Decorative Lighting Wire Layout for Tangle-Resistant Net Lights
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Solution Overview
Problem
Decorative lighting assemblies, particularly net lights, often tangle due to intricate wire patterns, leading to consumer frustration and potential safety hazards during untangling, and pose manufacturing challenges for achieving consistent appearances.
Innovation Solution
A decorative lighting assembly design featuring a first and second power wire surrounding a display area, with lamp assemblies arranged in rows connected by zig-zag paths of wires and cords, utilizing reinforced wires to prevent tangling and ensure mechanical support, while maintaining a uniform appearance through matching outer diameters and insulating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If elaborate patterns of interconnected wires are used to form desired shapes, then the decorative lighting assembly achieves the desired shape and structure, but the wires become prone to tangling
Solution Approach 1:
The wire assembly is divided into multiple separate components: a first wire assembly forming a first shape and a second wire assembly forming a second shape. These segments can be independently handled and stored, reducing tangling. When assembled, they form the complete decorative lighting structure with lamps distributed between them.
Solution Approach 2:
The patent transitions from a single two-dimensional wire pattern to a three-dimensional configuration where two separate wire assemblies are positioned at different spatial orientations (first and second substantially perpendicular directions). This dimensional separation reduces inter-wire interference and tangling while maintaining the desired overall shape.
2Shape
If extensive lengths of wire conductors are twisted together to form desired shapes, then the decorative lighting assembly achieves the desired outline, but the wires are pulled from connectors during untangling
Solution Approach 1:
The wire system is segmented into multiple independent wire assemblies rather than one extensive twisted conductor. Each assembly maintains its own connector attachments, so when handling or storing, the force is distributed across segments rather than concentrating stress at single connection points, preventing wires from being pulled from connectors.
Solution Approach 2:
The wire assemblies are pre-formed into their desired shapes and configurations before final assembly. This preliminary shaping reduces the need for extensive twisting and repositioning during installation and storage, minimizing mechanical stress on connector interfaces and preventing wire pullage.
3Shape
If intricate wire patterns are used to form net lights, then the decorative lighting achieves the net-like structure, but manufacturing consistency becomes challenging
Solution Approach 1:
The net-like structure is created by assembling multiple standardized wire assembly segments rather than forming one complex continuous pattern. Each segment can be manufactured with consistent dimensions and lamp spacing, and quality control is easier to maintain across repeated modular units. The segments are then joined to form the complete net structure.
Solution Approach 2:
The patent specifies precise geometric parameters for the wire assemblies, including that they form substantially perpendicular directions with lamps distributed at substantially regular intervals. By defining and controlling these key parameters (orthogonality, regular spacing), manufacturing consistency is achieved while maintaining the net-like appearance.
Data Source
AI summary
A decorative lighting assembly comprises a first power wire electrically connected to a first power contact and a second power wire electrically connected to a second power contact. The first power wire and the second power wire cooperate to surround a display area of the decorative lighting assembly. Lamp assemblies are distributed across the display area. The lamp assemblies include a first row of lamp assemblies aligned along a first line, a second row aligned along a second line, a third row aligned along a third line, and a fourth row of lamp aligned along a fourth line. A first cord is disposed along a first zig-zag path connecting the lamp assemblies in the first row with the lamp assemblies in the second row. Intermediate wires are disposed along a second zig-zag path connecting the lamp assemblies in the second row with the lamp assemblies in the third row.