Decorative Light String Cover Assembly With Welding-Rib Sealing
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Solution Overview
Problem
Conventional decorative light strings face issues with low production efficiency, high manufacturing costs, complex structures, and poor durability due to pre-embedded parts during injection molding or split shells with ribbon wires, leading to inefficient waterproofing.
Innovation Solution
A decorative light string design featuring a cover and bottom plate assembly with integrated welding ribs and waterproof steps, using flat shielded wires in interference fit with wire slots, and a ground inserting portion for enhanced waterproofing and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-embedded parts are used during injection molding of the shell, then waterproof effect is improved, but production efficiency decreases and manufacturing cost increases
Solution Approach 1:
The lamp shell is divided into two separate parts: the cover and the bottom plate. These parts are manufactured independently without pre-embedded components, then assembled together with the light source assembly. This segmentation eliminates the need for complex pre-embedding during injection molding, thereby improving production efficiency while maintaining waterproof performance through the sealing structure between the two plates.
2Reliability
If pre-embedded parts are used during injection molding of the shell, then waterproof effect is improved, but manufacturing cost increases
Solution Approach 1:
The lamp shell is divided into two separate parts: the cover and the bottom plate. These parts are manufactured independently without pre-embedded components, then assembled together with the light source assembly. This segmentation eliminates the need for complex pre-embedding during injection molding, thereby improving production efficiency while maintaining waterproof performance through the sealing structure between the two plates.
3Ease of operation
If split shell structure is adopted, then assembly is simplified, but material consumption increases and durability decreases
Solution Approach 1:
The cover and bottom plate are merged through a waterproof adhesive layer to form a complete lamp shell structure. This merging approach maintains the simplicity of split-shell assembly while reducing material consumption compared to traditional split-shell designs that require excessive sealing materials. The adhesive layer provides durable bonding without requiring additional protective coatings or redundant sealing components.
4Reliability
If ribbon wire with semi-circular arcs is used, then electrical connection is achieved, but wire slot structure becomes complex and sealing difficulty increases
Solution Approach 1:
Instead of conforming the wire to a curved ribbon shape that requires complex wire slots, the invention inverts the approach by creating a simple linear wire slot in the bottom plate and passing a flat wire directly through it. This simplifies the wire slot structure from a complex curved channel to a simple linear opening, making sealing much easier while maintaining electrical connection reliability.
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
Achieves high waterproof performance, simple structure, easy assembly, low production costs, and high durability by integrating welding ribs and flat shielded wires with interference fit wire slots, ensuring effective sealing and robust construction.
Implementation Method 1
a first welding rib that is welded and fixed to the waterproof step
Implementation Method 2
two sides of the side wall are provided with wire slots in interference fit with the electric wire
Data Source
AI summary
A decorative light string comprises a plurality of lamp bodies and an electric wire connected to the lamp bodies; the lamp body comprises a cover, a bottom plate for sealing an opening of the cover, a circuit board mounted in the cover, and an LED light source mounted on the circuit board; the electric wire is connected to the circuit board and extends out from two sides of the cover; the cover comprises a top wall and a side wall; the top wall is provided with a lens; two sides of the side wall are provided with wire slots; a waterproof step and a first welding rib are arranged on a surface where an end surface of the side wall and the bottom plate are joined; the present invention achieves high waterproof performance, simple structure, easy assembly, high production efficiency, low production cost and high durability.