Solid State Downlights with Junction Box Mounting
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Solution Overview
Problem
Conventional solid state lighting fixtures are costly due to the need for integrated power conversion circuitry and heat sinking structures, and often require a sheet metal lighting can for installation, which increases material and installation costs.
Innovation Solution
The development of solid state downlights with a junction box that allows direct ceiling mounting, eliminating the need for a sheet metal can, using spring mounting arms or a ring mounting structure to secure the fixture, and integrating a driver circuit and light emitting diodes within a compact housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If integrated power conversion circuitry and heat sinking structures are included in solid state lighting fixtures, then the fixtures can function properly and manage heat, but the cost of manufacturing increases
Solution Approach 1:
The patent extracts the power conversion circuitry from the lighting fixture housing, placing it in a separate junction box located in the ceiling cavity. This separation removes the costly integrated power conversion requirements while maintaining functional performance, as the LED array can be powered through the separated driver circuit in the junction box.
Solution Approach 2:
The lighting system is divided into separate functional modules: the LED array in the fixture housing, the driver circuit in the junction box, and the mounting structure. This segmentation allows each component to be optimized independently and reduces manufacturing complexity and cost while maintaining overall system reliability.
2Reliability
If sheet metal lighting cans are used for installation, then the fixtures can be properly mounted and protected, but material and installation costs increase
Solution Approach 1:
The patent eliminates the sheet metal lighting can entirely, extracting the mounting function and replacing it with spring mounting arms that attach directly to the ceiling structure. This removes the costly intermediate can component while maintaining secure installation through the spring-loaded arms that grip the ceiling edges.
Solution Approach 2:
The spring mounting arms serve as a simpler, less expensive alternative to permanent sheet metal cans. These arms provide adequate mounting stability for the fixture while being cheaper to manufacture and install, accepting that they may need replacement rather than being permanent installations.
3Adaptability or versatility
If complex mounting structures are used, then the fixtures can be securely attached to various ceiling types, but installation time and complexity increase
Solution Approach 1:
The spring mounting arms utilize elastic deformation to adapt to different ceiling thicknesses and materials. The spring mechanism dynamically adjusts to accommodate variations in ceiling construction while maintaining secure attachment, eliminating the need for multiple fixed mounting configurations for different ceiling types.
Solution Approach 2:
The spring mounting arm design serves multiple functions: attaching to various ceiling types, providing electrical isolation, enabling fixture removal and replacement, and accommodating ceiling thickness variations. This multi-functionality reduces installation complexity compared to specialized mounting systems for each ceiling type.
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 reduces material and installation costs, simplifies installation, and allows for quicker and safer installation, while maintaining efficient energy use and compliance with electrical and fire safety regulations.
Implementation Method 1
each spring mounting arm may include a spring section that directly engages a sidewall of the opening in the ceiling
Data Source
AI summary
Solid state downlights include a fixture that has a solid state lighting housing, a plurality of light emitting diodes within the solid state lighting housing and a junction box, and at least one mounting structure that is configured to releasably attach the fixture directly to a ceiling to mount the fixture within an opening in the ceiling.