Asymmetric Stamped Fixing Ring for Halogen Reflector Lamps
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Solution Overview
Problem
Existing reflector lamps with halogen incandescent burners face challenges in cost-effectiveness and material efficiency, particularly in designing a fixing ring that can be easily produced and adapted for various burner configurations without compromising structural integrity or symmetry.
Innovation Solution
A stamped and bent fixing ring made from sheet metal, with a width less than its length, featuring a central plateau and angled side walls, is used to securely hold the burner, allowing for adjustable height and material savings by not requiring complete circular base filling, and can be produced through a method involving punching and folding of a rectangular metal sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rotationally symmetrical fixing ring is used, then structural stability is improved, but material usage increases and manufacturing complexity increases
Solution Approach 1:
The fixing ring is designed with an asymmetric rectangular cross-section where the width W is less than the length D (W < D), breaking the rotational symmetry of traditional designs. This asymmetric geometry maintains structural stability while reducing material consumption by eliminating redundant material in areas not required for functional performance.
Solution Approach 2:
The fixing ring is segmented into distinct functional zones: edge zones with circular segments at the narrow sides, intermediate zones forming side walls, and a central plateau. This segmentation allows optimized material distribution where material is concentrated only where structurally necessary, reducing overall material usage while maintaining stability.
2Strength
If a deep-drawn three-dimensional fixing ring is used, then structural integrity is improved, but manufacturing cost increases
Solution Approach 1:
Indentations for fixing the ring in the neck are punched out in advance during the stamping process, before final assembly. This preliminary action integrates the fastening feature into the base manufacturing step, eliminating the need for separate operations and reducing manufacturing cost while maintaining structural integrity.
Solution Approach 2:
The fixing ring utilizes controlled plastic deformation through bending at folds to achieve its three-dimensional U-shaped configuration from a flat sheet. This parameter change from 2D to 3D form through bending, rather than deep-drawing, simplifies the manufacturing process and reduces tooling complexity while preserving structural strength.
3Stability of the object's composition
If the fixing ring width is increased to fill the circular base, then structural stability is improved, but material efficiency decreases
Solution Approach 1:
The rectangular cross-section with width W < D creates an asymmetric profile that fits efficiently within the circular base without requiring full circular coverage. This asymmetric design provides structural stability through optimized geometry while improving material efficiency by eliminating wasted space in the circular footprint.
Solution Approach 2:
The edge zones are designed with circular segments that provide localized reinforcement at critical positions without requiring the entire base to be filled. This partial action approach concentrates material where structurally necessary, achieving stability with improved material efficiency.
4Ease of manufacture
If a stamped and bent fixing ring is used, then manufacturing cost decreases and material usage reduces, but assembly complexity may increase
Solution Approach 1:
Multiple features are merged into a single stamped and bent component: the U-shaped wall structure, the central plateau, the side walls, and the indentations for fixing are all integrated into one piece. This merging eliminates the need for separate parts and assembly steps, reducing overall assembly complexity despite the sophisticated geometry.
Solution Approach 2:
The fixing ring fastens itself in the reflector by means of a spring effect generated during assembly. This self-service mechanism automatically secures the burner without requiring additional fastening operations or complex assembly procedures, reducing assembly complexity while maintaining secure fixation.
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The invention relates to a reflector lamp comprising a fixing ring (20) that holds a burner in a reflector. The fixing ring is a stamped and bent part, the length D of which is greater than the width W thereof.