Opple 4W downlight structure disassembly

No nonsense, straight to the point:

　　First, let's take a look at its packaging:

　　1. The inner box should be made of three-layer (single-corrugated) corrugated paper: F-corrugated (I don't know much about packaging materials, please correct me if I'm wrong), with a clear outline of the lamp and detailed information printed on the surface, including: operating voltage, current, rated power, color temperature, lumen, etc. From Figure 4 we can see that the sample of Chaojie this time is 4W, 5700K, 270lm. We will test its actual data below.

　　2. The structure of the inner box to fix the lamp is the inner card structure we usually use. I will not show the picture here because it is a relatively common structure.

　　Now let's take a look at what the luminaire looks like:

　　1. You can see that the face ring is made of white plastic. After the flame retardant test, I infer that its material should be 94VO PC.

　　2. The two stamped iron sheets of the spring bracket are about 1.5mm thick.

　　3. The radiator is an aluminum alloy ring made by spinning or stamping, with an oxidized and sandblasted surface and a lamp parameter label attached.

　　On top of the heat sink is a fixed external power supply.

　　Disassembly begins:

　　There is one thing to pay attention to here: from the surface of the entire lamp, there are only two rivets to connect the various parts. Apart from the two screws that press the wires of the power box, you cannot find the third screw.

　　1. When we separate the face ring and the radiator (cup), we can get a preliminary understanding of the structure of this lamp from the above four pictures:

　　a: The LED light source board is fixed to the outer cover power box together with the heat sink (cup) through three M3 screws to form a light source module.

　　b: The plastic face ring, the roller plate and the spring bracket are combined together to form a module.

　　c: The two modules are fixedly connected by rivets through the hole-to-hole method: spring bracket → face ring → heat sink (cup).

　　Face ring:

　　1. As mentioned before, the face ring is made of white fireproof PC material. Usually, it is molded in one step, and rarely processed twice. But this face ring is a little special: its surface is sprayed with a layer of light silver paint with fine sand (the camera is too bad to show it), so the surface looks more textured and upscale than ordinary PC plastic parts. Of course, the cost is not the same (a finished product will increase by 5-7 yuan). But I guess there is another purpose for spraying such a layer of paint, which is to cover its melt line.

　　2. Here I want to talk about its structure:

　　First of all, everyone knows that if the wall thickness of plastic products is uneven or there is local accumulation of material, serious shrinkage will occur. If this occurs on the surface of the product, it will affect the appearance and become a defective product.

　　So where is the most likely place for uneven wall thickness or local accumulation of material on a plastic recessed lamp face ring? It is at points A and B (see the figure above).

　　As can be seen from the above figure, the two different face rings have different treatments for A and B: Face ring 2 is formed in one mold. In order to increase the strength and avoid the spring bracket from breaking or the overall appearance deformation during use, A and B must be thickened, so that local material accumulation will form and shrinkage problems will also occur. Face ring 1 divides the "thickness" of B into two, forming two rings with relatively thin wall thickness. The problem of excessive material accumulation is solved without affecting the strength by connecting with ribs; and the direct use of metal sheets at A is also the same. Of course, the spray paint mentioned above also has this shielding effect.

　　spring:

　　Here I want to talk about the spring it uses:

　　This OPPLE lamp uses a spring A (I forgot what it is called) that is commonly used in traditional downlights in China. This spring has strong elasticity and is easy to install. Whether it is in the production process or in the hands of end customers, it is very simple and fast to use. OPPLE's method is to pack this pair of springs in a small bag, then directly put them in the inner box, and finally let the customer install them by themselves, which saves a lot of labor costs.

　　Of course, this spring has its disadvantages such as slow rise, low quality and high cost.

　　As for Oupu Spring B, it is currently used by many domestic manufacturers. Its advantages are fast volume growth, relatively low price, and high quality. However, its disadvantages are also obvious: it is difficult to install and has different directions. Not to mention the customers, some structural engineers will not know how to install it if they have never been exposed to it. Therefore, this spring must be installed on the production line before the whole lamp can be shipped, and the labor cost will also increase.

　　Mixing board:

　　The light mixing board has a mirror surface and a frosted surface. During the disassembly, I noticed that the mirror surface is facing outwards and the frosted surface is facing inwards. The effect of this is that the light is fully "mixed" inside the lamp before being emitted, which looks more even to the human eye.

　　Mixed light (reflective) paper:

　　This is a kind of mixed light (reflective) paper called PET, which is not widely used by domestic manufacturers at present. We know that most reflectors are made of aluminum or plastic electroplating products, which will absorb part of the reflected light and reduce the luminous flux. Its function is to prevent the light from being absorbed too much inside the lamp, and help the light to be fully reflected and mixed inside the lamp to increase the luminous flux.

　　According to the manufacturer, the reflectivity of good quality PET can reach 120%. However, it should be noted that if the quality of this reflective paper is not up to standard, after a period of time, about 3-4 months, the PET will wrinkle, deform, and "powder off" due to the heat.

　　Another thing to note is the way to assemble it, there is a little trick to it. You can compare it in the above pictures 1 and 2.

　　Light source module:

　　As can be seen from the picture, 7 5730 lamp beads are connected in series on a substrate. The LED parameters are also indicated on the packaging box and label as 0.5W. Remove the three screws and you can separate the LED light, heat sink (cup) and external power supply. The structure here is relatively simple, so I won't describe it in detail.

　　In the picture, we can see that its substrate material should be FR4 (some netizens say it is only 94VO). And the contact with the heat sink (cup) does not use the process we usually use: apply thermal grease.

　　Finally, let’s look at its photoelectric parameters:

　　The lighting effect of this lamp is quite satisfactory: uniform without dark areas, and the light is also soft. The luminous flux is slightly lower than the nominal value, only 216lm. As for the temperature rise of LED: the temperature of the LED soldering foot is about 80 degrees, which will not affect the life and light decay of the LED. From this point of view, it can also explain why it can use FR4 substrate and does not need to apply thermal grease.