Lamp Holder Design Eliminating Brass Heads
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Solution Overview
Problem
Existing lamp holders have complex manufacturing processes and high costs due to the need for two injection molding steps and the use of brass heads for bulb connection, increasing the production cost of luminaires.
Innovation Solution
A lamp holder design featuring a hard plastic housing with integrated wire clamping grooves and terminal mounting holes, eliminating the need for brass heads by directly connecting to the bulb's PIN, and using metal terminals embedded in the housing, simplifying the structure and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brass heads are used for bulb connection, then reliable electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive brass heads with inexpensive metal terminals that are embedded directly in the plastic housing. The metal terminals serve the same electrical connection function but at a lower cost, aligning with the principle of using cheaper substitute materials to reduce manufacturing cost while maintaining functionality.
Solution Approach 2:
The patent combines the terminal mounting function directly into the plastic housing structure through embedded metal terminals, eliminating the need for separate brass head components. This merging of functions reduces part count and assembly complexity, thereby reducing manufacturing cost while maintaining reliable electrical connection.
2Ease of manufacture
If two injection molding procedures are used, then complete lamp holder structure is achieved, but manufacturing process complexity increases
Solution Approach 1:
The patent merges the terminal mounting features directly into the single plastic housing component through embedded metal terminals. This integration eliminates the need for separate terminal holders or additional injection molding steps, simplifying the manufacturing process from two procedures to one while achieving complete structural functionality.
Solution Approach 2:
The plastic housing serves multiple functions simultaneously: structural support, electrical insulation, and terminal mounting. By making the housing multi-functional through integrated terminal embedding, the design eliminates the need for separate dedicated terminal components and their associated manufacturing steps.
Data Source
AI summary
The utility model discloses a lamp holder with an improved structure. A lamp holder housing of the lamp holder comprises a housing main body and a housing top cap; a main body mounting hole with a downward opening is formed in the housing main body, and a main body wire clamping groove is formed in the position. Through the structural design, a lamp holder with an improved structure disclosed by the utility model has the advantages of being novel in design, simple in structure, and low in manufacturing cost, and the product cost of the luminaire can be effectively reduced.