Integrated Injection-Molded LED Lamp String for Waterproofing
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Solution Overview
Problem
Conventional LED lamp bulb manufacturing processes involve high-temperature sintering, leading to environmental pollution, health hazards, and safety risks due to non-waterproof properties, with complex structures making them difficult to manufacture and prone to failure.
Innovation Solution
A highly waterproof and insulative simple injection-molded integrated lamp string without a conventional lamp holder, where the lamp core, conductive wires, and power lines are integrated through injection molding, forming a sealing insulation plastic head for enhanced waterproofing and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional multi-component lamp bulb structure is used with glass core column and copper lamp cap, then the lamp bulb can be manufactured through traditional assembly process, but the manufacturing process requires high-temperature flame sintering which causes environmental pollution and health hazards to workers
Solution Approach 1:
The patent merges the lamp holder, lamp bulb, and sealing structure into a single integrated plastic component through injection molding. The lamp holder body, insulation structure, and sealing elements are formed as one piece, eliminating the need for separate glass core column assembly and high-temperature sintering processes. This integration directly resolves the technical contradiction by simplifying manufacturing while eliminating harmful high-temperature processes.
Solution Approach 2:
The patent replaces the traditional mechanical assembly process involving glass core column sintering and copper cap threading with a single injection molding process. The plastic lamp holder is molded directly onto the LED lamp core, substituting complex mechanical assembly and high-temperature thermal processes with a simpler polymer molding operation that avoids environmental pollution and health hazards.
2Reliability
If conventional lamp holder with copper sleeve is used to screw down or clamp the lamp bulb, then the lamp bulb can be securely mounted, but gaps are formed between the lamp bulb and lamp holder which disable waterproof protection
Solution Approach 1:
The patent merges the mounting function and sealing function into a single integrated plastic lamp holder structure. The lamp holder body directly embraces the LED lamp core with an integrated sealing interface that eliminates gaps between components. This integration ensures both secure mounting and waterproof protection simultaneously, resolving the contradiction between mounting security and water resistance.
Solution Approach 2:
The patent uses plastic material with appropriate elasticity and sealing properties to create the lamp holder. The plastic material provides both the mechanical grip needed for secure mounting and the flexible sealing capability to prevent water penetration. This composite material approach resolves the contradiction by providing dual functionality in a single material system.
3Productivity
If conventional integrated lamp string structure is used, then the lamp string can be manufactured, but the structure is very complex making it very difficult to manufacture with waterproof rating below IP45
Solution Approach 1:
The patent merges multiple functional components (lamp holder, insulation structure, sealing elements, and mounting features) into a single injection-molded plastic piece. This integration dramatically simplifies the manufacturing process, enabling high-volume production while achieving superior waterproof rating above IP45. The single-mold construction eliminates the complexity of assembling multiple separate components.
4Adaptability or versatility
If conventional lamp string with spacing lamp holders is used, then several lamp bulbs can be mounted on the power line, but the gaps between lamp bulbs and lamp holders lead to high failure rate and shorter service life
Solution Approach 1:
The patent merges the electrical connection function and mechanical mounting function into a single integrated plastic lamp holder structure. The lamp holder simultaneously provides electrical insulation, mechanical support, and environmental sealing in one component. This integration eliminates the gaps that cause moisture ingress and connection failures, thereby extending service life while maintaining adaptability for mounting LED lamp bulbs.
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 solution simplifies the manufacturing process, reduces health risks, and significantly improves the waterproofing and insulation performance, enabling longer service life and easier production with reduced failure rates and costs.
Implementation Method 1
The semi-finished lamp bulb, the positive pole conductive wire and the negative pole conductive wire are integrally connected with the power line through injection molding
Implementation Method 2
An injection plastic fusion body and the semi-finished lamp bulb are fused integrally through a mold to form a sealing insulation plastic head
Implementation Method 3
The lamp bulb includes a lampshade, a lamp core body, and at least one insulation plastic piece
Data Source
AI summary
An injection-molded integrated lamp string includes a power line and several lamp bulbs spaced apart on a power line. The lamp bulb comprises a lampshade, a lamp core body, and at least one insulation plastic piece. The lampshade is provided with an insertion portion, and the lamp core body is inserted into the insertion portion and protruded into the lampshade. The lamp core body is provided with at least one LED lamp filament, and both ends of the LED lamp filament are connected with a positive pole conductive wire and a negative pole conductive wire to form a semi-finished lamp bulb. The semi-finished lamp bulb, the positive pole conductive wire, and the negative pole conductive wire are integrally connected with the power line through injection molding. An injection plastic fusion body and the semi-finished lamp bulb are fused integrally through a mold to form a sealing insulation plastic head.