Ultra-thin Downlight Thermal Dissipation via Segmented Housing

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Solution Overview

Problem

Current downlights face issues with low thermal dissipation performance, leading to component deformation and reduced service life, increased thickness and manufacturing costs due to inefficient heat management, and stability concerns from improper fixation structures.

Innovation Solution

An ultra-thin downlight design featuring a housing with a first ring portion, cylindrical portion, and second ring portion forming an accommodating space for the light source board, combined with a spring fixation plate and elastic ring body for enhanced thermal dissipation and structural stability, and a connecting wire with strain relief for cost reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If indirect-lighting type structure with light guide plate is adopted, then lighting function is achieved, but thermal dissipation performance deteriorates and service life decreases

Engineering Contradiction:

Improvelighting functionVSAvoidservice life

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The housing is segmented into first ring portion, cylindrical portion, and second ring portion to create an accommodating space that exposes part of the light source board, enabling effective heat dissipation while maintaining lighting function

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent converts the harmful heat generated by the light source into a beneficial feature by designing the housing structure to expose part of the light source board, transforming the heat problem into an effective heat dissipation solution that extends service life

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If direct-lighting type structure is adopted, then thermal dissipation is improved, but device thickness increases and packaging cost rises

Engineering Contradiction:

Improvethermal dissipation performanceVSAvoiddownlight thickness

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The patent transitions from traditional planar housing structures to a three-dimensional ring-based structure with accommodating space, enabling heat dissipation in multiple directions while maintaining thin profile

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If traditional fixation structure with spring fixation plates is used, then component assembly is achieved, but structural stability deteriorates due to loosening

Engineering Contradiction:

Improvecomponent assemblyVSAvoidstructural stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The spring buckle mechanism uses elastic force to counteract the loosening tendency of fixation plates, maintaining continuous clamping force on the light source board to prevent structural instability

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Solution Approach 2:

The fixation structure incorporates dynamic spring elements that automatically adjust to maintain optimal clamping force, transitioning from static fixation to dynamic self-adjusting fixation

Inventive Principle:

Principle #15Dynamics

4Ease of operation

If several spring fixation plates are used for component fixation, then assembly flexibility is achieved, but manufacturing cost increases

Engineering Contradiction:

Improveassembly flexibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent merges multiple fixation functions into a single integrated spring buckle mechanism, reducing the number of separate fixation plates needed while maintaining assembly flexibility and reducing manufacturing cost

Inventive Principle:

Principle #5Merging (Combining)

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 design significantly improves thermal dissipation, reduces manufacturing and packaging costs, enhances structural stability and safety, and simplifies installation, making the ultra-thin downlight more comprehensive in application.

Implementation Method 1

an elastic ring body... can be disposed in the ring-shaped groove so as to achieve buffering effect

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

one end of the spring buckle is provided with a spring. The two L-shaped hook portions are inserted into the two ends of the spring, such that the two ends of the spring press against the two L-shaped hook portions

Methodology Applied

Scientific EffectElastic force: Spring

Data Source

PatentUS11965646B2Ultra-thin downlight with enhanced thermal dissipation performance

Publication Date: 2024.04.23 XIAMEN PVTECH CO LTD

AI summary

An ultra-thin downlight with enhanced thermal dissipation performance includes a housing, a light source board and a light cover. The housing includes a first ring portion, a cylindrical portion and a second ring portion connected to each other. The cylindrical portion is disposed between the first ring portion and the second ring portion, such that an accommodating space is formed between the first ring portion, the cylindrical portion and the second ring portion. The light source board is fixed on the inner surface of the second ring portion and disposed in the accommodating space. A portion of the light source board is covered by the second ring portion and the other portion of the light source board is exposed from the second ring portion. The light cover is disposed on the inner surface of the first ring portion.