Injection-Molded LED Lamp Structure for Short-Circuit Reduction
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Solution Overview
Problem
Existing LED lamps manufactured through an injection process face issues with solder short circuits due to small LED luminous bodies and matched solder pads, and thicker conducting wires become inconvenient to solder, especially as the number of LED lamp beads increases.
Innovation Solution
A band-shaped LED lamp body with a first linear conductor and printed circuit board accommodated in an injection body, where conducting wires are insulated and connected to corresponding terminals, and the structure is formed through injection, including barbs and flexible protruding parts for fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of LED lamp beads in a lamp string increases, then the load capacity is enhanced, but the conducting wires become thicker and more difficult to solder to the LED luminous body
Solution Approach 1:
The patent divides the connection structure into multiple components: the injection body is segmented with distinct features including barbs for mechanical anchoring, flexible protruding parts for positioning, and a blocking part for electrical isolation. This segmentation allows each feature to address specific manufacturing challenges independently, making the overall assembly easier to manufacture despite thicker wires.
Solution Approach 2:
The injection body acts as an intermediary component between the thicker conducting wires and the LED luminous body. It provides a structured interface with multiple fixation features that facilitate connection without requiring direct soldering between the wire and the small LED components, thus resolving the soldering convenience issue while maintaining load capacity.
2Volume of moving object
If small LED luminous bodies and matched solder pads are used, then the LED lamp structure is compact, but solder short circuits are prone to occur
Solution Approach 1:
The injection body serves as an intermediary structure between the conducting wires and the LED luminous body. It provides a larger, more stable connection interface with multiple fixation features (barbs, flexible protruding parts, blocking part) that reduce the risk of solder short circuits while maintaining the compactness of the overall LED lamp structure.
Solution Approach 2:
The injection body provides beforehand cushioning by incorporating multiple fixation features that prevent misalignment and stabilize the connection before electrical contact is made. The barbs provide mechanical anchoring, the flexible protruding parts provide positioning, and the blocking part prevents excessive insertion, all of which cushion against potential short circuit conditions.
3Power
If thicker conducting wires are used to enhance load capacity, then the power transmission is improved, but the connection process becomes increasingly inconvenient
Solution Approach 1:
The connection process is segmented into multiple independent fixation stages provided by the injection body: mechanical anchoring via barbs, positioning via flexible protruding parts, and electrical connection control via the blocking part. This segmentation makes the connection of thicker wires more convenient by breaking down a complex task into simpler, sequential steps.
Solution Approach 2:
The injection body acts as an intermediary that facilitates the connection of thicker conducting wires to the LED luminous body. It provides a structured interface with multiple fixation features that accommodate the larger wire diameter while maintaining ease of operation through its modular design and multiple attachment mechanisms.
Data Source
AI summary
Disclosed is an LED lamp manufactured through an injection process. According to the LED lamp, a printed circuit board together with an LED luminous body electrically connected to the printed circuit board is accommodated in an injection body of the LED lamp, and each of a plurality of conducting wires insulated from one another in a first linear conductor is electrically connected to one corresponding terminal of the printed circuit board to realize power supply to and even control on the LED luminous body. In addition, through injection, the present disclosure may realize rapid, simple and convenient formation of a housing of the lamp for the linear conductor to penetrate.