Electrodeless LED String Light Layout for Bipolar Wiring
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Solution Overview
Problem
Conventional LED string lights have low wire utilization, material waste, and inconvenient bipolar LED usage, leading to inefficiencies in production and application.
Innovation Solution
An electrodeless surface-mounted LED string light design featuring intertwined wires with strategically removed insulating layers to form welding spots, where each welding region holds two oppositely polarized surface-mounted LEDs, allowing for efficient material use and easy polarity switching with current direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional LED string lights use one LED per assembly position with side-by-side wires, then the structure is simple to manufacture, but the wire utilization rate is low causing waste of manpower, raw materials and apparatus
Solution Approach 1:
The patent merges two wires into a single integrated structure where two wires are intertwined and welded together at multiple positions along the string light. This combining approach increases wire utilization by allowing both wires to serve dual functions (structural support and electrical conduction) while reducing the total amount of wire material needed compared to using separate wires for each LED assembly position
Solution Approach 2:
The intertwined wire structure serves multiple functions simultaneously: it provides mechanical support for mounting LEDs, acts as electrical conductors for power delivery, and creates a compact bundled structure that reduces material usage. The wires are not just simple conductors but serve as both structural framework and electrical pathway
2Reliability
If conventional LED string lights use unipolar LEDs requiring corresponding positive and negative electrodes, then the LED polarity is fixed for reliable operation, but the usage is inconvenient requiring strict polarity matching with drive power
Solution Approach 1:
The patent inverts the traditional unipolar LED configuration by using two opposite-polarity LEDs at each assembly position. Instead of having one LED that requires strict polarity matching, the system uses two LEDs with opposite polarities so that regardless of how the string light is connected, at least one LED at each position will illuminate correctly
Solution Approach 2:
The patent changes the electrical parameter configuration by switching from unipolar to bipolar LED arrangement. By altering the polarity parameter from fixed (unipolar) to variable (bipolar with opposite orientations), the system adapts to different connection scenarios and eliminates the need for strict polarity matching during installation and use
3Ease of manufacture
If conventional LED string lights weld one LED per assembly position, then the assembly process is straightforward, but the productivity and manufacturing efficiency are reduced due to low wire utilization
Solution Approach 1:
The patent combines multiple welding operations into a single integrated process by welding two wires together at multiple positions simultaneously. Instead of separately assembling and welding individual LEDs on separate wires, the intertwined wire structure allows for consolidated welding operations that reduce the number of discrete assembly steps while maintaining product quality
Solution Approach 2:
The wires are pre-intertwined and pre-positioned along the string light structure before the LED welding process. This preliminary arrangement of the wire framework allows subsequent LED assembly and welding to proceed more efficiently, as the structural and electrical pathway is already established, reducing overall manufacturing time
Data Source
AI summary
An electrodeless surface-mounted LED string light, a method and an apparatus for manufacturing the same are disclosed. The electrodeless surface-mounted LED string light includes: a first wire and a second wire; a plurality of LED units, wherein each LED units includes two surface-mounted LEDs, and luminous surfaces of the two surface-mounted LEDs are opposite to each other, and the luminous surfaces of the two surface-mounted LEDs are parallel to an axial direction of the first and second wires; and a plurality of encapsulants respectively encapsulating the two surface-mounted LEDs of the plurality of LED units therein.