Direct-Lit Panel Lamp Riveting for Thin Base Plate Assembly
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Solution Overview
Problem
Panel lamps with thin base plates face challenges in securely fixing light source boards due to difficulties in drilling threaded holes, leading to potential loosening of screws and instability.
Innovation Solution
A direct lighting type panel lamp design that uses rivets with flexible washers and thermally conductive tape to securely attach light source boards to the base plate, eliminating the need for threaded holes and ensuring long-term stability, along with a connecting component for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If threaded holes are drilled and screws are used to fix the light source board, then the light source board can be securely attached, but the base plate thickness must be sufficient to accommodate threaded holes
Solution Approach 1:
The patent replaces the traditional screw-threaded hole mechanical connection system with a rivet-based mechanical fastening system. The rivet passes through both the base plate and light source board, and is then deformed using a rivet pulling tool to create a secure permanent connection, eliminating the need for threaded holes in the base plate
Solution Approach 2:
The patent introduces a flexible washer as an intermediary component between the rivet and the base plate. This flexible washer distributes the mechanical stress and provides a stable mounting surface, enabling reliable rivet fixation even in ultra-thin base plates where traditional mechanical fastening would fail
2Ease of manufacture
If screws are used to fix the light source board in thin base plates, then initial attachment is achieved, but the screws are likely to loosen during use
Solution Approach 1:
The patent replaces the reversible screw connection system with an irreversible rivet deformation system. The rivet is inserted through both components and then mechanically deformed using a rivet pulling tool to create a permanent, non-loosening connection that maintains stability throughout the product lifecycle
Solution Approach 2:
The patent employs a rivet pulling tool to perform preliminary deformation of the rivet during the assembly process. This preliminary action pre-loads and secures the connection between the base plate and light source board, preventing any subsequent loosening that would occur with traditional screw fastening
3Ease of manufacture
If traditional gluing methods are used to attach the light source board, then assembly is simple, but the bonding strength and heat dissipation are insufficient
Solution Approach 1:
The patent replaces the chemical bonding mechanism of gluing with a mechanical fastening mechanism using rivets. The rivet physically penetrates and mechanically interlocks both the base plate and light source board, providing superior bonding strength compared to adhesive methods while maintaining assembly simplicity
Solution Approach 2:
The patent employs a composite fixation system combining the rigid rivet structure with the flexible washer material. This composite approach provides both the mechanical strength of metal fastening and the stress-distributing properties of flexible materials, achieving superior bonding strength while maintaining ease of assembly
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 solution provides a stable and durable attachment of light source boards, preventing loosening and improving heat dissipation, while allowing for uniform lighting and easy assembly, without the risks of traditional gluing methods.
Implementation Method 1
a flexible washer is arranged between the rivet and the base plate
Implementation Method 2
a thermally conductive tape is arranged between the light source board and the base plate
Data Source
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AI summary
The present disclosure discloses a direct lighting type panel lamp, which comprises a base plate (1), at least one light source board (2) arranged on the base plate (1), a rivet (3) connected between the light source board (2) and the base plate (1), and a diffusion plate (4) connected to the base plate (1). The base plate (1) is provided with a first riveting through hole (11), the light source board (2) is provided with a second riveting through hole (21), and the rivet (3) passes through the first riveting through hole (11) and the second riveting through hole (21) so that the light source board (2) is in riveting connection to the base plate (1). During assembling of the direct lighting type panel lamp, the light source board (2) is first placed on the base plate (1), and the second riveting through hole (21) of the light source board (2) is aligned with the first riveting through hole (11) of the base plate (1), a rivet (3) is passed through the first riveting through hole (11) and the second riveting through hole (21), and the rivet (3) is deformed into a desired pattern by using a rivet pulling tool, so that the light source board (2) is closely attached to the base plate (1), such that the light source board (2) is fixedly mounted to the base plate (1). This can ensure long-term stability and less loosening of the light source board (2), as compared with the manner of screw connection.