LED Battery Box Terminal Assembly With Waterproof Gasket Sealing
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Solution Overview
Problem
The existing LED lamp string and battery box connection process is complex, labor-intensive, and prone to errors, with potential health hazards from soldering and material waste, and the waterproofing is inadequate, leading to defective products and increased costs.
Innovation Solution
A battery box design with a circuit board mounting groove, battery placement groove, and a cover plate with clamping mechanisms and an up-turning mechanism, featuring a power source terminal seat with through-line holes and a waterproof gasket with varying thickness for improved sealing, simplifying assembly and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tin soldering is used to connect the LED lamp string to the battery box, then electrical connection is achieved, but harmful gas is generated causing health hazards to workers
Solution Approach 1:
The patent extracts the harmful soldering process from the connection method and replaces it with a mechanical plug-socket connection system. The LED lamp string is connected to the battery box through terminal plugs and socket holes without any soldering, eliminating harmful gas generation while maintaining reliable electrical connection.
Solution Approach 2:
The patent replaces the thermal/mechanical soldering process with a purely mechanical plug-socket connection system. Terminal plugs with electrical contacts are inserted into corresponding socket holes on the battery box, achieving both mechanical fixation and electrical connection without heat generation.
2Reliability
If tin soldering with electric soldering iron is used, then electrical connection is established, but small parts on circuit board may fall off or plastic housing may be burned
Solution Approach 1:
The patent removes the soldering iron and heating process from the connection procedure. Electrical connections are made through pre-installed terminal plugs and socket holes that require no thermal processing, eliminating the risk of burning plastic housing or dislodging small circuit board components.
Solution Approach 2:
The terminal plugs and socket holes are pre-prepared during manufacturing before final assembly. The electrical connection interfaces are already in place and properly positioned, so no additional heating or manipulation is needed during assembly, preventing damage to the circuit board and housing.
3Reliability
If the LED lamp string is packaged as a finished product, then product protection is improved, but consumers cannot check product quality before purchase
Solution Approach 1:
The patent segments the LED lamp string into modular components: the battery box with integrated circuit board, terminal plugs, and the LED lamp string itself. This modular design allows consumers to purchase components separately or in kits, enabling quality verification of individual parts before final assembly while maintaining overall product protection.
4Stability of the object's composition
If a large cover plate is used to press batteries in the battery box, then batteries are securely fixed, but the battery box height increases causing material waste and increased cost
Solution Approach 1:
The patent merges the battery fixation function with the existing battery box structure by integrating spring-loaded terminal plugs that simultaneously provide electrical connection and mechanical retention. The springs press against the battery terminals, securing batteries in place without requiring a separate large cover plate, thus maintaining compact dimensions.
Solution Approach 2:
The terminal plug structure serves multiple functions: it provides electrical connection, secures the battery through spring pressure, and maintains compact battery box dimensions. This multi-functional design eliminates the need for separate fixation mechanisms that would increase overall height.
Data Source
AI summary
A battery box, including a box body and an LED lamp string. A circuit board mounting groove and a battery placement groove are disposed in the box body, a power supply source is disposed in the battery placement groove, and a circuit board and a cover plate are disposed in the circuit board mounting groove. A power source terminal seat is disposed at one side of the circuit board, at least two terminal plugholes are disposed in the power source terminal seat, a through-line hole is disposed on a side wall of each of the terminal plugholes facing the box body, a collosol groove is between the through-line hole and the power source terminal seat, power source plug terminals are disposed at one end of the LED lamp string, and the power source plug terminals are correspondingly inserted into the terminal plugholes respectively.