Flat Cable String Lights for High-Voltage Direct Plug-In
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Solution Overview
Problem
Traditional manufacturing methods for string lights lack flexibility in customization and are not suitable for mass production using mechanized processes.
Innovation Solution
The method involves soldering LED chips to flat cables, cutting the wires to form series connections, and adjusting the voltage using resistors and/or capacitors, allowing the string lights to be directly plugged into high-voltage power supplies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for string lights, then mass production can be achieved, but customization flexibility is lost
Solution Approach 1:
The patent segments the string light system into modular components: flat cable sections with integrated LED chips, wire cutting sections for series connection, and voltage adjustment sections with resistors/capacitors. This segmentation allows standardized mass production of modules while enabling flexible customization through different combinations and configurations of these modules.
Solution Approach 2:
The patent enables parameter changes by allowing adjustment of voltage characteristics through combinations of resistors and capacitors, and by permitting different wire configurations (4-wire or 5-wire flat cables). This allows the same basic manufacturing process to produce string lights with different electrical parameters and lighting schemes, achieving both mass production efficiency and customization flexibility.
2Adaptability or versatility
If LED chips are soldered to flat cables and wires are cut to form series connections, then customization becomes possible, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-soldering LED chips to flat cables in standardized configurations before final assembly. The flat cables are prepared with predetermined wire arrangements and LED placements, which simplifies the final customization process. This preliminary preparation allows for efficient mass production of base components that can then be easily customized through wire cutting and voltage adjustment.
Solution Approach 2:
The patent achieves universality by designing a flat cable system that can serve multiple functions: it provides structural support, electrical connection, and LED mounting. The same flat cable structure works for both 4-wire and 5-wire configurations, and can accommodate different LED chip sizes and arrangements, reducing manufacturing complexity while maintaining customization capability.
3Adaptability or versatility
If voltage is adjusted using resistors and capacitors for high-voltage direct connection, then power supply compatibility improves, but circuit complexity increases
Solution Approach 1:
The patent uses resistors and capacitors as intermediary components between the high-voltage power supply and the LED chips. These intermediaries perform multiple functions: they adjust voltage levels, limit current, and provide voltage division. By placing these intermediary components at strategic points in the circuit, the patent achieves broad power supply compatibility (100V-230V) while keeping the overall circuit design relatively simple and modular.
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
This approach enables mass production and customization of flat cable string lights, allowing them to be directly plugged into a wide range of power supplies while offering various lighting schemes through function controllers.
Implementation Method 1
soldering light emitting diode ("LED") chips to some of the wires
Implementation Method 2
adjusting the voltage of these lights through a combination of resistors and/or capacitors
Data Source
AI summary
A method of making a string light is disclosed. The method includes providing a flat cable comprising at least 4 wires; soldering one or more light chips to at least 2 of the 4 wires of the flat cable; cutting the at least 2 of the 4 wires at a plurality of locations; and connecting a voltage reducing box to the wires.