Direct-Lit Panel Lamp Steel Frame Structure for Lower-Cost Assembly
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Solution Overview
Problem
Existing direct-lit panel lights face issues with high manufacturing costs, low structural strength, and cumbersome manufacturing processes due to the use of aluminum frames, which are prone to cracking and require complex milling for screw connections.
Innovation Solution
A direct-lit panel light design utilizing a frame composed of integrally formed steel frame strips with bent walls, connected end-to-end, and a stable fastening mechanism between the lamp panel and frame, along with a lamp shade and light source assembly, to enhance structural strength and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If aluminum extruded frame is used, then the frame can be easily formed, but the structural strength is low and cracking occurs when bent
Solution Approach 1:
The patent changes the material parameter from aluminum to steel, fundamentally altering the mechanical properties of the frame. This material substitution resolves the contradiction by providing both high strength and resistance to cracking while maintaining formability through steel's ductile characteristics.
Solution Approach 2:
The frame is constructed as a composite structure combining steel material with a specific geometric configuration of bent walls. This composite approach integrates the high strength of steel with the formability achieved through the bent wall geometry, simultaneously addressing both ease of manufacture and structural strength requirements.
2Ease of operation
If threaded grooves are milled on aluminum extruded frame, then screw connection with base is enabled, but the manufacturing process becomes cumbersome
Solution Approach 1:
The threaded grooves are pre-formed during the steel plate rolling process rather than being milled afterward. This preliminary action integrates the connection feature into the main manufacturing flow, eliminating the need for separate milling operations and reducing overall manufacturing complexity while maintaining connection capability.
Solution Approach 2:
The patent merges the frame forming process with the threaded groove creation process. By integrating these two operations into a single steel plate rolling step, the manufacturing process is simplified, reducing the number of separate operations required while ensuring both the frame structure and connection features are properly formed.
3Ease of manufacture
If aluminum frame is used, then the frame can be formed, but the material cost and processing cost are high leading to high overall lamp cost
Solution Approach 1:
The patent changes the material parameter from aluminum to steel, which has different cost characteristics. This material substitution resolves the cost contradiction by utilizing steel's lower material cost and reduced processing requirements, thereby lowering the overall lamp cost while maintaining formability through appropriate steel selection and processing methods.
Data Source
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AI summary
The present application discloses a direct-lit panel light, including a lamp panel, a frame, a lamp shade, and a light source assembly. An outer peripheral edge of the lamp panel is provided with a support part and a first connecting part; the first connecting part is provided with a first connecting hole; and an accommodating cavity is formed inside the lamp panel; the frame is arranged around the outer peripheral edge of the lamp panel; the frame includes a plurality of frame strips connected end to end; each frame strip is integrally formed and includes a plurality of bent walls; the plurality of bent walls jointly enclose to form a first accommodating groove and a second accommodating groove adjacent to the first accommodating groove; a bottom wall of the second accommodating groove is provided with a second connecting hole; the first connecting part is accommodated in the second accommodating groove; and the first connecting hole and the second connecting hole are connected by a fastener; an outer peripheral edge of the lamp shade is accommodated in the first accommodating groove and abuts against the support part; and the light source assembly is arranged in the accommodating cavity and configured to emit light toward a side of the lamp shade. Compared with the prior art, the direct-lit panel light has lower manufacturing cost and higher structural strength.