Retrofit LED Panel with Spring-Magnet Mounting
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Solution Overview
Problem
The high labor costs associated with replacing pre-existing fluorescent lighting fixtures with LED lighting fixtures in high-cost regions, as existing methods require significant labor to remove and replace the fixtures entirely.
Innovation Solution
A retrofit lighting solution that uses an LED panel with a magnet and spring mechanism to attach to the existing troffer, allowing for minimal tooling and modifications, where the LED panel is positioned in front of the troffer instead of inside, and electrical connections are made without removing the troffer, utilizing a safety cable for additional support and alignment blocks for proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the old fluorescent bulb is replaced with a new LED bulb configured as a similar bulb structure, then the lighting fixture can be simply fitted to existing sockets, but the labor cost remains high in high-cost regions
Solution Approach 1:
The invention extracts only the essential functional components (LED array, mounting mechanism, electrical connections) from a complete LED fixture, allowing installation without removing the existing troffer housing. This selective extraction enables workers to retain the existing structural framework while replacing only the light-generating components, significantly reducing installation time and labor costs.
Solution Approach 2:
The LED panel assembly is designed with universal mounting features that can be installed in standard troffer housings without modification. The spring-loaded clips and alignment blocks provide multi-functional attachment that works with existing fluorescent fixture frameworks, eliminating the need for custom fabrication or complete fixture replacement.
2Adaptability or versatility
If a trim kit is attached to a T-bar roof and LED attaches to the mounted trim kit, then LED lighting can be installed, but the device complexity and tooling requirements increase
Solution Approach 1:
The invention merges the mounting function and the lighting function into a single integrated LED panel assembly. The spring-loaded clips, alignment blocks, and LED array are combined into one unit that attaches directly to the existing troffer, eliminating the need for separate trim kits and multiple mounting components required by conventional approaches.
Solution Approach 2:
The spring-loaded clips serve as intermediaries between the LED panel and the existing troffer structure. These clips provide a simple mechanical interface that connects the new LED assembly to the old fixture framework without requiring complex adapters or modification of either component.
3Stability of the object's composition
If the LED panel is positioned inside the troffer cavity, then the lighting fixture can be fully integrated, but significant labor is required to remove and replace the entire fixture
Solution Approach 1:
The LED panel is pre-assembled with spring-loaded clips and alignment blocks in a factory setting, preparing it for rapid installation. This preliminary preparation allows the panel to be simply snapped into the existing troffer during installation, eliminating the need for on-site assembly or complex mounting procedures.
Solution Approach 2:
The spring-loaded clips provide dynamic, flexible attachment that allows the LED panel to be easily installed and removed. The springs accommodate minor variations in the troffer dimensions and provide secure holding force once installed, enabling quick installation without permanent modifications or complex fastening procedures.
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
Enables efficient and cost-effective retrofitting of existing lighting fixtures by minimizing labor and tooling requirements, allowing for quick installation of LED lighting without removing the pre-existing troffer, thus reducing overall installation costs and time.
Implementation Method 1
a magnet is used. The magnet is connected to one end of a spring or spring-like part
Implementation Method 2
The magnet is connected to one end of a spring or spring-like part. The other end of the spring is connected to the LED panel. The spring force of the spring pulls the LED panel against the outer perimeter of the troffer
Implementation Method 3
The LED panel includes one or more LEDs and related circuitry mounted to a substrate. The light emitted from the LEDs travels through the substrate from the edges, and then refracts down through the bottom surface of the substrate to illuminate underneath
Data Source
AI summary
A retrofit lighting fixture for retrofitting a pre-existing lighting fixture. The pre-existing lighting fixture includes electrical wiring and a troffer having a recessed center portion and an outer perimeter edge, which together form a hollow inner cavity, the electrical wiring extending into the cavity. The retrofit lighting fixture includes a lighting panel, a spring and a magnet. The lighting panel has light sources and electrical wiring. The lighting panel electrical wiring is connected to the electrical wiring of the pre-existing lighting. The spring has a first end connected to the lighting panel and a second end connected to the magnet. The magnet is attached to the recessed center portion of the troffer, and the spring is configured to pull the lighting panel against the outer perimeter edge of the troffer. In some applications the retrofit lighting fixture is a LED lighting fixture.