Flexible Lamp Shell with Groove Tracks for Automated Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing decorative lamp manufacturing processes are limited by the difficulty in automating the assembly of contact and welding types, with the shrink type being unsuitable for large-scale production due to variable product quality and high production costs associated with injection molded types.

Innovation Solution

A decorative lamp design featuring a flexible mounting shell with a stepped structure and snap-fit mechanism for easy assembly, allowing for automated production and reduced costs, where the light emitting body is inserted from the rear end and wires are aligned with grooves for secure sealing and fastening.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If shrink type processing is used to isolate exposed pins, then pin isolation is achieved, but automation difficulty increases and production efficiency decreases

Engineering Contradiction:

Improvepin isolationVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges the pin isolation function with the wire fixing function into a single integrated structure. The groove structure serves dual purposes: isolating pins from each other and providing pathways for wire routing, eliminating the need for separate shrink sleeves and isolation components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The groove structure performs multiple functions simultaneously: it acts as an isolation barrier between pins, provides channels for wire routing, and serves as a fixing mechanism for securing wires in place. This multi-functional design simplifies the overall assembly and enables automated production.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If injection molded type processing is used to fix pin and wire postures, then positioning precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvepin and wire positioningVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent segments the mounting shell into distinct regions with grooves that separately accommodate pins and wires. This segmentation allows for precise positioning of each component through the molded groove structures, achieving injection-molded level precision while maintaining the simplicity of a single molded part.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using complex multi-component assemblies to achieve precise positioning, the patent uses a simplified molded groove structure that replicates the positioning function. The grooves are directly formed in the mounting shell during molding, providing precise guidance and positioning at low cost.

Inventive Principle:

Principle #26Copying

3Reliability

If sealed type processing is used to seal light emitting body and exposed wire, then sealing performance is improved, but manufacturing cost increases

Engineering Contradiction:

Improvesealing performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the sealing function with the structural housing into a single integrated component. The mounting shell itself forms the sealing barrier, with grooves and recesses that provide both structural support and sealing functionality, eliminating the need for separate sealing materials or complex sealing assemblies.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mounting shell is designed as a flexible or elastic material that can deform to accommodate components and then seal around them. This flexible shell approach provides effective sealing through the molded structure itself, achieving protection against environmental factors without requiring additional sealing layers or materials.

Inventive Principle:

Principle #30Flexible shells and thin films

4Ease of repair

If contact type connection is used for light emitting body, then ease of replacement is improved, but electrical conductivity reliability deteriorates due to rust

Engineering Contradiction:

Improvelight emitting body replacementVSAvoidelectrical conductivity

Core Design Contradiction:

Ease of repairVSReliability

Solution Approach 1:

The patent applies preliminary protective action by providing a molded groove structure that immediately isolates the pin connections from the external environment. This preliminary isolation prevents exposure to moisture and corrosive elements, maintaining electrical conductivity reliability while preserving the ease of replacement benefit.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11287112B2Decorative lamp and manufacturing method thereof

Publication Date: 2022.03.29 DONGGUAN KAILANG IND

AI summary

A decorative lamp includes a flexible mounting shell with a first end, a second end opposite the first end, a through hole extending through the first and second ends, a ridge extending into the through hole, and a first plurality of grooves. A light emitting body is positioned at least partially within the mounting shell, and the light emitting body extends through the second end of the mounting shell. A tail plug is positioned at least partially within the mounting shell adjacent the first end, and the tail plug includes a second plurality of grooves. The first plurality of grooves and the second plurality of grooves are aligned to form tracks configured to receive wires coupled to the light emitting body, and an outer surface of the mounting shell includes a stepped structure.