LED Light String Waterproof Housing with Spacer Plug
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Solution Overview
Problem
Conventional light strings are not adequately waterproof, making them unsuitable for outdoor use due to exposed electrical connections that can be vulnerable to water and moisture.
Innovation Solution
A light string design featuring a housing assembly with a light cap and spacer plug, where the light emitting source is encapsulated with a filler that bonds the light cap and spacer plug, ensuring sealed electrical connections and water resistance through the use of conductive lead wires and an insulative spacer plug to prevent electrical shorts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional light strings are used with exposed electrical connections, then the device complexity is reduced and ease of manufacture is improved, but water resistance and reliability deteriorate
Solution Approach 1:
The light string is divided into modular light string assemblies, each containing a housing assembly with light cap, spacer plug, and electrical connections. This segmentation allows each module to be independently sealed and waterproofed, improving reliability while maintaining ease of assembly through standardization
Solution Approach 2:
The light cap is nested within the housing assembly, and the spacer plug is nested within the light cap. This nested structure allows multiple components to be integrated into a compact, sealed unit that provides water resistance without excessive complexity
2Reliability
If exposed electrical connections are used in light strings, then ease of manufacture is improved and device complexity is reduced, but reliability and safety deteriorate due to vulnerability to water and moisture
Solution Approach 1:
The spacer plug is inserted into the light cap before the light source is installed, pre-establishing the sealed environment for electrical connections. This preliminary action ensures water resistance is built into the structure before final assembly, improving reliability without significantly complicating the manufacturing process
Solution Approach 2:
The spacer plug acts as an intermediary component between the light cap and the electrical connections. It provides a sealed barrier that protects electrical connections from water and moisture while maintaining the structural integrity of the assembly
3Object-affected harmful factors
If a housing assembly with light cap and spacer plug is used to seal electrical connections, then water resistance and reliability are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The spacer plug serves multiple functions: it provides electrical insulation between conductors, creates a sealed environment for electrical connections, and structurally supports the light source within the housing assembly. This multi-functionality reduces the need for separate components, thereby reducing overall device complexity while maintaining protection from water and moisture
Solution Approach 2:
The housing assembly merges the light cap, spacer plug, and electrical connection housing into a single integrated structure. This consolidation protects electrical connections from water and moisture while reducing the number of separate components that would otherwise be needed
Data Source
AI summary
A light string is comprised of a housing assembly, a light emitting source, a first conductive lead wire and a second conductive lead wire. The housing assembly is comprised of a light cap extending from a housing. A spacer plug secures a first and second conductive lead wire, and an light emitting source to the housing assembly. A first conductive lead wire and a second conductive lead wire each extend into the housing and are secured within the housing via the spacer plug. An insulative projection of the spacer plug is seated between the first conductive lead wire and the second conductive lead wire within the housing so as to prevent a direct electrical short between the first conductive lead wire and the second conductive lead wire. Glue is used to fill the housing to create a waterproof electrical connection.