit board. The second reflector insert is configured to reflect the light from the LED. The first reflector insert and the second reflector insert are removable from the lighting fixture without removing the circuit board.