Downlight Spring Assembly Simplifies Recessed Installation
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Solution Overview
Problem
Traditional flush recessed ceiling downlights face challenges during manufacture and assembly due to the complexity of aligning and mounting individual springs, which can lead to damage and misalignment issues.
Innovation Solution
A downlight unit design featuring a spring assembly with at least two retaining springs connected by a connection element, forming a single independent unit, which is mounted to the housing using a cover that sandwiches the assembly, simplifying the assembly process and providing stability with self-alignment features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual springs are independently attached to the housing during assembly, then the downlight can be held in place effectively, but the assembly process becomes complex and prone to misalignment and damage
Solution Approach 1:
The patent combines multiple individual springs into a single pre-assembled spring unit that functions as one integrated component. This spring unit includes several springs arranged in a specific configuration and connected through a common structure, allowing the entire assembly to be installed as a single unit rather than requiring separate attachment of each spring, thereby simplifying the assembly process while maintaining the holding effectiveness
Solution Approach 2:
The springs are pre-assembled and pre-positioned in their correct configuration before being attached to the housing. The spring unit is prepared in advance with all necessary connections and alignments already in place, eliminating the need for complex alignment operations during the final assembly process and reducing the risk of misalignment and damage
2Reliability
If individual springs are independently mounted to the housing, then each spring can function independently, but accurate alignment is required which complicates the assembly process
Solution Approach 1:
Multiple springs are merged into a single pre-assembled unit where their relative positions and orientations are fixed during manufacturing. This eliminates the need for precise alignment operations during field assembly, as the entire spring unit is installed as one component with predetermined geometry
Solution Approach 2:
The spring unit acts as an intermediary component that encapsulates the complexity of multiple spring alignments. By treating the entire assembly of springs as a single modular unit with standardized mounting features, the patent simplifies the interface with the housing while maintaining the functional independence of individual springs within the unit
3Ease of manufacture
If traditional spring mounting methods are used, then the downlight can be assembled, but there is a high risk of damage to the housing and spring connections
Solution Approach 1:
The spring unit is designed with built-in protection features that prevent damage during assembly. The pre-assembled structure includes cushioning elements and protective geometries that absorb assembly stresses and prevent direct contact between sharp edges or rigid components that could cause damage to the housing or spring connections
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 simplifies the assembly process, reduces the risk of damage, and ensures accurate alignment and stability, resulting in a more robust and efficient installation method for flush-mounted downlights.
Implementation Method 1
The spring arrangement comprises two springs, one on each side of the unit. The spring bias pushes each arm downwardly, so they push down on the back surface of the ceiling structure
Data Source
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AI summary
A downlight unit comprises a housing for passing through an opening in a surface and a spring assembly for holding the downlight unit in place. The spring assembly has at least two retaining springs connected by a connection element to form a single independent unit. A mounting element fixes the spring assembly to the housing. This provides a simplified assembly method and gives a more robust design. In one example, the mounting element is a cover mounted over a back of the annular housing, to sandwich the spring assembly between the housing and the cover.