LED Light String Controller Waterproofing via Ultrasonic Welding
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Solution Overview
Problem
Conventional LED light string controllers are prone to water ingress due to the failure of silicone seals over time, leading to manufacturing difficulties and reliability issues.
Innovation Solution
A controller structure comprising a control box with a high voltage circuit unit and a lid, where the lid's second fitting portion is ultrasonically welded to the control box's first fitting portion to create a waterproof seal, preventing water from entering the control box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicone is applied to seal the controller components, then waterproof feature is achieved, but manufacturing becomes troublesome and silicone drops easily after use
Solution Approach 1:
The patent replaces the silicone sealing system with a mechanical interlocking system consisting of a locking groove on the control box and a corresponding locking protrusion on the lid. This mechanical structure provides waterproofing through physical barrier and interference fit, eliminating the need for silicone application and subsequent curing processes, thereby simplifying manufacturing while maintaining reliability
Solution Approach 2:
The patent extracts and removes the silicone sealing material from the controller structure entirely. Instead of relying on silicone to provide waterproofing, the design uses a dedicated mechanical locking mechanism that achieves the same waterproofing function without the manufacturing complications and degradation issues associated with silicone
2Reliability
If silicone is applied to seal the controller components, then waterproof feature is achieved, but the silicone drops easily after a period of using time
Solution Approach 1:
The patent replaces the degradable silicone sealing system with a permanent mechanical interlocking system. The locking groove and locking protrusion create a durable physical barrier that does not degrade, crack, or detach over time, thereby extending the service life of the waterproofing function
Solution Approach 2:
The mechanical locking mechanism provides beforehand protection against water ingress by establishing a reliable seal before the controller is put into service. The interference fit and locking structure prevent water penetration from the outset and maintain this protection throughout the product's entire service life without degradation
3Reliability
If the lid is tightly sealed to prevent water ingress, then waterproof integrity is improved, but assembly and disassembly become difficult
Solution Approach 1:
The patent segments the sealing function into discrete mechanical elements: a locking groove on the control box and a locking protrusion on the lid. This segmentation allows the sealing mechanism to be simple, reversible, and easily operated, while still providing effective waterproofing when engaged
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 ultrasonic welding of the lid to the control box effectively prevents water ingress, enhancing the waterproof feature and reducing manufacturing time by ensuring a reliable seal.
Implementation Method 1
the second fitting portion and the first fitting portion are ultrasonically welded together
Data Source
AI summary
A controller structure is applied to electrically conduct at least one LED light string and contains: a control box, a high voltage circuit unit, and a lid. The control box includes an opening, a hollow accommodation portion, two pins, and a first fitting portion. The high voltage circuit unit is accommodated in the hollow accommodated portion and includes an input segment and an output segment, a positive-electrode contact and a negative-electrode contact of the input segment are electrically connected with the two pins, a positive-electrode contact and a negative-electrode contact of the output segment are electrically connected with at least two power wires, and the high voltage circuit unit further includes a control unit. The lid covers the opening and includes a socket and a connection portion which is electrically connected with the output segment of the high voltage circuit unit via the at least two power wires.