Integrated Lamp Base Structure for Simpler Assembly and Insulation
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Solution Overview
Problem
Conventional lamp bases and holder structures face manufacturing complexity, high costs, and inefficiencies due to multi-step processes, and suffer from alignment issues and short-circuit risks in T-shaped internal insulating frames, leading to operational inconveniences and safety hazards.
Innovation Solution
An integrated lamp base without an inner frame, featuring a connecting cavity, inward-protruding lip, and integral PVC construction, along with a T-shaped insulating frame with a partition plate and reinforcing ribs, ensures stable connections and prevents short circuits through precise wire separation and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional multi-step manufacturing process is used for lamp bases, then the structural complexity can be managed, but the production cost increases and production efficiency decreases
Solution Approach 1:
The patent combines multiple manufacturing steps into a single integrated injection molding process. The lamp base, inner frame, and insulating components are molded as one unified structure, eliminating the need for separate assembly operations. This merging of processes directly resolves the contradiction by simplifying manufacturing while simultaneously increasing production efficiency through reduced cycle time and eliminated handling steps.
Solution Approach 2:
The lamp base structure is designed to perform multiple functions simultaneously: it provides mechanical support, electrical insulation, and structural framing all in one component. The integrated design allows a single molding process to produce a component that replaces what would traditionally require multiple separate parts and assembly steps, thereby improving both ease of manufacture and productivity.
2Ease of manufacture
If a conventional multi-step manufacturing process is used for lamp bases, then the structural complexity can be managed, but the production cost increases
Solution Approach 1:
The patent combines multiple manufacturing steps into a single integrated injection molding process. The lamp base, inner frame, and insulating components are molded as one unified structure, eliminating the need for separate assembly operations. This merging of processes directly resolves the contradiction by simplifying manufacturing while simultaneously increasing production efficiency through reduced cycle time and eliminated handling steps.
Solution Approach 2:
The integrated design eliminates the need for separate inner frames and insulating components that would traditionally be manufactured and assembled separately. By discarding these as separate parts and recovering their functions within the unified lamp base structure, the patent reduces both material costs and manufacturing costs while improving process simplicity.
3Reliability
If a T-shaped internal insulating frame with straight-line cross-section wiring slots is used, then the insulating function is provided, but the operational convenience decreases and production efficiency is impacted
Solution Approach 1:
The patent changes the wiring slot cross-section from a straight-line configuration to an arc-shaped configuration. This curvature allows wires to be routed along a natural arc path, making wire insertion and connection operations much more convenient. The arc-shaped slots maintain the insulating function while dramatically improving ease of operation, allowing workers to easily bend and position wires during assembly.
4Reliability
If a T-shaped internal insulating frame with straight-line cross-section wiring slots is used, then the insulating function is provided, but the alignment precision decreases
Solution Approach 1:
The patent changes the wiring slot cross-section from a straight-line configuration to an arc-shaped configuration. This curvature allows wires to be routed along a natural arc path, making wire insertion and connection operations much more convenient. The arc-shaped slots maintain the insulating function while dramatically improving ease of operation, allowing workers to easily bend and position wires during assembly.
5Reliability
If a conventional lamp base structure with separate components is used, then the insulating function is provided, but the device complexity increases
Solution Approach 1:
The patent combines multiple manufacturing steps into a single integrated injection molding process. The lamp base, inner frame, and insulating components are molded as one unified structure, eliminating the need for separate assembly operations. This merging of processes directly resolves the contradiction by simplifying manufacturing while simultaneously increasing production efficiency through reduced cycle time and eliminated handling steps.
Solution Approach 2:
The lamp base structure is designed to perform multiple functions simultaneously: it provides mechanical support, electrical insulation, and structural framing all in one component. The integrated design allows a single molding process to produce a component that replaces what would traditionally require multiple separate parts and assembly steps, thereby improving both ease of manufacture and productivity.
6Ease of manufacture
If resin leakage occurs between the plastic socket body and PVC lamp base, then the manufacturing process can be completed, but the electrical contact quality deteriorates
Solution Approach 1:
The patent combines multiple manufacturing steps into a single integrated injection molding process. The lamp base, inner frame, and insulating components are molded as one unified structure, eliminating the need for separate assembly operations. This merging of processes directly resolves the contradiction by simplifying manufacturing while simultaneously increasing production efficiency through reduced cycle time and eliminated handling steps.
Data Source
AI summary
An integrated lamp base without an inner frame and a lamp holder structure are provided. The lamp holder structure includes the integrated lamp base, a T-shaped insulating base, horizontal wires, and vertical wires. The integrated lamp base includes the lamp base body that defines a connecting cavity therein, a connecting thread is disposed on an inner wall of the lamp base body within the connecting cavity. A wire connecting portion is fixed at a bottom portion of the lamp base body, a terminal post is disposed at an inner bottom end of the lamp base body and extends into the wire connecting portion, and a bottom portion of the terminal post passes through a bottom portion of the wire connecting portion. The T-shaped insulating base includes a T-shaped internal insulating frame and a partition plate, and the T-shaped internal insulating frame includes a frame body.