Downlight Housing With Detachable Spring Slots for Compact Packaging
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Solution Overview
Problem
Traditional downlights secure springs with screws, which complicates production and increases packaging size and cost.
Innovation Solution
A downlight design featuring a housing with a boss and slots for detachable springs, allowing separate packaging and assembly, and a toggle switch for color temperature adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If springs are secured by screws in traditional downlights, then the springs are firmly fixed, but the production process becomes troublesome and packaging size increases
Solution Approach 1:
The patent removes the screw fastening method from the spring fixation system. Instead of using screws to secure the springs, the design extracts the fastening function and replaces it with a snap-fit mechanism where the spring legs directly engage with slots in the housing, eliminating the need for additional fasteners and simplifying the assembly process
Solution Approach 2:
The patent merges the spring support function with the housing structure by integrating slots directly into the housing body. The slots are formed as part of the housing geometry, combining the housing and spring mounting features into a single integrated component, thereby reducing part count and assembly complexity
2Ease of operation
If springs stand upright in traditional downlights, then the springs are easily accessible, but the packaging box size significantly increases
Solution Approach 1:
The patent segments the spring structure into multiple independent legs that can be positioned at different orientations. Instead of a single upright spring, the design uses multiple spring legs that extend in different directions, allowing compact arrangement within the housing and efficient space utilization during packaging
Solution Approach 2:
The patent transitions from vertical spring orientation to multi-directional spring leg arrangement. The spring legs extend not only vertically but also horizontally and at angled orientations, utilizing three-dimensional space more efficiently and reducing the overall height required for packaging
Data Source
AI summary
A downlight with multiple installation methods includes a cover, a reflector cup, a light source, a housing, and two springs. The housing has a boss extending along a thickness direction of the housing, and an opening surface of the boss extends radially outward to form a skirt. The cover is disposed on the opening surface of the boss to be spliced to the housing to form a cavity for accommodating the reflector cup and the light source. The reflector cup is disposed on a light-emitting surface of the light source to enable light emitted by the light source to be reflected to be emitted out of the cover. The housing includes two slots symmetrically located on an outer side of the boss, and the two springs are detachably connected to the two slots.