Integrated Lamp Plate Frame with Inclined Walls and Press-Fit Groove
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Solution Overview
Problem
Traditional LED panel lights face inefficiencies in manufacturing, installation, and transportation due to separate assembly of components, high packaging costs, and susceptibility to dust and damage.
Innovation Solution
An integrated lamp panel face frame design with inclined sidewalls and deformable pressing grooves for seamless diffusion plate installation, eliminating the need for screws and allowing panels to be stacked for transportation, along with a simplified assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the base plate and face frame are integrated, then the manufacturing process is simplified, but the installation stability and airtightness of the diffusion plate may be affected
Solution Approach 1:
The integrated lamp panel is segmented into functional zones: the deformable pressing groove for diffusion plate installation, the inclined sidewalls for stacking, and the face frame installation part for structural support. This segmentation allows each zone to perform its specific function optimally while maintaining overall integration.
Solution Approach 2:
The pressing groove is designed to be deformable, allowing it to change shape during installation to securely hold the diffusion plate. The sidewalls are designed with specific inclination angles that change the geometric parameters to enable stable stacking while maintaining a compact form factor.
2Productivity
If the diffusion plate is installed without screws using a sealing gasket, then the installation process is simplified, but additional accessories are required
Solution Approach 1:
The sealing function and the mounting function are merged into a single integrated structure. The deformable pressing groove serves both to seal the diffusion plate in place and to provide the mounting mechanism, eliminating the need for separate sealing gaskets and fasteners.
Solution Approach 2:
The pressing groove is designed to be self-sealing and self-fastening through its deformable structure. When the diffusion plate is inserted, the groove deforms to create a secure fit and seal automatically without requiring additional sealing accessories or manual fastening operations.
3Reliability
If lamp panels are packaged separately with corner guards, then product protection is improved, but transportation size and cost increase
Solution Approach 1:
The lamp panels are designed with inclined sidewalls that allow them to nest within each other during packaging. One panel can be placed inside or alongside another in a space-efficient arrangement, reducing the overall packaging volume while maintaining protection through the integrated structural design.
Solution Approach 2:
The inclined sidewalls create an asymmetric geometry that optimizes stacking and nesting arrangements. This asymmetric design allows panels to fit together more efficiently in packaging configurations compared to traditional symmetric designs, reducing the space required for corner guards and overall packaging volume.
4Reliability
If multiple screws are used to fix the diffusion plate and face frame, then installation stability is improved, but manufacturing efficiency decreases
Solution Approach 1:
The fastening function is extracted from the traditional multi-screw approach and replaced by the integrated deformable pressing groove structure. This extraction eliminates the need for multiple separate fastening operations while maintaining secure installation through the groove's deformable locking mechanism.
Solution Approach 2:
The mechanical screw-fastening system is replaced by a deformable structural system. The pressing groove uses elastic deformation and geometric interlocking instead of threaded mechanical fasteners, reducing the number of fastening operations from 20-40 screws to a single integrated deformation action.
Data Source
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AI summary
An integrated lamp plate surface frame, an integrated panel lamp without a surface frame and an assembly method therefor. The integrated lamp plate surface frame comprises an integrally formed lamp plate (1), wherein a bottom plate (11) of the lamp plate (1) and four side walls (12) of the lamp plate (1) are obliquely arranged; a deformable press-fit groove (121) protrudes from the periphery of inner walls of the side walls (12) of the lamp plate (1) to outer walls of the lamp plate (1), so as to mount a diffusion plate (2); and the periphery of ends of the side walls (12) of the lamp plate (1) is bent towards the bottom plate (11) of the lamp plate (1) to form a surface-frame mounting portion (13). In the integrated lamp plate surface frame, by means of the provided surface-frame mounting portion (13) formed by bending the periphery of the ends of the side walls (12) of the lamp plate (1) towards the bottom plate (11) of the lamp plate (1), the integration of the lamp plate (1) and the surface frame is realized; the side walls (12) of the lamp plate (1) are obliquely arranged, so that the lamp plate can be directly stacked when same is packaged and transported, thereby minimizing the package volume, thus reducing the transport volume, and decreasing the transport costs and the transfer costs; and the diffusion plate (2) is mounted in the provided deformable press-fit groove (12), such that the assembly procedure is simplified and dust and foreign matter are also prevented from entering the panel lamp, thereby improving the product quality.