Light Bulb Assembly Connector Eliminates Soldering
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Solution Overview
Problem
The existing light bulb assembly manufacturing process is time-consuming and prone to quality defects due to the soldering operations required to connect electrical wires to the positive terminal and shell, increasing production costs and reducing output.
Innovation Solution
A light bulb assembly design that uses an electrical connector with a connector housing, negative contact, and positive terminal, where the positive terminal is exposed for mating with the light bulb socket, eliminating the need for electrical wires by integrating the connector housing with an insulative plug that extends within the shell, allowing direct electrical connection to the PCB.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering operations are used to connect electrical wires to the positive terminal and shell, then electrical connections are achieved, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent extracts and eliminates the electrical wires from the assembly, replacing them with direct electrical contacts integrated into the connector housing. The positive terminal and negative contact are formed as integral parts of the connector housing structure, removing the need for separate wire soldering operations and enabling faster assembly.
Solution Approach 2:
The patent merges the electrical connection function directly into the connector housing structure. The positive terminal and negative contact are combined with the connector housing as a single integrated component, eliminating the need for separate wire components and soldering operations, thereby reducing manufacturing time while maintaining reliable electrical connections.
2Reliability
If soldering operations are used to connect electrical wires to the positive terminal and shell, then electrical connections are achieved, but manufacturing costs increase
Solution Approach 1:
The patent removes the electrical wires and soldering operations from the manufacturing process. The electrical connections are achieved through direct contact between the integrated positive terminal and negative contact within the connector housing, eliminating material costs for wires and labor costs for soldering operations.
Solution Approach 2:
The patent integrates the electrical connection components directly into the connector housing structure, reducing the total number of parts and assembly steps. This integration eliminates the need for separate wire materials and soldering operations, thereby reducing manufacturing costs while maintaining connection reliability.
3Reliability
If soldering operations are used to connect electrical wires to the positive terminal and shell, then electrical connections are achieved, but quality defects increase due to human and machine error
Solution Approach 1:
The patent eliminates the soldering operation entirely by removing electrical wires from the design. The electrical connections are achieved through precision-machined direct contacts integrated into the connector housing, which can be manufactured with consistent precision through automated machining processes rather than manual or automated soldering operations that are prone to defects.
Solution Approach 2:
The patent integrates the electrical connection components directly into the connector housing as a single precision-machined component. This integration eliminates the need for separate wire soldering operations, allowing for more consistent and reliable electrical connections through precision manufacturing processes that are less susceptible to human and machine error compared to soldering.
Data Source
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AI summary
A light bulb assembly (410, 510, 610) includes a bulb housing (412, 512, 612) that mounts to a base (416, 516, 616) that includes an electrically conductive shell (432, 532, 632) connected to a light bulb socket. The shell defines a negative terminal of the light bulb assembly. A light bulb (414, 514, 614) is held by the bulb housing and includes a printed circuit board (PCB) (418, 518, 618). The assembly includes an electrical connector (420, 520, 620) having a connector housing (450, 550, 650), a negative contact (454, 554, 654), and a positive terminal (446, 546, 646) of the light bulb assembly. The positive terminal and the negative contact are held by the connector housing. The electrical connector mounts to the PCB such that the positive terminal and the negative contact are electrically connected to the PCB. The negative contact is configured to mate with the shell of the base. The positive terminal is configured to be exposed for mating with a corresponding terminal of the light bulb socket when the bulb housing is mounted to the base.