Lighting Frame Tongue-and-Pocket Joint Design
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Solution Overview
Problem
Recessed lighting fixtures often experience light leakage through gaps at the joints of their frames, which can negatively affect their aesthetic appearance and require additional components for coverage, leading to assembly challenges and potential failures.
Innovation Solution
The lighting fixture frame is designed with a configuration where at least one side of each joint includes a tongue that fits into a pocket on the opposing side, effectively obscuring the gap and preventing light leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a separate component (e.g., adhesive backed material) is used to cover the gap at the joint, then light leakage is mitigated, but assembly complexity increases and reliability decreases due to adhesive failure over time
Solution Approach 1:
The gap covering function is merged into the frame structure itself by forming an overlapping configuration where one side of the frame overlaps the other side at the joint. This eliminates the need for separate gap covering components and adhesives, thereby reducing assembly complexity while maintaining light leakage mitigation.
Solution Approach 2:
The frame structure serves its own gap covering need through its overlapping configuration. The geometry of the frame sides themselves provides the light blocking function, eliminating the need for additional materials like adhesive backed coverings and reducing potential points of failure.
2Object-affected harmful factors
If a separate component (e.g., adhesive backed material) is used to cover the gap at the joint, then light leakage is mitigated, but reliability decreases due to adhesive failure from age and heat
Solution Approach 1:
The gap covering function is merged into the frame structure itself through overlapping sides, eliminating the need for separate adhesive-based components. This integration removes the adhesive from the system entirely, preventing adhesive failure due to age and heat while maintaining effective light leakage prevention through the geometric overlap.
Solution Approach 2:
The frame structure provides its own light blocking capability through the overlapping configuration of its sides. This self-service approach eliminates dependence on external adhesive materials that are susceptible to degradation, thereby improving long-term reliability while maintaining aesthetic appearance.
3Object-affected harmful factors
If separate parts are used for each gap at the joints, then light leakage is addressed, but manufacturing and assembly complexity increases
Solution Approach 1:
The gap covering function is merged into the frame structure itself through overlapping sides, eliminating the need for separate gap covering parts. This reduces the total part count and simplifies manufacturing processes while maintaining effective light leakage prevention at all joints.
Solution Approach 2:
The overlapping frame side configuration serves multiple functions simultaneously: it provides structural integrity to the frame, maintains aesthetic appearance by concealing joints, and prevents light leakage. This multi-functionality eliminates the need for dedicated separate parts for each function, simplifying manufacturing.
Data Source
AI summary
A lighting fixture may include a housing, an illumination source disposed within the housing, and a frame coupled to the housing. The frame may include a first side and a second side abutting the first side to form a joint, wherein a gap extends at the joint and at least one of the first side or the second side is configured to obscure at least a portion of the gap.