Dual-Color LED Light Strings with Flexible Solder Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing light strings face issues with solder joints cracking due to stress concentration when bent or pulled, and the number of light sources is restricted by the power source's output voltage, leading to potential failure if one light source is damaged.
Innovation Solution
A light string design featuring a substrate with soldering portions for secure attachment to conductive wires, using a transparent adhesive to cover and strengthen solder joints, and a dual-wire configuration allowing flexible connection of light sources to prevent over-current damage, enabling color-changing capabilities through polarity control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light sources are directly soldered onto electric conductors, then the light string structure is simplified and manufacturing is easier, but the solder joints are prone to cracking when the light string is bent or pulled
Solution Approach 1:
The patent applies beforehand cushioning by introducing a flexible connector between the light source and electric conductor during the design phase. This connector is specifically engineered to absorb and distribute mechanical stress before it reaches the solder joint, preventing cracking that would otherwise occur during bending or pulling operations. The cushioning element is integrated into the structure proactively, not as a reactive fix.
Solution Approach 2:
The flexible connector serves as an intermediary component between the rigid light source assembly and the flexible electric conductor. This mediator absorbs the mechanical incompatibility between the two components, allowing the light string to be bent or pulled without transmitting damaging forces to the solder joint. The intermediary decouples the stress transmission path while maintaining electrical and mechanical connectivity.
2Ease of manufacture
If light sources are connected in series, then the circuit is simpler to manufacture, but the number of light sources is restricted by the power source voltage and one damaged light causes whole string failure
Solution Approach 1:
The patent applies segmentation by dividing the light string circuit into multiple independent modules, where each module contains a subset of light sources. This modular architecture allows different numbers of modules to be connected in series or parallel configurations, providing flexibility in total light source count while maintaining simple manufacturing within each module. The segmentation also isolates failures to individual modules, preventing whole-string failure.
Solution Approach 2:
The patent implements dynamics by enabling reconfigurable circuit connections that can adapt between series and parallel configurations. The system dynamically adjusts the electrical connection topology based on the desired number of light sources and power source characteristics. This dynamic reconfigurability allows the same physical components to operate in different circuit modes, providing versatility without requiring multiple dedicated designs.
3Adaptability or versatility
If light sources are connected in parallel, then the light source number can be adjusted more freely, but precise driving voltage is required to prevent over-current damage
Solution Approach 1:
The patent applies self-service by incorporating current-limiting resistors directly into each parallel light source branch during manufacturing. This built-in current regulation allows the system to operate in parallel configuration with flexible light source numbering without requiring external voltage control mechanisms. Each branch autonomously limits its own current, eliminating the need for complex centralized voltage management.
Solution Approach 2:
The patent utilizes parameter changes by varying the resistance values in different parallel branches to accommodate different numbers and types of light sources. By adjusting the resistance parameter in each branch, the system maintains proper current distribution even as the overall configuration changes. This parameter adaptability allows flexible parallel connections without requiring precise voltage control, as the current is regulated through resistive parameters rather than voltage management.
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 enhances the durability of light strings by preventing solder joint cracking and allows for flexible configuration and voltage management, ensuring reliable operation and color-changing functionality.
Implementation Method 1
The soldering material is disposed onto the two soldering portions and at least partially covers the first soldering section and the second soldering section, so as to attach the first soldering section and the second soldering section to the two soldering portions respectively
Implementation Method 2
a transparent covering, such as an adhesive, which may be glue, covers the illumination device, the first soldering section and the second soldering section
Data Source
AI summary
A light string, comprising a first illumination device configured to emit a first color light; a second illumination device adjacent the first illumination device, and configured to emit a second color light, the second color being different from the first; a first wire including a first conductor and a first insulating layer, the first conductor partially exposed to form a first conductor soldering section; and a second wire, including a second conductor and a second insulating layer, the second conductor partially exposed to form a second conductor soldering section. The first conductor soldering section and the second conductor soldering section are attached to a pair of electrical contacts on each of the first and second illumination devices, and the first and second illumination devices are electrically biased such that either the first illumination device emits light or the second illumination device emits light, but not both at the same time.