Electronic Candle Assembly for Light String Connection
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Solution Overview
Problem
Existing electronic candles face challenges in arranging a string of lights around a wax candle tube due to the difficulty in electrically connecting the string of lights to the PCBA board, as the wax tube is thin and long, making it hard to mold and assemble with the core assembly.
Innovation Solution
A cylindrical wax tube made from paraffin wax with a defined cavity allows a tubular battery compartment and an elongated PCBA board to be inserted, with the PCBA board exposed to the cavity, enabling the string of lights to be electrically connected to the board through the wax tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the core assembly is directly placed into a waxing mold for molding, then the wax tube can be formed, but the PCBA board is completely wrapped and the string of lights cannot be electrically connected to the PCBA board
Solution Approach 1:
The patent divides the assembly process into two separate stages: first molding the wax tube independently, then assembling the core assembly (containing PCBA board and string of lights) into the pre-formed wax tube. This segmentation allows the wax tube to be molded without obstruction while preserving access to the PCBA board for electrical connections.
Solution Approach 2:
The wax tube is molded in advance as a separate component before the core assembly is installed. This preliminary action creates a ready-to-receive housing that does not interfere with subsequent assembly steps, allowing the PCBA board to remain accessible for electrical connections while the wax tube provides its protective and aesthetic functions.
2Shape
If the wax tube is made thin and long to imitate a real wax candle, then the aesthetic effect is improved, but the wax tube cannot be easily molded independently and lacks sufficient strength for assembly
Solution Approach 1:
By separating the wax tube molding from the core assembly installation, the patent enables production of thin, long wax tubes that would be difficult to mold with embedded components. The segmentation allows each component to be optimized independently for its specific requirements.
Solution Approach 2:
The wax tube is pre-formed as a separate component with optimized dimensions and shape for aesthetic purposes. This preliminary molding action allows the wax tube to achieve thin, long candle-like proportions without compromising manufacturability, as the complex assembly operations are performed afterward on the already-formed tube.
3Device complexity
If the PCBA board is completely wrapped by the wax tube, then the wax tube structure is simplified, but the string of lights cannot be arranged around the electronic candle
Solution Approach 1:
The patent separates the wax tube from the core assembly, creating distinct functional zones. The wax tube provides structural support and aesthetic appearance, while the core assembly housing contains and protects the PCBA board and string of lights, allowing the light string to be arranged and connected without compromising the wax tube's structural simplicity.
Solution Approach 2:
The core assembly housing acts as an intermediary component between the wax tube and the PCBA board. It provides a protective enclosure for the electronics while allowing the wax tube to maintain its simple, clean structure. This intermediary enables the string of lights to be arranged and connected within the housing without requiring complex features in the wax tube itself.
Data Source
AI summary
An electronic candle includes: a wax tube, a battery compartment, and a PCBA board. The wax tube is cylindrical and made from paraffin wax. The wax tube defines a cavity therein and has a first end and a second end, the second end defines an opening communicated to the cavity. The battery compartment is inserted into the cavity from the second end, the battery compartment has a third end and a fourth end, the fourth end defines an opening facing towards the first end. The PCBA board is inserted to the fourth end. The PCBA board is elongated. A maximum width of the PCBA board is in an interference fit with an inner diameter of the battery compartment, enabling the PCBA board to be snapped with the battery compartment.