Modular Baffle Components for Deep Ridge Downlight Manufacturing

Solution Overview

Problem

Current manufacturing techniques, such as molding, struggle to produce square or rectangular downlight baffles with deep ridges due to mold design limitations, resulting in aesthetically unappealing and costly alternatives.

Innovation Solution

The use of modular baffle components made of opaque material with coupling features allows for the assembly of square or rectangular shapes, enabling the creation of baffles with deep ridges that can be molded using a two-piece mold, avoiding re-entrant shapes that complicate mold removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If molding techniques are used to produce square or rectangular downlight baffles with deep ridges, then the baffles can be manufactured, but the mold design becomes complex and costly due to re-entrant shapes that complicate mold removal

Engineering Contradiction:

Improvemanufacturability of baffleVSAvoidmold design complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The baffle is divided into multiple modular components that can be assembled together to form the complete baffle structure. Each component can be manufactured separately using standard molding techniques without complex re-entrant shapes, and then assembled to create the final product with deep ridges and square/rectangular geometry.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If modular baffle components are used to avoid re-entrant shapes, then mold removal is simplified, but the assembly process becomes more complex

Engineering Contradiction:

Improvemold removal easeVSAvoidassembly process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The baffle is divided into multiple modular components that can be assembled together to form the complete baffle structure. Each component can be manufactured separately using standard molding techniques without complex re-entrant shapes, and then assembled to create the final product with deep ridges and square/rectangular geometry.

Inventive Principle:

Principle #1Segmentation

3Shape

If deep ridges are added to the baffle for aesthetic appeal and glare reduction, then the visual quality improves, but the manufacturing difficulty increases due to mold design limitations

Engineering Contradiction:

Improveaesthetic quality of baffleVSAvoidmanufacturing ease of baffle

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The baffle is divided into multiple modular components that can be assembled together to form the complete baffle structure. Each component can be manufactured separately using standard molding techniques without complex re-entrant shapes, and then assembled to create the final product with deep ridges and square/rectangular geometry.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11339949B1Downlight luminaire baffles and baffle components

Publication Date: 2022.05.24 ABL IP HLDG LLC

AI summary

A baffle component for a luminaire includes a portion of opaque material that forms a front surface and a back surface as major surfaces. The front surface includes multiple ridges. The material also includes a top surface and a bottom surface, and a first end surface and a second end surface. The first end surface includes a first coupling feature, and the second end surface includes a second coupling feature that is configured to engage the first coupling feature of a second baffle component that is substantially identical to the baffle component. A baffle for a luminaire includes a plurality of such components. The baffle components engage with one another, with the first coupling feature of each of the baffle components engaging with the second coupling feature of another of the baffle components, to form a shape that surrounds a central opening of the luminaire.