Multi-wire LED String Light Wire Fixing Structure
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Solution Overview
Problem
Existing multi-wire LED rubber-covered string lights suffer from low connection strength and instability due to relative movement of wires, leading to LEDs falling off when subjected to external forces, resulting in poor practicality.
Innovation Solution
The solution involves forming solder joints at fixed intervals on the wires, creating bead soldering areas where patch LED beads are connected in parallel, series, or series and parallel, and fixed using dispensing seats with wire fixing slots and spiral positioning structures to enhance axial fixation and reduce movement, along with a processing method that includes heating and gas mixture use for improved glue fluidity and wrapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wires are fixed by dispensing in traditional string lights, then the structure is simple and easy to manufacture, but the wires are prone to relative movement and LEDs fall off under external forces
Solution Approach 1:
The wire fixing structure is segmented into multiple components: wire fixing slots in the base, spiral positioning structures, and dispensing seats. This segmentation allows each component to perform a specific function (fixing, positioning, sealing) and collectively provides strong connection strength without excessive overall complexity.
Solution Approach 2:
The wire fixing slots and spiral positioning structures are pre-formed in the base before LED assembly. These structures preliminarily secure the wires in position, preventing relative movement during subsequent dispensing and assembly operations, thereby improving connection strength.
2Reliability
If wires are allowed to move freely for easy assembly, then the ease of manufacture is improved, but the stability and reliability of the LED connections deteriorate
Solution Approach 1:
The wire fixing slots and spiral positioning structures are integrated into the base itself, allowing the base to automatically secure the wires during assembly without requiring separate fixing operations. This self-service approach maintains ease of manufacture while ensuring wire stability and connection reliability.
3Reliability
If multiple fixing structures are added to prevent wire movement, then the stability is improved, but the device complexity increases
Solution Approach 1:
Multiple fixing functions (wire securing, positioning, and sealing) are merged into a single integrated base structure with embedded wire fixing slots and spiral positioning structures. This consolidation provides high wire stability while avoiding the complexity of separate fixing components.
Data Source
AI summary
The present disclosure discloses a multi-wire LED rubber-covered string light and a processing method thereof, and is applicable to the technical field of manufacturing and processing of colored lights. The dispensing bonding strength is high, wires are free of relative movement and have high stability, and practicality is high. According to the technical solution, insulation layers are removed in an axial direction of the wires at fixed length intervals to form a plurality of solder joints, the solder joints of the wires are in one-to-one correspondence and form bead soldering areas, patch LED beads are disposed in the bead soldering areas, the patch LED beads are fixed by dispensing after being connected to the bead soldering areas, and beads are formed by connecting the patch LED beads with the bead soldering areas.