LED String Light Lamp Assembly Modular Housing Design
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Solution Overview
Problem
Existing LED string light assemblies face challenges in being easily and conveniently assembled while maintaining high waterproof and dustproof qualities, especially since the circuit board is vulnerable to weather conditions.
Innovation Solution
The lamp assembly features an outer housing, inner housing, lamp module, lower shell, and lamp cover module, with a multi-step cylindrical design and engagement/fastening parts that provide airtight sealing and tool-free assembly, protecting the circuit board with a guard ring and ensuring easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly is used for LED string light, then flexibility is maintained, but assembly efficiency is low
Solution Approach 1:
The lamp assembly is divided into modular components including outer housing, inner housing, lamp module, lower shell, and lamp cover module. Each module can be independently manufactured and assembled, significantly improving assembly efficiency while maintaining design flexibility.
Solution Approach 2:
The inner housing is nested within the outer housing, and the lamp module is nested within the inner housing. This nested structure allows for compact assembly while enabling straightforward step-by-step manual assembly without requiring complex alignment procedures.
2Reliability
If housing is not sufficiently airtight, then manufacturing cost is reduced, but electrical elements are affected by weather
Solution Approach 1:
A guard ring is introduced as an intermediary sealing component between the inner housing and lamp module. This guard ring creates an additional protective barrier that enhances weather resistance without requiring complete redesign of the housing structure.
Solution Approach 2:
The housing design incorporates flexible sealing mechanisms including gaskets and sealing rings that can adapt to manufacturing tolerances while maintaining airtightness. These flexible sealing elements protect electrical components from moisture and dust without adding significant structural complexity.
3Reliability
If circuit board is exposed, then assembly is simplified, but vulnerability to moisture and dust increases
Solution Approach 1:
The circuit board is nested within the inner housing, which itself is nested within the outer housing. This multi-layer nesting provides progressive protection against moisture and dust while maintaining a relatively simple overall structure through modular design.
Solution Approach 2:
The guard ring acts as an intermediary protective element specifically positioned to seal around the circuit board area. This localized sealing approach protects the vulnerable circuit board without requiring complete redesign of the entire housing structure.
Data Source
AI summary
A lamp assembly of LED string light has a lamp module, an inner housing, an outer housing, a lower shell and a lamp cover module. The lamp module has a circuit board and an LED bulb and a set of power lines mounted on the circuit board. The inner housing has two symmetrical and engaged inner cases and a space to receive the lamp module. The outer housing has two symmetrical outer cases assembled together and encloses the inner housing. The lower shell is sleeved around a bottom portion of the inner housing. The lower shell has a multi-step portion formed on a periphery thereof for the lamp cover module to sleeve on the lower shell. Given the aforementioned elements, the lamp assembly of LED string light is easily assembled and highly waterproof and dustproof.