Concave Lighting Cover Deformation Method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional medical lighting devices with concave covers are complex and expensive to produce, and require improved sealing to prevent liquid ingress, especially during cleaning.
Innovation Solution
A method involving a flat cover that is deformed to conform to a concave shape, using an annular ring for stress distribution and sealing, and a seal made of elastomer to ensure a secure fit without local stresses, allowing for easier production and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a concave cover is produced using conventional three-dimensional molding methods, then the desired concave shape is achieved, but the production process becomes complex and expensive
Solution Approach 1:
The cover is first produced in a flat state before installation, avoiding complex molding processes. The concave shape is then created in-situ by applying force through the annular ring during assembly, separating the manufacturing step from the shaping step
Solution Approach 2:
The physical state of the cover is changed from flat to concave through mechanical deformation by applying force via the annular ring. This parameter change (shape transformation) occurs after production, using the installation process itself to create the final geometry
2Reliability
If the cover is sealed directly to the body without additional components, then the structure remains simple, but sealing reliability is insufficient to prevent liquid ingress
Solution Approach 1:
An annular ring is introduced as an intermediary component between the flat cover and the body. This ring serves dual functions: distributing mechanical stress during deformation and providing a sealing interface, thereby improving reliability without excessive complexity
Solution Approach 2:
The seal is implemented using an elastomeric material that can deform to accommodate the concave shape of the cover while maintaining sealing contact. The flexible nature of the elastomer allows it to conform to the deformed cover surface effectively
3Shape
If hot molding processes are used to create the concave shape, then the desired shape is achieved, but the anti-scratch layer integrity is compromised
Solution Approach 1:
Instead of using thermal processes (hot molding) to change the shape parameter, the invention uses mechanical force applied through the annular ring during installation. This alternative parameter change method avoids thermal exposure that would damage the anti-scratch coating
Solution Approach 2:
The thermal-mechanical process (hot molding) is replaced with a purely mechanical deformation process. Force is applied through the annular ring to create the concave shape cold, preserving temperature-sensitive surface treatments
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 method simplifies and reduces the cost of producing concave covers, enhances sealing to prevent liquid ingress, and maintains the anti-scratch layer integrity by avoiding hot molding processes.
Implementation Method 1
The seal can be made of elastomer, for example EPDM rubber or silicone
Implementation Method 2
deforming the flat cover so as to conform it to its concave shape, by pressing on the central area of the cover
Data Source
Figure 1~2
Figure 3~4
AI summary
This document describes a method for constructing a lighting device (1), the device comprising a body (4) equipped with at least one lighting module (10), the body (4) having a rim (5) defining an opening (7), said opening (7) being closed by a cover (13) adapted to allow the passage of light from the lighting module (10) through said cover (13), said cover (13) having a concave shape and comprising a central area adapted to be fixed to a central area (10) of the body (4), the method comprising the steps of placing the cover (13), which is in the form of a flat plate, opposite the opening of the body (4), so that the periphery of the cover (13) rests, at least partially, on the rim (5) of the body (4), deforming the flat cover (13) to conform it to its concave shape by pressing it against the central area of the cover (13), and fixing the central area of the cover (13) on the central area (10) of the body (4).