Panel Light Spacer Alignment Mechanism
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Solution Overview
Problem
Existing panel lights face challenges in achieving accurate alignment of their lighting components due to high tolerances, leading to lighting deficiencies like bright spots.
Innovation Solution
The design incorporates spacers with recessed side edges that guide and secure the light passage panel and LED modules within the frame body, allowing for precise alignment and efficient light emission, with the spacers being easily producible by methods like laser cutting for minimal tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If individual components are positioned and aligned separately within the frame body, then each component can be independently installed, but alignment accuracy deteriorates due to high tolerances leading to lighting deficiencies
Solution Approach 1:
The patent introduces alignment markers as intermediary reference elements that are pre-positioned on the frame body. These markers serve as mediators between the frame body and the optical components, providing a common reference system that enables accurate alignment without requiring complex separate positioning operations. The markers create a standardized interface that resolves the tolerance accumulation problem.
Solution Approach 2:
The alignment markers are pre-positioned and fixed to the frame body before the optical components are installed. This preliminary action establishes the reference framework in advance, allowing subsequent components to be aligned relative to these pre-positioned markers rather than requiring independent positioning of each component, thereby improving overall alignment accuracy.
2Reliability
If separate fixing means are used for each component, then each component can be securely fixed, but device complexity increases due to multiple additional components
Solution Approach 1:
The patent combines the alignment reference function and the fixation function into an integrated solution. The alignment markers are designed to serve dual purposes: they provide the reference for accurate positioning and simultaneously serve as the fixation mechanism. This merging eliminates the need for separate fixing means while maintaining secure attachment, thereby reducing device complexity without compromising reliability.
Solution Approach 2:
The alignment markers are designed as multi-functional elements that perform multiple functions: they serve as alignment references, positioning guides, and fixation points. This universality allows a single component to replace what would traditionally require multiple separate components (alignment tools plus fixing mechanisms), thereby reducing overall device complexity while maintaining both alignment accuracy and secure fixation.
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention is directed to a panel light (1) comprising a frame body (2) having a front wall (20) with an opening (21), and a sidewall (22) at least partially surrounding the front wall (20), an LED module (3) extending along a first section (221) of the sidewall (22), and a light passage panel (5) covering the opening (21) to allow light emitted by the LED module (3) exiting the panel light (1) via the light passage panel (5) and the opening (21). The panel light (1) further comprises a first spacer (6) having two opposing surfaces (60) being connected via a circumferential first side edge (61), the first spacer (6) extending with a first side edge section (610) above the first sidewall section (221), and a second spacer (7) having two opposing surfaces being connected via a circumferential second side edge (71), the second spacer (7) extending with a second side edge section (710) above a second sidewall section (222) being opposite to the first sidewall section (221). The first spacer (6) has a first recessed side edge section (611) opposite to and offset towards the first sidewall section (221), and the second spacer (7) has a second recessed side edge section (711) opposite to and offset towards the second sidewall section (222) and facing the first recessed side edge section (611). At least part of the light passage panel (5) extends between the first and second spacers (6, 7) such that opposite peripheral edge sections (50, 51) of the light passage panel (5) are received by the first and second recessed side edge sections (611, 711), respectively, to push the spacers (6, 7) towards the opposite first and second sidewall sections (221, 222), respectively.