Light string and ornamental article including the same
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Solution Overview
Problem
Existing ornamental articles, particularly those using lights for aesthetic enhancement, face challenges in maintaining an appealing appearance due to bulky connectors and inefficient manual placement of light sources, which degrade the overall visual impact and increase manufacturing costs.
Innovation Solution
A light string design featuring a flexible conductive wire with light sources having leads of varying lengths and two-pin connectors, allowing precise placement of light sources at the tips of needles and minimizing connector visibility, facilitated by automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual placement of light sources is used, then flexibility in positioning is maintained, but manufacturing efficiency decreases and costs increase
Solution Approach 1:
The light sources are pre-assembled onto the flexible conductive wire with connectors attached at predetermined locations before final installation. This preliminary assembly allows automated systems to handle pre-configured units, significantly improving manufacturing efficiency while reducing the complexity of on-site assembly operations.
Solution Approach 2:
The light string is divided into modular segments with standardized connectors at regular intervals. Each segment can be independently manufactured and assembled, enabling automated production lines to work with discrete, manageable units rather than continuous complex structures, thereby improving both productivity and reducing assembly complexity.
2Reliability
If bulky connectors are used, then electrical connection reliability is improved, but aesthetic appearance deteriorates
Solution Approach 1:
The connector housing is extracted and separated from the main light source body, allowing the electrical connection components to be minimized for reliability while the aesthetic appearance is maintained by the separate, streamlined light source design. The connectors are positioned at intervals where they can function reliably without dominating the visual profile.
Solution Approach 2:
The connectors are designed with different properties at different locations: the electrical contact portions are robust and reliable for functional performance, while the external housing portions are minimized and streamlined for aesthetic appearance. This local differentiation allows simultaneous optimization of both reliability and appearance.
3Shape
If light sources are placed at needle tips, then aesthetic effect is enhanced, but positioning precision requirements increase
Solution Approach 1:
The light sources are pre-positioned at exact locations on the flexible conductive wire during manufacturing, with connectors attached at predetermined intervals. This preliminary precision positioning eliminates the need for high-precision field installation, as the positioning is accomplished under controlled factory conditions where precision can be ensured.
Solution Approach 2:
The flexible conductive wire provides dynamic adaptability, allowing the rigidly positioned light sources to conform to the contours of the ornamental article during installation. The flexibility compensates for positioning tolerances and enables accurate needle tip placement without requiring extreme manufacturing precision.
Data Source
Figure 1
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Figure 2B
AI summary
The present disclosure proposes an article (10), which includes a support structure (110), a plurality of needles (112) connected to the support structure, and a light string. The light string (120) includes a flexible conductive wire affixed to the needles, and a plurality of light sources. Each of the light sources includes at least two leads electrically coupled to the flexible conductive wire. The leads of the light sources arranged at different heights of the article include different lengths.