Light String with Bare Spot Conductors for Automated LED Assembly
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Solution Overview
Problem
Existing light string manufacturing methods are costly and inefficient, requiring multiple control chips and manual wire cutting for color flicker effects, which limits production efficiency and increases costs.
Innovation Solution
A light string design featuring a single controller connected to three enameled conductor wires with exposed bare spots, allowing for multiple LEDs to be connected in series without individual controllers, using a light transmissive glue for insulation and stability, enabling automated production and various lighting effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a control chip is provided for each light source to achieve color flicker effects, then lighting control functionality is improved, but device complexity and production cost increase
Solution Approach 1:
The patent merges multiple control chips into a single controller that manages all light sources through three enameled conductor wires. This consolidation reduces device complexity while maintaining lighting control functionality, as the single controller can still achieve color flicker effects by controlling the voltage on the three wires that connect to multiple LEDs.
Solution Approach 2:
The single controller serves multiple functions by controlling all light sources in the light string through the three enameled conductor wires. This multi-functional approach allows one controller to replace what would traditionally require multiple individual control chips, reducing overall device complexity while maintaining full lighting control capability.
2Ease of operation
If wires are cut into segments for connection between light bulbs, then connection flexibility is improved, but manufacturing efficiency and production cost worsen
Solution Approach 1:
The enameled conductor wires are prepared in advance with pre-defined connection points and insulation characteristics. The enameled coating is applied beforehand to specific sections, allowing for automated connection processes without requiring manual wire cutting and segmentation during assembly, thus improving manufacturing efficiency.
Solution Approach 2:
The patent replaces manual wire cutting and mechanical connection processes with an automated system using enameled conductor wires. The enameled coating allows for automated soldering or welding at predetermined points, substituting the manual mechanical wire segmentation process with a more efficient automated manufacturing approach.
3Manufacturing precision
If manual wire cutting and connection is used, then connection precision is improved, but labor cost and production time increase
Solution Approach 1:
The enameled conductor wires are pre-prepared with insulation removed at specific locations before assembly. This preliminary preparation of connection points enables automated precision connections during manufacturing, maintaining connection precision while eliminating the time-consuming manual wire cutting and stripping operations.
4Adaptability or versatility
If individual control chips are used for each light source, then lighting effect control is improved, but production cost increases
Solution Approach 1:
The patent combines multiple individual control chips into a single controller unit that manages all light sources. This merging reduces the total quantity of electronic components required, lowering production cost while maintaining the ability to achieve various lighting effects through coordinated control of the three enameled conductor wires.
Data Source
AI summary
A light string includes at least two conductor wires each covered with an insulating coating defining plural holes acting as electrical bare spots, a controller with an input terminal connected to an external power supply and an output terminal electrically connected to the at least two conductor wires, and plural light sources. Each light source includes one or more LEDs and a circuit board having a first surface used for fixing the one or more LEDs and a second surface defining at least two conductive strips across the second surface. The at least two conductive strips are electrically connected to the at least two conductor wires through the electrical bare spots, respectively. Each connecting part between the conductive strips and the conductor wires is wrapped around by a light transmissive glue. Two conductive ends of each LED are electrically connected to two of the at least two conductive strips.