Lamp Frame Manufacturing via Integrated Base and Corner Welding
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Solution Overview
Problem
The existing methods for manufacturing lamps require a separate edge or frame element to be produced and applied to the lamp trough, complicating the manufacturing process and not allowing for a seamless, visually appealing outer surface.
Innovation Solution
A method involving the production of a box-shaped base part with 90° bends, followed by the creation and connection of corner parts through welding to form a continuous, visible lamp frame, eliminating the need for a separate frame element and allowing for design flexibility such as sloping surfaces and rounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a separate edge or frame element is produced and applied to the lamp trough, then a visible outer surface is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention merges the lamp trough and frame into a single integrated component. The lamp trough is designed with side walls that are bent at angles other than 90° to form the frame structure directly, eliminating the need for separate frame elements. This integration simplifies the manufacturing process while maintaining the visible outer surface quality.
Solution Approach 2:
The side walls of the lamp trough are segmented into different functional zones: the base area, the side wall portion forming the visible frame, and the connection areas. By bending these segments at specific angles, the frame structure is formed directly from the trough material, reducing manufacturing steps.
2Shape
If a separate frame element is produced and connected to the lamp trough, then a lamp frame is formed, but visible transitions and seams appear
Solution Approach 1:
By forming the frame directly from the lamp trough material through bending operations, the invention eliminates the boundaries between separate components. The continuous material flow ensures no visible transitions or seams appear, achieving a seamless appearance while maintaining structural integrity.
Solution Approach 2:
The side walls are given different local qualities through selective bending. Certain portions are bent at angles other than 90° to create the visible frame surface, while other portions maintain the original configuration for structural support. This local differentiation achieves both aesthetic and functional requirements without visible joints.
3Ease of manufacture
If the side walls are bent at 90° only, then the lamp trough structure is simple, but the frame appearance is limited
Solution Approach 1:
The invention changes the geometric parameters of the side wall bends from fixed 90° angles to variable angles. By bending side walls at angles other than 90°, the frame can achieve different visual appearances and proportions while maintaining the basic lamp trough structure. This parameter variation provides design flexibility without significantly complicating manufacturing.
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 approach simplifies the lamp manufacturing process, enables a seamless and visually appealing frame without visible transitions, and allows for customization of the frame's appearance, enhancing the lamp's external appearance and functionality.
Implementation Method 1
The connection is made by welding in step c)
Implementation Method 2
A side wall of the box-shaped base part is advantageously bent to form the lamp frame
Implementation Method 3
The forming mentioned in step b2) can be deep drawing, for example
Data Source
Figure 1
Figure 2~3
AI summary
The method involves manufacturing a box-shaped base part to form a lamp tray (2) of the lamp. Corner portions (14,14',14'',14''') are manufactured and are connected with the box-shaped base part for forming a lamp frame (16). The connection takes place by welding. A part is stamped out for manufacturing the corner portions. The corner portions are formed by shaping the stamped out part.