Button Cell Lamp Box Assembly Without Screws or Copper Sheets
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Solution Overview
Problem
Existing cell boxes for outdoor LED lamps have complex structures, leading to complicated assembly, poor connection stability, and high manufacturing costs.
Innovation Solution
A simplified lamp cell box design that includes a switch, button cells, a metal elastic sheet, and a box holder, which reduces the number of copper sheets needed and eliminates the use of screws for assembly, thereby lowering costs and improving connection stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cell box structure is used, then connection stability is improved, but device complexity increases and manufacturing cost rises
Solution Approach 1:
The patent combines multiple functions into the box holder: it serves as both the structural housing and the electrical connection component. The connection ports are integrated directly into the box holder body, eliminating the need for separate connection components. This merging reduces device complexity while maintaining connection stability through the rigid, integrated structure.
Solution Approach 2:
The box holder is designed as a multi-functional component that simultaneously provides structural support, electrical connection, and mechanical assembly functions. The same component that houses the button cell also contains the connection ports and provides the assembly interface, reducing the overall number of parts while ensuring stable connections through its robust, multi-purpose design.
2Reliability
If traditional assembly method with screws is used, then connection stability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent replaces the traditional mechanical screw-fastening system with a snap-fit or insert-based assembly mechanism. The connection ports are designed to receive and secure electrical contacts through dimensional interference or elastic retention features built into the box holder, eliminating the need for separate screws and simplifying assembly while maintaining stable electrical and mechanical connections.
3Reliability
If multiple copper sheets are used for electrical connection, then connection stability is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the electrical connection function with the structural box holder by integrating the connection ports directly into the housing. This eliminates the need for separate copper sheets or terminal blocks, reducing material quantity while maintaining stable electrical connections through the integrated conductive pathways and contact interfaces built into the box holder.
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 simplifies assembly, enhances connection stability, and significantly reduces manufacturing costs by minimizing the use of materials and eliminating the need for screws.
Implementation Method 1
The metal elastic sheet includes a first elastic contact part. The first elastic contact part penetrates through the second connection port and is in electrical contact with the positive electrode, located at the side surface, of the button cell
Data Source
AI summary
A lamp cell box includes a switch, a least one button cell, a metal elastic sheet and a box holder. The switch includes a body, a button and a contact terminal. The metal elastic sheet includes a first elastic contact part. The box holder includes a cell trough, a switch trough, an elastic sheet trough, a first connection port and a second connection port, where the button cell is disposed in the cell trough, a portion of the metal elastic sheet is disposed in the elastic sheet trough, the body is disposed in the switch trough, the contact terminal penetrates through the first connection port and is in electrical contact with the negative electrode of the button cell, and the first elastic contact part penetrates through the second connection port and is in electrical contact with the positive electrode of the button cell.