Joggle Snap-Fit Assembly for LED Lamp Cap Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional bulb assembly using screws or glue is time-consuming and results in low manufacturing efficiency and product reliability due to the small size of components and potential heat-induced damage to glue bonds.
Innovation Solution
The use of joggle structures on light bodies and modules allows for easy assembly of lamp cap and sensor modules without screws or glue, utilizing matching joggle slots and blocks to securely connect components, thereby enhancing assembly efficiency and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws or glue are used to connect components in a bulb, then the components can be securely connected, but the assembling process takes lots of time and causes low manufacturing efficiency
Solution Approach 1:
The patent replaces the traditional mechanical connection methods (screws or glue) with a snap-fit mechanism consisting of a protrusion on the lamp cap module that engages with a corresponding recess in the lamp body. This mechanical interlocking system eliminates the need for time-consuming screw assembly or glue application while maintaining secure connection, thereby significantly improving manufacturing efficiency without compromising connection reliability
Solution Approach 2:
The snap-fit connection structure enables self-aligning and self-securing of the lamp cap module to the lamp body. The protrusion automatically guides the lamp cap into the correct position and the elastic deformation of the lamp body material provides automatic locking, eliminating the need for additional fastening operations or materials, thus reducing assembly time and improving productivity
2Reliability
If glue is used to fix components in a bulb, then the components can be held in position, but when the bulb generates high heat the glue may melt and change shape causing components to be moved or damaged
Solution Approach 1:
The patent completely removes the glue material from the connection system between the lamp cap module and lamp body, replacing it with a purely mechanical snap-fit structure. By extracting the organic adhesive component, the system eliminates the vulnerability to heat-induced glue melting and deformation, ensuring component fixation reliability under high temperature operating conditions
Solution Approach 2:
The patent employs a heat-resistant synthetic material for the lamp body that can elastically deform during snap-fit connection and then recover its shape. This material acts as a heat-stable alternative to organic glue, maintaining its mechanical properties at high temperatures where traditional adhesives would fail, thus preventing component displacement or damage
3Reliability
If screws or glue are used to assemble small components in a bulb, then secure connection can be achieved, but the small size of components makes them not easily connected
Solution Approach 1:
The patent employs an asymmetric snap-fit structure where the lamp cap module has a protrusion that matches an asymmetric recess in the lamp body. This asymmetric design provides self-guiding during assembly, making it easy to align and connect the small components without requiring precise manual positioning or additional fastening operations, thereby improving assembling ease while maintaining connection strength
Solution Approach 2:
Instead of using small fasteners or adhesive application methods suited for small components, the patent inverts the approach by making the lamp cap module itself the active element that engages with the lamp body through an integrated snap-fit structure. This reversal eliminates the need for separate fastening operations on small components, making assembly easier while ensuring reliable connection
Data Source
AI summary
The present invention relates to a combination type illumination apparatus that includes a lamp body, a lamp cap module and a LED light emitting module. The LED light emitting module is disposed on the lamp body. The lamp body has an accommodation hole and a center sleeve stored in the accommodation hole. The center sleeve includes a first joggle structure. The lamp cap module includes a second joggle structure. The second joggle structure of the lamp cap module is assembled to the first joggle structure of the center sleeve. With such structure configuration, manufacturers may assemble the combination type illumination apparatus in a joggling way instead of in a screwing or gluing method.