Medical Lighting Device Fixing Orifices Molding
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Solution Overview
Problem
Conventional medical lighting devices for operating theaters face high manufacturing costs and complexity due to the need for drilling or tapping orifices for fixing lighting modules, which are oriented non-parallel and vary in angle, making the process tedious and costly.
Innovation Solution
A method of producing a lighting device where orifices are created during molding, with a sphere-shaped fixing member and complementary housing allowing for angle adjustment and using self-tapping screws, reducing manufacturing complexity and cost, and incorporating conical orifices for easier demolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If holes for fixing modules are drilled or tapped after molding, then the lighting modules can be fixed to the body, but the manufacturing process becomes tedious and costs increase significantly
Solution Approach 1:
The fixing holes are pre-formed in the mold itself before the actual molding process. This preliminary action eliminates the need for subsequent drilling or tapping operations, directly resolving the contradiction by maintaining reliable fixing capability while dramatically simplifying the manufacturing process and reducing costs
2Shape
If the body is made by casting with a concave shape, then the desired form is achieved, but the bottom wall cannot be perpendicular to the demolding direction
Solution Approach 1:
The mold is designed with pre-formed holes that are oriented perpendicular to the demolding direction before the molding process begins. This preliminary design of the mold allows the concave shape to be achieved while maintaining precise hole orientation, as the holes are formed during molding rather than requiring post-processing
3Adaptability or versatility
If multiple holes with varying orientations are drilled to match module positions, then modules can be fixed at different angles, but the manufacturing process becomes more complex and costly
Solution Approach 1:
A single spherical fixing element is designed to perform multiple functions: it can accommodate holes with different orientations and allow modules to be fixed at various angles. This universal element eliminates the need for multiple specially-oriented holes, maintaining adaptability while significantly reducing manufacturing complexity
Data Source
Figure 1~2
Figure 3~4
AI summary
This document describes a method for making a lighting device, comprising the steps of obtaining a body (4) by molding using a mold having a parting line, the body (4) having at least one bottom surface (5) inclined with respect to the parting line and fixing holes (8) extending perpendicularly to the parting line, the body (4) being removed from at least a part of the mold by translation along a demolding direction perpendicular to the demolding plane, then fixing at least one lighting module (9) having a base optical block (10) fixed to said bottom surface (5) of the body (4), by means of at least one fixing member (15, 16) engaged at least in part in one of the fixing holes (8) of the body (4), the fixing member (15, 16) having a portion (16) in the form of a portion of a sphere engaged in a housing (10b) of complementary shape to the base optical block (10).