Troffer LED Fixture with Indented Driver Mounting
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Solution Overview
Problem
Existing retrofit solutions for troffer-based fluorescent light fixtures to LED light fixtures are inefficient and often require separate mounting of components, leading to environmental concerns and increased complexity.
Innovation Solution
A unitary LED light fixture with a carrier plate having a flat first and second portion and an indented portion, where the driver is secured within the indented portion without extending through the common plane, allowing for efficient mounting within a troffer housing, and a method for retrofitting fluorescent light fixtures by disconnecting power, coupling lead wires, and securing the carrier plate using mechanical fasteners and bushings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate mounting of power supply and other components is used, then component installation flexibility is improved, but device complexity and installation time increase
Solution Approach 1:
The power supply is integrated into the same mounting structure as the LED array, creating a unified component assembly that reduces the number of separate parts and simplifies installation while maintaining installation flexibility
2Ease of manufacture
If raised LED-supporting panel is used, then LED mounting capability is improved, but troffer housing space is reduced
Solution Approach 1:
The mounting structure utilizes the vertical dimension by extending downward from the troffer housing bottom surface, allowing LED array mounting without occupying additional horizontal space within the troffer housing
3Volume of moving object
If completely flat LED-supporting panel is used, then troffer housing space is maximized, but LED mounting and heat dissipation capability are reduced
Solution Approach 1:
The mounting structure features a localized raised portion specifically at the LED array mounting location to provide proper LED mounting and heat dissipation, while the remainder of the structure remains flat to maximize troffer housing space
4Ease of operation
If driver extends through common plane, then driver accessibility is improved, but aesthetic appearance and compactness are reduced
Solution Approach 1:
The driver is positioned within an indented portion of the mounting structure that is located behind the LED array, nesting the driver within the overall assembly to maintain a compact, flat appearance while preserving electrical connectivity and functionality
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 a compact, efficient, and environmentally friendly retrofitting process that maintains energy efficiency and reduces waste, providing a seamless integration of LED lighting into existing troffer housings with improved installation ease and aesthetics.
Implementation Method 1
At least one LED is mounted to the first portion
Data Source
AI summary
A LED light fixture is provided herein for mounting into a troffer housing. The light fixture includes a carrier plate dimensioned to fit within the troffer housing, the carrier plate having a generally flat first portion, a generally flat second portion, and an outwardly indented portion located therebetween. The first and second portions are generally coplanar in a common plane. At least one LED is mounted to the first portion. A driver is electrically coupled to the at least one LED and disposed within the indented portion without extending through the common plane with the driver being fixed to the carrier plate. At least two lead wires are electrically coupled to the driver, and extending therefrom, configured to allow electrical power to pass therethrough to the driver. Advantageously, a LED light fixture is provided herein which is a unitary construction that can be efficiently mounted in a troffer housing.