Inseparable LED Lamp Assembly via Nested Sealing
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Solution Overview
Problem
Existing LED light strings with separable lamps are prone to disconnection during shipping or installation, leading to operational failures, and are susceptible to theft and vandalism, while inseparable strings are costly to manufacture and can be damaged by high temperatures in the injection molding process.
Innovation Solution
A substantially inseparable LED lamp assembly is created by using a lamp holder shaped as an annulus with a permanently attached lamp cover and plug, forming a watertight seal, and connecting wires directly to LED pin leads, preventing disassembly without excessive force or specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If LED lamps are made separable for easy installation and replacement, then ease of operation is improved, but reliability deteriorates due to disconnection during shipping or installation
Solution Approach 1:
The LED lamp is inserted through a lamp holder annulus and nested within the lamp cover, creating a layered structure where the lamp is physically contained and secured by the annulus and cover assembly, preventing disconnection while maintaining ease of installation
Solution Approach 2:
The lamp assembly is divided into separable components (lamp, lamp holder annulus, lamp cover, plug) that can be manufactured independently and assembled together, allowing the lamp to be easily installed and replaced while forming a secure unified structure when assembled
2Reliability
If LED lamps are made inseparable to prevent disconnection, then reliability is improved, but manufacturing cost increases due to injection molding process requirements
Solution Approach 1:
The assembly is segmented into separately manufacturable components (annulus, lamp cover, plug) that can be produced using standard molding processes without requiring expensive inseparable injection molding, then assembled through simple insertion and sealing operations
Solution Approach 2:
The lamp holder annulus serves as an intermediary component that receives both the LED lamp and the plug, coordinating their assembly and securing them together without requiring the lamp itself to be molded as an inseparable unit
3Reliability
If traditional inseparable manufacturing methods are used, then connection stability is improved, but the LED lamps are damaged by high temperatures in the injection molding process
Solution Approach 1:
The LED lamp is pre-assembled into the lamp holder annulus and secured with the lamp cover and plug before final sealing, allowing the lamp to be positioned and secured without exposure to high-temperature injection molding processes that would damage it
Solution Approach 2:
The mechanical assembly process replaces the thermal injection molding process, using physical insertion, friction fit, and sealing mechanisms instead of high-temperature melting and molding to create the inseparable connection
4Ease of repair
If separable lamp design is used, then ease of repair is improved, but the lamps are susceptible to theft and vandalism
Solution Approach 1:
The LED lamp is nested within the lamp holder annulus and secured by the lamp cover and plug, creating a layered containment structure that makes removal difficult without tools while still allowing replacement by reversing the assembly process
Data Source
AI summary
Disclosed are LED lamp assemblies that are substantially inseparable. The LED lamp assemblies use discrete components that are individually manufactured and then assembled in a manner that substantially prevents disassembly or disengagement of components. An interference fit can be used to substantially secure components of the LED lamp assemblies. Bonding techniques can also be used, including adhesive and solvent bonds, as well as thermal bonds, including sonic bonds.