Downlight Spring Fixing Structure with Insertion Lock
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Solution Overview
Problem
Traditional downlight spring fixing structures are complex to install manually, leading to low productivity and potential loose connections due to unbalanced forces during installation.
Innovation Solution
A downlight fixing structure featuring a housing with insertion lock structures and springs composed of a coil, head, and tail portions, where the head portion is inserted into a snap-fit component or raised part to secure the spring in place, allowing for automatic installation and preventing slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional spring fixing structures are used with inverse T slots, then the spring fixing function is achieved, but the installation process becomes complex and requires manual operation, leading to low productivity
Solution Approach 1:
The spring is divided into distinct functional segments: a head portion for insertion, a coil portion for elastic function, and a tail portion for engagement. The insertion lock structure is also segmented with a insertion channel and a locking component. This segmentation allows each part to perform its specific function independently, enabling automated insertion while maintaining secure fixation.
Solution Approach 2:
The insertion lock structure acts as an intermediary mechanism between the spring head and the housing. It provides a controlled path (insertion channel) for the spring to enter and a locking component to secure it, mediating the transition from manual to automated installation while ensuring reliable fixation.
2Reliability
If traditional spring fixing structures are used, then spring fixation is achieved, but unbalanced forces during installation can cause the spring to loosen and slide out, reducing reliability
Solution Approach 1:
The locking component is designed to preemptively counteract the unbalanced forces that occur during installation. As the spring head is inserted through the insertion channel, the locking component automatically engages with the spring head, creating a preliminary anti-action that prevents the spring from sliding out due to installation forces before the installation process is complete.
Solution Approach 2:
The insertion lock structure is designed to automatically lock the spring head in place through the interaction between the locking component and the spring head geometry. This self-service mechanism eliminates the need for additional manual operations to secure the spring, reducing installation complexity while maintaining high reliability.
3Manufacturing precision
If manual installation of spring fixing structures is used, then precise positioning can be achieved, but labor costs increase and automation is not possible
Solution Approach 1:
The insertion channel is pre-configured with specific geometric features that guide the spring head into the correct position automatically. The locking component is pre-positioned to engage with the spring head at the precise moment of insertion. This preliminary action ensures that automated insertion achieves the same positioning precision as manual installation without requiring human operators.
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
Facilitates easy and secure spring insertion and locking, enabling automated installation and reducing labor costs while ensuring stable fixation of downlights.
Implementation Method 1
The spring comprises a coil portion, a head portion, and a tail portion... The coil portion can be elastically deformed to push the tail portion towards the light component
Implementation Method 2
The spring cover comprises a snap-fit component below the bottom opening... The snap-fit component locks the head portion
Data Source
AI summary
A downlight fixing structure is provided. The downlight fixing structure comprises a housing and a spring. The housing is for accommodating light components. The housing has an insertion lock structure on a side of the housing. The spring comprises a coil portion, a head portion, and a tail portion. The coil portion, the head portion and the tail portion are formed by the same metal wire. The head portion is inserted into the insertion lock structure.