Downlight Spring Buckling Structure for Compact Mounting
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Solution Overview
Problem
Traditional downlights with screws for securing springs are cumbersome in production and increase packaging size and cost.
Innovation Solution
A downlight design featuring a housing with slots and buckling blocks that allow springs to be detachably connected, enabling adjustable positioning and installation on various hole sizes and depths, reducing production and packaging costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws are used to secure springs in traditional downlights, then the springs can be firmly fixed, but the assembly process becomes troublesome and production efficiency decreases
Solution Approach 1:
The patent replaces the screw-based mechanical fastening system with a buckling block system that uses elastic deformation and geometric interlocking. The buckling blocks are integrated into the housing structure and engage with the springs through a buckling action, eliminating the need for separate screw fasteners and simplifying the assembly process while maintaining secure spring fixation.
2Ease of operation
If springs stand upright in traditional downlights, then the springs can be easily installed, but the packaging box size increases and cost significantly adds up
Solution Approach 1:
The patent changes the spatial arrangement of the springs from a vertical upright configuration to a horizontal configuration where the springs are buckled to the housing along its length. This dimensional reorientation allows the springs to be compactly arranged within the housing footprint, significantly reducing the packaging volume while maintaining ease of installation through the buckling mechanism.
3Adaptability or versatility
If multiple slots with sub-slots are provided for spring attachment, then the downlight can be mounted on holes of different diameters and depths, but the housing structure becomes more complex
Solution Approach 1:
The patent segments the housing structure by incorporating multiple discrete slots with sub-slots at different positions and orientations. Each slot can independently receive and buckle a spring, allowing the system to accommodate various mounting configurations. This segmentation approach provides versatility for different hole diameters and depths while keeping each individual slot structure relatively simple.
4Ease of repair
If the rib is made movable to enable buckling block swinging, then the spring connection can be released, but the housing structure becomes more complex
Solution Approach 1:
The patent introduces dynamic elements to the housing structure by making the rib movable rather than fixed. The rib can swing between positioned and released states, enabling the buckling blocks to transition from engaged to disengaged positions. This dynamic mechanism allows for easy spring connection release while the rib remains an integrated part of the housing structure, minimizing additional complexity.
Data Source
AI summary
A downlight includes a cover, a reflector cup, a light source, a housing, and two springs. The housing has a boss, 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, and 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 comprises two slots. The two springs are configured to be respectively detachably connected to the two slots, and a selective one of two sub-slots of each of the two slots receives a corresponding one of the two springs.