Recessed Lamp Sealed Enclosure Design

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Solution Overview

Problem

Conventional recessed light source enclosures in IP66 environments face issues with dust and moisture ingress, leading to damage and potential explosions due to toxic gas exposure, and are prone to glass breakage from excessive stress points.

Innovation Solution

A recessed enclosure design featuring a housing with a mounting fixture, a lid frame with a first groove and gasket for sealing, and retainer clips to prevent dust and moisture ingress, reducing stress on the glass lid and ensuring safe operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the lid is attached hingably to the housing with multiple holes for screws, then the enclosure can be assembled and disassembled, but dust and moisture can enter through the holes and gaps, damaging the light source

Engineering Contradiction:

Improveassembly and disassemblyVSAvoiddust and moisture ingress

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

A gasket is introduced between the lid and housing to create a flexible sealing barrier. The gasket compensates for gaps and holes in the rigid structure, preventing dust and moisture ingress while maintaining the hinged attachment mechanism for easy assembly and disassembly.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The gasket acts as an intermediary element between the lid and housing, filling the gaps and holes created by the hinged attachment system. This mediator prevents harmful factors from penetrating through the necessary openings required for assembly operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If multiple holes are punctured on the glass lid and housing for fastening, then the enclosure can be securely assembled, but the stress on the areas surrounding the holes increases, making the glass more prone to breakage

Engineering Contradiction:

Improveattachment strengthVSAvoidglass breakage risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Instead of distributing fastening points across multiple holes in the glass lid, the design concentrates the attachment mechanism at specific locations using the hinged lid structure. This localizes the stress to manageable areas rather than creating multiple high-stress concentration points across the glass surface.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The gasket and hinged attachment mechanism serve as intermediaries that transfer and distribute fastening forces away from the glass lid itself, reducing direct stress on the glass material while maintaining secure attachment between the lid and housing.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a sealed enclosure is used to prevent dust and moisture ingress, then the light source is protected, but the complexity of the enclosure structure increases

Engineering Contradiction:

Improveprotection from dust and moistureVSAvoidenclosure structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A simple gasket (flexible thin film) is used to create the seal between the lid and housing. This single component provides comprehensive protection against dust and moisture ingress without requiring complex multi-layer sealing systems or additional protective structures.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sealing function is merged with the existing lid and housing structure through the gasket integration. The gasket combines the sealing, stress distribution, and gap-filling functions into a single element, avoiding the need for separate complex sealing mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

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 enclosure effectively prevents dust and moisture ingress, reduces the risk of glass breakage, and ensures safe operation by minimizing stress on the lid while maintaining ease of installation and light emission.

Implementation Method 1

A first gasket is configured to be housed in the first groove

Methodology Applied

Scientific EffectSealing:

Implementation Method 2

A transparent body is nested in the crevice for reflecting light, emitted by the light source, through the opening

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 3

The retainer clips are configured to compress and seal the first gasket in the first groove

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS11852315B2Recessed lamp with sealed enclosure

Publication Date: 2023.12.26 APPLETON GROUP LLC

AI summary

A lamp includes a light source, a housing having a mounting fixture fitting the light source, a lid frame defining an opening, a first gasket provided in a first groove formed in the lid frame, a transparent body nested with the first gasket and reflecting light emitted by the light source to be outputted through the opening, retainer clips provided along longitudinal edges of the first groove to compress and seal the first gasket to prevent ingress of dust and moisture through the opening, and three fasteners to securely attach the lid frame to the housing. The housing is configured to be installed recessed of a supporting surface.