LED Downlight Assembly Mechanism with Spring-Loaded Clamping
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Solution Overview
Problem
The complexity and fragility of LED downlight components during assembly and transportation lead to loose or failed installations due to increased parts and functions, making cost-efficient and simple assembly challenging.
Innovation Solution
An assembly mechanism for LED downlights featuring a cylindrical body with springs, a cover, a sealing strip, and a glass window, utilizing clamping gaps, stop bars, and barbs to securely fasten components, preventing loosening during rotation and ensuring waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If multiple LED chips are integrated into high-power light sources to reduce size, then power consumption decreases and brightness increases, but assembly complexity increases and components become difficult to fix
Solution Approach 1:
The patent divides the LED downlight into modular components: a head assembly containing the LED module and driver, and a separate body assembly with reflective cup and lens. These modules are designed to be independently manufactured and then assembled together, reducing overall assembly complexity while maintaining the high-power integrated LED benefits
Solution Approach 2:
The patent employs nested结构设计 where the LED module is integrated within the head assembly, which then connects to the body assembly. The reflective cup is positioned within the body to hold the LED module, creating a compact nested arrangement that simplifies the overall structure while maintaining high power density
2Illumination intensity
If multiple functional parts are added to improve lighting effects, then lighting performance improves, but assembly difficulty and component loosening during transport increase
Solution Approach 1:
The patent incorporates preliminary assembly features during manufacturing, such as pre-installed fixing ears on the reflective cup, pre-positioned sealing rings, and pre-formed connecting structures. These preliminary actions ensure that when modules are assembled, components remain securely fixed and do not loosen during transport, maintaining both lighting performance and reliability
Solution Approach 2:
The patent combines multiple functions into integrated components: the head assembly integrates the LED module, driver circuit, and connection terminals; the body assembly combines the reflective cup, lens, and sealing structures. This merging reduces the number of separate parts that could potentially loosen, while still providing enhanced lighting effects through the coordinated functionality of these multi-functional assemblies
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 mechanism provides a secure and cost-efficient assembly process that maintains component alignment and functionality during transport and installation, preventing failures and ensuring reliable operation.
Implementation Method 1
at least one spring (20) is fixed on the cylindrical body (10)... the cover (30) is mounted on the spring (20)... allowing the cover (30) to move relative to the cylindrical body (10) in an axial direction
Data Source
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AI summary
An assembly mechanism for LED downlight includes a cylindrical body (10), at least one spring (20) fixed on the cylindrical body (10), and a cover (30) assembled on the at least one spring (20). Each of the at least one spring (20) includes a fixing portion (21), a reed (22) extending from the fixing portion (21) along a rotation direction of the cylindrical body (10), and a catching portion (23) disposed on the reed (22). The catching portion (23) extends along the radial direction of the cylindrical body (10). The cover (30) includes at least one clamping gap (31). Each of the at least one clamping gap (31) includes an opening (313) provided along the rotation direction of the cylindrical body (10). The catching portion (23) is inserted into the clamping gap (31) from the opening (313) by rotating the cover (30).