Integrated LED Light String Assembly for Durable High-Voltage Connections
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Solution Overview
Problem
Traditional light strings with mini tungsten filament bulbs are in need of improvement.
Innovation Solution
A high-voltage plug-in light string with integrated LED bulbs is developed, utilizing a method that involves connecting LED glass bulbs to wires with striped ends using riveting metal connectors, enclosing them with an inner insert and heat shrink tube, and securing them within a lamp holder and collar, before connecting multiple assemblies in series and parallel to form a complete light string.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mini tungsten filament bulbs are used in light strings, then the structure is simple and easy to manufacture, but the durability and energy efficiency are poor
Solution Approach 1:
The patent applies nesting by placing the LED bulb inside a glass envelope, which is then enclosed by a metal connector, followed by an inner insert, and finally a heat shrink tube. This nested structure protects the LED bulb while maintaining a compact design, resolving the contradiction between improved durability and structural complexity.
Solution Approach 2:
The patent uses composite materials by combining LED technology with traditional glass bulb structure and metal connectors. The integration of LED bulbs within the glass envelope and metal connector assembly creates a composite structure that enhances durability and energy efficiency while managing the complexity through standardized components.
2Use of energy by moving object
If traditional mini tungsten filament bulbs are used, then the manufacturing process is simple, but the energy efficiency and performance are poor
Solution Approach 1:
The patent merges LED technology with traditional light string structure by integrating LED bulbs into the existing glass envelope and metal connector framework. This combination allows the use of energy-efficient LED bulbs while maintaining compatibility with traditional manufacturing processes, thus improving energy efficiency without significantly complicating manufacturing.
3Reliability
If LED bulbs are integrated with glass envelopes and metal connectors, then the durability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-assembling the LED bulb with the glass envelope and metal connector into an integrated unit before installation into the light string. This pre-integration simplifies the final assembly process and reduces manufacturing complexity while maintaining the durability benefits of the protected LED structure.
Data Source
AI summary
A method of making a first light assembly of a string light is disclosed, the method includes providing a bulb, a first wire, and a second wire, each of the first and second wires has an exposed end; connecting the exposed ends of the first and second wires to the bulb; inserting an inner insert in a space between the first and second wires where the first and second wires converge; encapsulating the first and second wires using a heat shrink tube where the exposed ends of the first and second wires are connected to the bulb; and affixing a lamp holder around the bulb and a portion of the first and second wires and on top of the inner insert to secure at least a portion of the bulb within the lamp holder.