High-Voltage Lamp String Encapsulation for Oxidation Prevention
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Solution Overview
Problem
Existing high-voltage lamp strings face issues with poor contact due to oxidation and rusting of contact surfaces caused by long-term exposure to ambient air, leading to reduced yield and increased labor costs in manufacturing LED lamp beads.
Innovation Solution
A high-voltage lamp string system comprising a plurality of resistors, conducting wires, and lamp beads connected in series, where each lamp bead is encapsulated and fixed with glue to prevent air exposure, and connected with a plug to ensure reliable current transmission, alleviating oxidation issues and improving manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lamp beads are exposed to ambient air during manufacturing and operation, then the manufacturing process is simpler and more accessible, but the contact surfaces oxidize and rust over time causing poor contact and reduced reliability
Solution Approach 1:
The patent extracts the lamp bead from the ambient air environment by encapsulating it in a sealed structure formed by the U-shaped wire and glue combination. This isolation removes the harmful oxidative environment from the contact surfaces, preventing rust and maintaining reliable electrical contact over time.
Solution Approach 2:
The patent uses a flexible sealing approach where glue is applied to create a thin film barrier between the lamp bead and ambient air. The U-shaped wire provides a flexible mechanical structure that holds the lamp bead in place while the glue forms the hermetic seal, combining mechanical support with environmental protection.
2Duration of action of stationary object
If traditional wiring methods are used without proper insulation and sealing, then the manufacturing process is simpler, but oxidation and rusting occur leading to increased maintenance and reduced service life
Solution Approach 1:
The patent merges multiple functions into the U-shaped wire structure: it provides electrical connection, mechanical support, and structural framework for the sealing arrangement. The glue serves dual purposes of electrical connection and hermetic sealing, reducing the number of separate components needed and simplifying the overall manufacturing process.
Solution Approach 2:
The patent creates a composite sealing structure combining the metallic U-shaped wire with the adhesive glue material. This composite approach provides both the electrical conductivity needed for current flow and the hermetic sealing properties to prevent oxidation, achieving protection without requiring complex separate sealing components.
3Productivity
If contact surfaces are left exposed for easier assembly, then manufacturing is faster and less complex, but oxidation and rusting reduce contact quality and increase labor costs for rework
Solution Approach 1:
The patent applies the sealing and protective action during the initial assembly process itself, rather than requiring subsequent maintenance or rework. The glue is applied and cured to create the hermetic seal before the product leaves the manufacturing line, preventing oxidation from the start and eliminating future maintenance needs, thereby maintaining high productivity while ensuring reliability.
Data Source
Figure 1~3
AI summary
A high-voltage lamp string comprising: a plurality of resistors (110), a plurality of lamp beads (120), a first conducting wire (130) configured to conduct a current, a second conducting wire (140) configured to conduct a current and a working wire (150) for connecting the plurality of lamp beads (120) in series; each of the plurality of resistors (110) is connected between two respective adjacent wires among the three wires, and the first conducting wire (130) and the second conducting wire (140) are connected with a plug (160) so as to turn on the plurality of lamp beads (120) on the working wire (150) after the plug (160) is energized; and each of the plurality of lamp beads (120) is encapsulated and fixed by glue with portions of the first conducting wire (130) and the second conducting wire (140) at the position corresponding to the lamp bead (120).