LED Lamp Rigid Wire Assembly with Guide Bracket
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Solution Overview
Problem
The assembly of LED lamps is complicated due to solder mud bonding, leading to low production efficiency and circuit disconnection issues, and existing manufacturing processes do not allow for easy maintenance or replacement of lamp filament components.
Innovation Solution
An LED lamp design featuring a lighting assembly with rigid wires and a base component that includes a bracket with funnel-shaped wire guiding holes for accurate polarity matching and high-speed assembly, along with an insulating sleeve and snap-fit legs for secure integration of the driving unit, enabling efficient electrical connections and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder mud bonding is used to connect lamp filament component and driving board, then electrical connection is achieved, but assembly operation becomes complicated and production efficiency decreases
Solution Approach 1:
The patent replaces the traditional solder mud bonding process with a mechanical connection system consisting of connection terminals, connection wires, and connection holes. This mechanical substitution eliminates the need for complex soldering operations while ensuring reliable electrical connection, thereby improving both connection reliability and production efficiency.
Solution Approach 2:
The patent divides the connection system into separate modular components: connection terminals mounted on the driving board, connection wires for flexible electrical connection, and connection holes for precise alignment. This segmentation allows for simplified assembly operations and easier maintenance compared to traditional soldering.
2Reliability
If solder mud bonding is used to connect lamp filament component and driving board, then electrical connection is achieved, but circuit disconnection easily occurs due to solder mud falling off
Solution Approach 1:
The patent replaces solder mud bonding with a mechanical connection system using connection terminals and connection wires that are physically secured through connection holes. This mechanical system eliminates the risk of solder mud falling off and causing circuit disconnection, providing more stable and reliable electrical connection.
3Reliability
If lamp filament component is permanently connected with PCB through soldering, then electrical connection is established, but PCB cannot be maintained or replaced separately
Solution Approach 1:
The patent segments the electrical connection system into separable components: the lamp filament component, connection wires, connection terminals, and PCB. This modular design allows the lamp filament component to be disconnected and replaced without affecting the PCB, enabling easy maintenance and repair while maintaining stable electrical connection through the connection terminal system.
Solution Approach 2:
The patent creates a dynamic, reconfigurable connection system using connection wires and terminals that can be assembled and disassembled. This dynamic design contrasts with the static, permanent solder joint, allowing for easy maintenance and replacement of components while ensuring stable electrical connection during operation.
4Productivity
If traditional high-speed halogen lamp manufacturing line is used for LED lamp, then manufacturing speed is maintained, but assembly complexity increases due to driver integration
Solution Approach 1:
The patent segments the LED lamp assembly into distinct modules: lighting assembly with pre-installed connection terminals, driving board with connection holes, and connection wires. This segmentation allows each module to be prepared separately and assembled quickly, reducing overall assembly complexity while maintaining high manufacturing speed through modular assembly.
Solution Approach 2:
The patent employs preliminary action by pre-installing connection terminals on the lighting assembly and pre-positioning connection holes on the driving board before final assembly. This preparatory work simplifies the main assembly process, allowing for quick connection wire installation and maintaining high manufacturing speed despite the added complexity of driver integration.
Data Source
AI summary
The present application provides a LED lamp, wherein the LED lamp comprises: a lighting assembly comprises a lamp post, rigid wires are provided at the bottom of the lamp post; a driving unit comprises a PCB, a connector is provided on the PCB and is electrically connected with the PCB; and a base component is provided at the bottom of the lighting assembly, accommodates the driving unit, and electrically connected with the driving unit by connection wires extended from the driving unit, wherein, the LED lamp further comprises a bracket positioned in the base component, wire guiding holes are provided on the bracket, so that the rigid wires pass through the wire guiding holes to electrically connected with the connector. By such arrangement, automatic and high-speed assembly of the LED lamp may be achieved.