Panel Light Diffuser Plate Sag Reduction via Opposing Rib Support
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Solution Overview
Problem
Existing panel lights exhibit significant variations in light pattern output when in normal use versus being laid flat for display due to sagging of the diffuser plate, affecting optical quality.
Innovation Solution
A panel light design featuring a frame with an annular retaining rim and ribs, a diffuser plate with opposing pressure points from the annular flange and ribs, and a base plate with an annular flange to stabilize the diffuser plate, reducing sagging and maintaining uniform light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the diffuser plate is made thinner to reduce panel height, then the panel height is reduced, but the diffuser plate strength is insufficient causing sagging
Solution Approach 1:
The patent uses a composite structure combining the diffuser plate with a support plate having elastic deformation capability. This composite system allows the diffuser plate to remain thin while the support plate provides the necessary mechanical strength to prevent sagging, resolving the contradiction between reduced height and maintained strength.
Solution Approach 2:
The patent introduces a new dimensional element by adding the support plate structure beneath the diffuser plate. This additional structural dimension provides strength support without increasing the overall panel height, as the support plate is integrated within the existing panel thickness.
2Strength
If the diffuser plate is made thicker to increase strength, then the diffuser plate strength is improved, but the panel height increases
Solution Approach 1:
The patent segments the structural function from the diffuser plate by introducing a separate support plate. The diffuser plate can remain thin for optical function while the support plate provides structural strength, avoiding the need to increase diffuser plate thickness and thereby preventing height increase.
3Stability of the object's composition
If the diffuser plate is clamped tightly to prevent deformation, then the diffuser plate stability is improved, but the light pattern quality deteriorates due to stress on the diffuser plate
Solution Approach 1:
The patent changes the mechanical parameter of the support plate to have elastic deformation capability. This allows the support plate to adapt to the diffuser plate during assembly, providing stability through elastic support rather than rigid clamping, thereby avoiding stress-induced light pattern degradation.
Solution Approach 2:
The support plate acts as an intermediary between the frame and the diffuser plate. It provides stable support while its elastic properties allow it to accommodate the diffuser plate without transmitting excessive clamping forces that would degrade light pattern quality.
4Device complexity
If the panel light structure is simplified to reduce manufacturing complexity, then the manufacturing cost is reduced, but the ability to maintain consistent light pattern in different orientations is compromised
Solution Approach 1:
The support plate serves multiple functions: it provides structural strength to prevent sagging, maintains diffuser plate stability, and ensures consistent light pattern output in different orientations. This multi-functionality achieves orientation-independent performance without significantly increasing structural complexity.
Data Source
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Figure 3
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AI summary
The present application relates to the technical field of illumination devices, and more particularly to a panel light. In the panel light, ribs (12) are arranged on the annular retaining rim (11) of the frame (10). During assembling, an edge portion of an outer surface (20a) of the diffuser plate (20) abuts against the ribs, and the annular flange (31) of the base plate (30) abuts against an edge portion of an inner surface (20b) of the diffuser plate (20) to fix an edge of the base plate (30) to the frame (10). Since the pressure of the annular flange (31) of the base plate (30) on the diffuser plate (20) and the pressure of the ribs (12) on the diffuser plate (20) are in opposite directions, the distance between a position where the annular flange (31) abuts on the diffuser plate (20) and a center of the diffuser plate (20) is smaller than the distance between a position where the rib abuts on the diffuser plate (20) and the center of the diffuser plate (20), so that the diffuser plate (20) will bulge outwards, thereby increasing the strength of the diffuser plate (20), such that the deformation of the diffuser plate (20) when the panel light being in a normal use state or being laid flat for display is relatively small, the sag phenomenon of the diffuser plate (20) by gravity is reduced, the distance between the light source assembly (40) and the diffuser plate (20) is within a predetermined range, thereby the output light pattern is relatively uniform when being in the normal use state or being laid flat for display, the difference is small, thus realizing the improvement of optical quality.