Single Wire LED Light String with Composite Conductor Core
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Solution Overview
Problem
Existing LED light strings are large, heavy, and inflexible due to multiple wires and patch LEDs, limiting their application in fine settings and increasing costs, while attempts to reduce size compromise strength and volume.
Innovation Solution
An LED light string with a single composite wire core comprising conductor layers and an insulation layer, integrated to reduce size and weight, with patch LEDs electrically connected to these layers, allowing for smaller and lighter construction without sacrificing strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple wires and patch LEDs are used in conventional LED light strings, then the structural strength is sufficient, but the size and weight become large, reducing flexibility
Solution Approach 1:
The patent combines multiple wires into a single composite wire structure where multiple conductor layers are integrated within one insulation layer. This merging approach maintains the electrical function of multiple wires while significantly reducing the overall size and weight of the light string structure.
Solution Approach 2:
The patent uses composite wire structure consisting of multiple conductor layers (e.g., copper and aluminum layers) combined with an insulation layer. This composite structure provides both mechanical strength and electrical functionality while minimizing weight and volume compared to traditional separate wire arrangements.
2Volume of stationary object
If wire diameter is reduced to minimize light string volume, then the volume decreases, but the strength requirement cannot be ensured
Solution Approach 1:
The patent employs composite wire structure with multiple conductor layers of different materials (such as copper and aluminum) with different strengths. This allows the wire to achieve high strength-to-volume ratio, maintaining structural integrity while minimizing the overall volume of the light string.
Solution Approach 2:
The patent nests multiple conductor layers within a single insulation layer, creating a compact hierarchical structure. This nesting approach allows multiple functional elements to occupy the same spatial envelope, reducing overall volume while maintaining the strength contributions of each conductor layer.
3Reliability
If multiple independent wires with rubber sheath are used, then the electrical insulation is reliable, but the device complexity and cost increase
Solution Approach 1:
The patent merges multiple conductor layers into a single integrated composite wire with a unified insulation layer. This integration maintains reliable electrical insulation between conductors while significantly simplifying the overall wire structure, reducing the number of separate components, and lowering manufacturing complexity and cost.
Data Source
AI summary
An LED light string with single wire. The LED light string includes one wire including a composite wire core, and a plurality of light bodies. The composite wire core is composed of at least one first conductor layer extending in an axial direction of the wire, at least one second conductor layer extending in the axial direction of the wire, and an insulation layer therebetween. The plurality of light bodies arranged spaced away at set intervals along the axial direction of the wire. Each of the light bodies includes at least one patch LED light-emitting part and an encapsulation colloid coated on a surface of the at least one patch LED light-emitting part. A positive electrode and a negative electrode of the at least one patch LED light-emitting part being electrically connected to the at least one first conductor layer and the at least one second conductor layer, respectively.