LED String Light Bulb Assembly With Waterproof Rubber Core
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Solution Overview
Problem
Existing LED light bulbs and string lights require complex and costly injection molding processes due to the integration of metal leads with soft rubber lamp bases, leading to increased preparation costs and complicated assembly.
Innovation Solution
A novel LED light bulb design featuring a transparent lamp housing, metal lead lamp feet, and a waterproof rubber matrix, with a rubber core and integrated lamp bead limiting and stopping portions, allowing for SMD welding and simplified assembly through electrical contact with connecting terminal lugs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal leads are injection molded with soft rubber lamp base to form integrated structure, then electrical connectivity and structural integration are improved, but preparation cost and process complexity increase due to requiring different injection molds for different core column structures
Solution Approach 1:
The patent divides the integrated structure into separate components: the soft rubber lamp base is molded separately from the core column structure. The metal leads are embedded in the rubber base through a standardized mold, while the core column is assembled separately and then integrated into the lamp holder. This segmentation eliminates the need for different injection molds for different core column configurations, reducing tooling costs while maintaining electrical connectivity.
Solution Approach 2:
The core column structure is extracted from the injection molding process and treated as a separate assembly component. Instead of molding the core column together with the rubber base and lamp holder in one complex mold, the core column is prepared separately and then inserted into the lamp holder assembly, simplifying the injection molding requirements.
2Stability of the object's composition
If metal leads are injection molded with soft rubber lamp base to form integrated structure, then structural integration is improved, but assembly process becomes complicated
Solution Approach 1:
The assembly process is segmented into distinct steps: first, the soft rubber lamp base is molded with embedded metal leads using a standardized mold; second, the core column structure is assembled separately with the LED light bar and electrical connections; third, the core column is inserted into the lamp holder which already contains the rubber base. This segmentation makes the assembly process more systematic and easier to control quality, reducing complexity.
3Adaptability or versatility
If multiple injection molds are used for different core column structures, then adaptability to different LED configurations is improved, but preparation cost increases
Solution Approach 1:
The patent creates a universal lamp holder and rubber base assembly that can accommodate different core column structures. The standardized injection mold for the rubber base and lamp holder can be used across multiple product variants, while only the core column needs to be modified for different LED configurations. This universal design reduces the number of expensive custom molds required.
Solution Approach 2:
The core column structure is extracted as the variable component that changes with different LED configurations, while the lamp holder and rubber base remain standardized. This allows the majority of the assembly to use universal molds, with only the core column requiring customization, significantly reducing overall preparation cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enables a simple, low-cost assembly process with improved electrical connectivity and hermetic sealing, resulting in a novel structural design and reduced preparation costs for both the LED light bulb and string light.
Implementation Method 1
a waterproof rubber matrix is encapsulated in the LED SMD lamp bead
Implementation Method 2
a metal lead lamp foot is in SMD welding to each connecting terminal of the LED SMD lamp bead
Implementation Method 3
an upper end portion of the transparent lamp housing is inserted into the rubber core mounting hole
Data Source
AI summary
Disclosed are a light emitting diode (LED) light bulb and a string light using the LED light bulb. The LED light bulb includes an LED surface mounted device (SMD) lamp bead, a transparent lamp housing, and a rubber core. A metal lead lamp foot is in SMD welding to each connecting terminal of the LED SMD lamp bead, a waterproof rubber matrix is encapsulated in the LED SMD lamp bead. The string light includes a power line, a male connector, a female connector, and a plurality of lamp holders, and each lamp holder is equipped with the LED light bulb. Through the above structural design, the LED bulb and the string light using the LED bulb respectively have the advantages of a novel structural design, a simple assembly process, and low preparation cost.