LED String Lamp Holder Pre-Encapsulation Assembly
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Solution Overview
Problem
Conventional lamp holders for LED string lights require multiple assembly steps, leading to inefficiencies in production and a risk of pin contact during transportation, which can cause short circuits.
Innovation Solution
A lamp holder design where the LED lighting module is pre-encapsulated in the lamp housing, with cathode and anode pins extending through a groove in the plug, secured by lugs and limiting ribs, allowing direct assembly with the socket, reducing steps and preventing pin contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the LED lighting module and lamp housing are separately assembled with the plug in multiple steps, then the assembly process is flexible, but the production efficiency is low
Solution Approach 1:
The patent combines the LED lighting module and lamp housing into a single integrated assembly unit that is pre-assembled by the supplier. This merging eliminates the need for separate assembly steps at the user end, reducing the assembly process from multiple steps to a single insertion operation, thereby significantly improving production efficiency.
Solution Approach 2:
The LED lighting module is pre-installed into the lamp housing by the supplier before delivery to the user. This preliminary action of pre-assembly reduces the complexity of the final assembly process, allowing the user to simply insert the pre-assembled unit into the plug without needing to perform multiple assembly steps.
2Reliability
If the LED lighting module is not pre-encapsulated, then the assembly process is simpler, but the pins are prone to contact and short circuits during transportation
Solution Approach 1:
The patent employs an encapsulation structure where the lamp housing is inserted into a groove of the plug, and the LED lighting module is nested within the lamp housing. This nested arrangement provides physical isolation and protection for the cathode and anode pins, preventing them from contacting each other during transportation and storage, thereby improving reliability.
3Strength
If the LED lighting module is small in size, then the product is compact, but it is difficult to clamp and prone to damage
Solution Approach 1:
The patent uses a nested structure where the small LED lighting module is placed inside the lamp housing, which is then inserted into the groove of the plug. This nested arrangement provides protective clamping without requiring the LED module itself to be large, maintaining product compactness while improving strength and protection against damage.
Solution Approach 2:
The patent combines the protection function with the structural design by integrating the lamp housing and plug groove into a unified protective mechanism. This merging provides both structural support and protection for the small LED module, eliminating the need for separate clamping mechanisms that would increase size.
4Reliability
If the upper lug and lower lug have the same length, then the structure is symmetric and simple, but the assembly foolproof effect is reduced
Solution Approach 1:
The patent introduces asymmetry by designing the upper lug and lower lug with different lengths. This asymmetric design creates a foolproof assembly mechanism where the lugs can only be inserted in the correct orientation, preventing incorrect assembly. The first limiting rib corresponds to the upper lug and the second limiting rib corresponds to the lower lug, ensuring proper alignment and connection.
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
This design simplifies assembly, reduces production steps, prevents pin contact and short circuits, and enhances protection of the LED module, while ensuring secure electrical connections.
Implementation Method 1
An open end of the lamp housing is pre-sintered with an encapsulation layer
Data Source
AI summary
A lamp holder for an LED string light includes a lamp housing, an LED lighting module, a plug, and a socket. An open end of the lamp housing is pre-sintered with an encapsulation layer. The LED lighting module is disposed in the lamp housing, and has a cathode pin and an anode pin extending out from the encapsulation layer. Because the LED lighting module is pre-encapsulated in the lamp housing, when installed, only the LED lighting module and the plug need to be assembled so as to complete the assembly of the lamp housing, the LED lighting module and the plug. This reduces the assembly steps for production.