Lighting Apparatus Modular Assembly for Cost Reduction
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Solution Overview
Problem
The complexity in assembling lighting devices leads to high manufacturing costs, necessitating a design with an easy assembly structure for cost-effective production and efficient lighting solutions.
Innovation Solution
A lighting apparatus featuring a light source plate mounted on a support plate with a surface rim and light passing cover, incorporating a driver for power conversion, wireless module, and heat dissipation features, along with a reflective layer and elastic clips for secure alignment and easy installation, facilitating simplified assembly and enhanced light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lighting devices are assembled with complex structures, then manufacturing precision and reliability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The lighting device is divided into separate modular components: a light source module with light-emitting elements mounted on a circuit board, a housing structure, and a reflective surface. These modules can be manufactured independently and assembled through simple snap-fit or screw connections, reducing overall assembly complexity while maintaining reliability through standardized interfaces
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical support for the light source module, acts as a heat dissipation pathway, and incorporates the reflective surface for light distribution. This multi-functionality reduces the number of separate components needed, simplifying assembly while ensuring reliable operation
2Manufacturing precision
If traditional lighting devices use complex assembly structures, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The light-emitting elements are pre-mounted and soldered onto the circuit board in a controlled manufacturing environment to ensure precise electrical connections and optimal light output. This preliminary assembly of the light source module allows for quality control at an early stage, ensuring manufacturing precision while simplifying the final device assembly process
Solution Approach 2:
The circuit board serves as an intermediary platform that provides both mechanical support and electrical connectivity for the light-emitting elements. This standardized intermediate component enables precise positioning and electrical connection without requiring complex assembly operations, thereby reducing manufacturing cost while maintaining precision
3Ease of manufacture
If lighting devices are designed with easy assembly structures, then ease of manufacture is improved, but device complexity may increase
Solution Approach 1:
The light source module is designed to nest within the housing structure, with the circuit board and light-emitting elements contained within a compact assembly that fits into the larger housing. This nested arrangement simplifies manufacturing by allowing modular production while maintaining a compact, integrated final product that does not appear overly complex
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 design enables cost-effective and efficient assembly of lighting devices with improved light quality and flexibility, reducing manufacturing costs while ensuring reliable performance and easy installation.
Implementation Method 1
a driver, shown at 22, is placed on the circuit board 21. The driver 22 converts an external power source to a driving current supplied to the light source 23.
Implementation Method 2
The inner wall has a reflective layer used for reflecting a light of the light source.
Data Source
AI summary
A lighting apparatus includes a light source plate, a surface rim and a light passing cover. The light source plate is mounted with a light source. The light source plate is placed upon the support plate. The surface rim has an inner wall and an exterior wall. The inner wall has a top part and a bottom part. A bottom diameter of the bottom part is smaller than a top diameter of the top part. The light source is placed closer to the bottom part of the inner wall and surrounded by the bottom part of the inner wall. The light passing cover is attached to the top part of the inner wall. An exterior edge of the exterior wall is attached to a peripheral edge of the support plate.