Bulb Structure Weld-Free Electrical Connection

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Solution Overview

Problem

Existing bulb production processes are complex and inefficient, leading to high production costs due to the need for processes like injection molding and welding.

Innovation Solution

A bulb structure that eliminates the need for welding by using a positive wire and a negative wire that are electrically connected to the positive cover and negative cover respectively, through a sequence of connections without the requirement for welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding process is used to connect wires to covers, then electrical connection reliability is improved, but device complexity and production cost increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the welding process (thermal/mechanical system) with a mechanical insertion and contact system. The positive wire inserts into the positive base and contacts the positive cover, while the negative wire inserts into the negative cover, eliminating the need for welding operations and simplifying the production process while maintaining electrical connection reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces intermediate connection structures (the positive base and the contact points within the negative cover) that mediate between the wires and the external covers. These intermediaries provide reliable electrical connections without requiring direct welding, thereby reducing production complexity while ensuring connection reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If welding process is used to connect wires to covers, then electrical connection reliability is improved, but productivity decreases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the time-consuming welding process with a quick mechanical insertion and contact system. The wires can be inserted and connected without thermal processing, significantly reducing production time per unit and improving overall productivity while maintaining reliable electrical connections through the mechanical contact design.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent designs the bulb structure with pre-configured connection points and pathways for the wires (positive channel, negative channel, and contact points) so that during assembly, the wires can be directly inserted and connected without requiring on-site welding operations, thereby accelerating the production process.

Inventive Principle:

Principle #10Preliminary action

3Strength

If injection molding and welding processes are used, then structural strength is improved, but production cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidproduction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent eliminates the welding process (a costly and complex operation) by using mechanical insertion and contact systems. The positive wire inserts into the positive base and the negative wire contacts the negative cover through designed contact points, providing sufficient electrical and mechanical connection without the need for welding, thereby reducing production costs while maintaining structural integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent combines multiple functions into integrated components. The positive base serves both as a structural support and as an electrical connection point, while the negative cover integrates both protective enclosure and electrical contact functions. This merging reduces the number of separate manufacturing steps and associated costs while maintaining structural strength.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12320475B2Bulb structure

Publication Date: 2025.06.03 HU XIAOYAN

AI summary

A bulb structure is provided. The bulb structure includes: a bulb body, a wick, a support, a negative cover, a positive base, and a positive cover; the wick is provided with a positive wire and a negative wire; the support is connected to a top of the bulb body; the negative cover is connected to the bulb body; the positive base is connected to the negative cover; the positive cover is connected to the positive base; the wick is located in the bulb body, and the positive wire extends upwards out of the support and the negative cover in sequence and is connected to the positive base, to enable the positive wire to be electrically connected to the positive cover.