Screw-Free Downlight Fixation via Snap-Fit Slots
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Solution Overview
Problem
Current embedded downlights require manual screw locking or riveting for fixation, leading to increased production costs, reduced efficiency, and potential human error. Additionally, installation issues arise due to ceiling structure conflicts and inconvenient dip switch access.
Innovation Solution
A downlight with a screw-free fixation structure featuring a lamp body with a central hole, inner ring body, and protrusions, which engage with a disc-shaped light source board through slots and locking points, eliminating the need for additional fixing components and allowing for automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw locking or riveting is used to secure the light source board, then the fixation is reliable, but the production time and manpower costs increase
Solution Approach 1:
The patent replaces the traditional mechanical screw locking or riveting system with a snap-fit mechanical engagement system. The light source board features positioning protrusions that engage with corresponding positioning slots on the lamp body, eliminating the need for screws or rivets. This substitution maintains fixation reliability while enabling automated assembly, thereby improving production efficiency.
Solution Approach 2:
The light source board is designed with self-fixing features where positioning protrusions automatically engage with positioning slots during installation. The elastic deformation of the lamp body material provides self-locking capability, allowing the light source board to secure itself without additional fastening operations. This self-service mechanism reduces manual intervention and production time while ensuring reliable fixation.
2Reliability
If screw locking or riveting is used to secure the light source board, then the fixation is reliable, but the material costs increase due to additional fixing components
Solution Approach 1:
The patent extracts and eliminates the additional fixing components (screws, rivets) from the assembly system. The fixation function is integrated directly into the light source board and lamp body structures through positioning protrusions and slots. This extraction removes unnecessary material consumption while maintaining reliable fixation through the engineered mechanical engagement of the integrated features.
Solution Approach 2:
The patent merges the fixation function with the structural components of the light source board and lamp body. The positioning protrusions and slots are integrated into the existing parts rather than being separate fastening elements. This merging eliminates the need for additional fixing components, reducing material costs while ensuring reliable fixation through the combined structural design.
3Device complexity
If the dip switch is disposed on the driver, then the driver functions are complete, but the user access to dip switches becomes difficult
Solution Approach 1:
The patent relocates the dip switch from the driver's internal position to the outer surface of the lamp body, changing its spatial dimension and accessibility. The dip switch is positioned on the external surface where users can easily reach and operate it, while the driver maintains all its functional components. This dimensional relocation resolves the conflict between complete driver functionality and user accessibility.
Solution Approach 2:
The lamp body serves as an intermediary structure that hosts the dip switch on its outer surface while maintaining connection to the driver internally. This intermediary positioning allows the dip switch to be accessible to users on the external surface while still being functionally connected to the driver's control circuitry, resolving the accessibility issue without compromising driver functionality.
Data Source
AI summary
A downlight with screw-free fixation structure includes a lamp body and a light source board. The lamp body has a central hole, an inner ring body, and a plurality of protrusions. The inner ring body is disposed on the inner edge of the lamp body to partially cover the central hole. The protrusions are distributed along the inner edge of the lamp body and surrounding the central hole. A plurality of slots are formed respectively between the protrusions and the inner ring body. The light source board is disposed on the inner ring body and within the central hole, and engaged with the multiple slots. The light source board is disc-shaped.