Lamp Base Insulator Housing Rotation Prevention
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Solution Overview
Problem
Existing LED lamp designs face inefficiencies in assembly due to pinching or screw-connection methods, which can limit the assembly efficiency and lead to potential leakage of potting material, affecting the connection between the driver and the enclosure.
Innovation Solution
A base design featuring a tubular enclosure with an insulator that prevents rotation relative to the enclosure, and a housing attached to the insulator to prevent rotation, allowing for a snap-lock connection with the contact pin, ensuring a fixed axial position and reducing the need for separate assembly steps, thereby enhancing assembly efficiency and preventing potting material leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pinching or screw-connection methods are used to attach the housing to the enclosure, then the connection between housing and enclosure is achieved, but the assembly efficiency is limited and potting material leakage may occur
Solution Approach 1:
The insulator is integrated into the housing structure, forming a unified component that combines the functions of electrical insulation and mechanical attachment. This merging eliminates the need for separate pinching or screw-connection steps, thereby improving assembly efficiency while maintaining connection reliability through the unified structure.
Solution Approach 2:
The insulator acts as an intermediary component between the housing and the enclosure, providing both electrical insulation and mechanical support. By introducing this intermediary element, the design achieves reliable connection without requiring direct mechanical fastening methods that reduce assembly efficiency.
2Loss of time
If separate assembly steps are used for connecting housing to enclosure, then connection stability is achieved, but assembly time increases
Solution Approach 1:
Multiple functions (electrical insulation, mechanical support, and connection stabilization) are merged into the single insulator component. This integration reduces the number of separate assembly steps required, thereby decreasing assembly time and simplifying the overall assembly process while maintaining connection stability.
Solution Approach 2:
The insulator is designed as a multi-functional component that simultaneously provides electrical insulation, structural support, and connection stabilization. This universality allows a single component to fulfill multiple roles that previously required separate parts and assembly steps, reducing both time and complexity.
3Ease of operation
If the housing is not firmly attached to the insulator, then assembly is simpler, but rotation and axial displacement occur
Solution Approach 1:
The attachment features are integrated into the unified housing-insulator structure, creating inherent mechanical interlocking that prevents rotation and axial displacement. This integration maintains assembly simplicity while ensuring positional stability through the combined design.
Solution Approach 2:
The insulator and housing features include asymmetric geometries (such as non-circular cross-sections or specific engagement profiles) that prevent relative rotation between components. This asymmetric design provides inherent anti-rotation capability while maintaining ease of assembly through straightforward insertion.
Data Source
AI summary
According to an aspect there is provided a base for an electric lamp which may be assembled in an efficient and convenient manner. The base comprises: a tubular enclosure (2) extending along an axial direction between a first and a second end portion of the enclosure, an insulator (4) attached to the first end portion of the enclosure such that a rotation of the insulator relative to the enclosure about the axial direction is prevented, the insulator having an inner portion (4b) facing towards an inner space of the enclosure, an outer portion (4a) facing away from said inner space and at least one channel for receiving an electrically conducting contact pin (5), the channel extending from the outer portion, through the insulator and leading into said inner space, and a housing (3) for accommodating electrical circuitry (11) for operating the electric lamp, wherein an end portion (5a) of the electrically conducting contact pin (5) has a lateral projection or recess being adapted to engage with an engagement portion (3c) of the housing such that a separation between the insulator and the housing is prevented in at least said axial direction, and wherein the housing is attached to the inner portion of the insulator such that a rotation of the housing relative to the insulator about the axial direction is prevented, wherein a rotation of the housing relative to the enclosure is prevented.