Integrally Formed Lamp Panel Structure for High-Yield Stamping
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Solution Overview
Problem
The existing manufacturing process for lamp panels is inefficient, prone to steel damage under large-angle impact, and costly, with low yield and high pollution from powder paint spraying, failing to meet requirements for high efficiency and low cost.
Innovation Solution
A panel structure comprising a reflective film layer, an adhesion layer, a base material layer, and a protective layer, where the reflective film layer has a reflectivity greater than 95%, and the base material layer includes a metal layer with a chemical treatment layer, enhancing yield strength, tensile strength, and elongation percentage, allowing for integrally formed lamp panels with improved reflection and reduced film laminating costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional embedded lamp panels are manufactured by splicing multiple panels together, then the structural complexity is reduced, but the production efficiency is low and the manufacturing process is tedious
Solution Approach 1:
The patent merges multiple separate panels into a single integrated panel structure. The lamp panel comprises a front panel, rear panel, and side panels that are connected to form an integrated shell structure, eliminating the need for splicing multiple panels together and thereby improving production efficiency while reducing manufacturing complexity.
Solution Approach 2:
The integrated panel is segmented into functional regions including a light-emitting region with LED lamp bars, a driving region with driving assemblies, and a reflective region with high-reflective films. This segmentation allows for specialized manufacturing of each region while maintaining overall integration, resolving the contradiction between integration benefits and manufacturing complexity.
2Shape
If steel panels are subjected to large-angle impact during forming, then the shaping capability is improved, but the steel is prone to damage and the yield is low
Solution Approach 1:
The patent applies preliminary actions to the steel panel before large-angle impact forming. Chemical treatment layers are applied to the metal layer surface, and adhesion layers are pre-coated on the chemical treatment layers. These preliminary treatments enhance the steel's resistance to damage during subsequent large-angle impact forming operations, maintaining both shaping capability and reliability.
Solution Approach 2:
The patent creates a composite structure with multiple layers including metal layers, chemical treatment layers, adhesion layers, and high-reflective film layers. This composite material structure provides both the necessary formability for large-angle impact shaping and enhanced durability to prevent damage during the forming process, thereby maintaining high yield.
3Illumination intensity
If powder paint spraying is used after lamp panel production, then the light-reflecting effect is achieved, but the cost is high and the process is high-pollution
Solution Approach 1:
The patent replaces the mechanical powder paint spraying process with a chemical and physical coating approach. High-reflective films are directly coated or laminated onto the chemical treatment layers of the metal panels, eliminating the need for powder paint spraying. This substitution achieves the light-reflecting effect while reducing pollution and manufacturing cost.
Solution Approach 2:
The patent changes the reflective surface parameters by applying high-reflective films with specific optical properties directly to the panel surface. The reflective films have reflectivity greater than 95% in the visible light range, providing superior light-reflecting performance compared to powder painting, while eliminating the environmental pollution and high costs associated with powder paint spraying processes.
4Adaptability or versatility
If multiple panels are spliced together to form the lamp shell, then the manufacturing flexibility is maintained, but the production efficiency is low and the process is tedious
Solution Approach 1:
The patent combines multiple functional panels into a single integrated lamp panel structure that includes front panels, rear panels, side panels, and functional regions for LEDs and driving assemblies. This merging maintains manufacturing flexibility through modular functional regions while dramatically improving production efficiency by eliminating the splicing process.
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
The panel structure increases yield and production efficiency, simplifies the production process, reduces costs, and enhances the reflection effect, while the integrally formed lamp panels improve fixation and transportation efficiency, and the anti-glare effect is achieved with wave or bead grains on the lampshade.
Implementation Method 1
the adhesion layer covers the reflective layer on the base material layer by adhering to the chemical treatment layer
Implementation Method 2
the reflective film layer is arranged on one surface of the base material layer through the adhesion layer... a reflectivity of the reflective film layer is greater than 95%
Data Source
AI summary
The present application relates to a panel structure for stamping of an integrally formed lamp panel. The panel structure for stamping of the integrally formed lamp panel at least includes a reflective film layer, an adhesion layer, a base material layer and a protective layer, wherein the reflective film layer is arranged on one surface of the base material layer through the adhesion layer, and the protective layer is arranged on the other surface of the base layer; the base material layer includes a metal layer, and a chemical treatment layer arranged on at least one surface of the metal layer, the base material layer can be integrally formed lamp panel with the reflective film layer. The present application has the following beneficial effects: the panel structure can be applied to stamping of the integrally formed lamp panel; the yield is increased and the production efficiency is improved.