Light String Power Supply Button Assembly for Solder-Safe Key Triggering
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Solution Overview
Problem
Existing light string power supplies suffer from key failure due to solder material entering the key during dip soldering and misalignment issues between the triggering end of the key and the button, leading to unreliable operation.
Innovation Solution
The design incorporates a push rod with a first annular boss to prevent solder entry and a second annular boss for secure connection, along with chamfered surfaces and protrusions for easy assembly, ensuring reliable triggering and waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a push rod-type key or surface-mounted key is used during dip soldering, then the key can be triggered by the button, but solder material enters the key causing key failure
Solution Approach 1:
The key structure is segmented into a key body and a triggering end, with the triggering end located inside the first annular boss and separated from the button. This segmentation prevents solder material from directly entering the key while maintaining the triggering function through the push rod mechanism.
Solution Approach 2:
A push rod is introduced as an intermediary component between the button and the key triggering end. The push rod transmits the triggering force from the button to the key without allowing direct contact between the button and key, thereby preventing solder material from entering the key during dip soldering.
2Device complexity
If the button directly triggers the key, then the triggering action is simple, but misalignment occurs between the button and key triggering end causing key failure
Solution Approach 1:
The triggering mechanism is segmented into distinct components (button, push rod, key) with defined spatial relationships. The push rod connects the button to the key through the first annular boss, creating a guided transmission path that eliminates misalignment issues while maintaining structural simplicity.
Solution Approach 2:
The triggering end of the key is nested inside the first annular boss, and the push rod is inserted into the first annular boss to abut against the triggering end. This nested arrangement ensures proper alignment and positioning without requiring high manufacturing precision for direct button-key alignment.
3Ease of manufacture
If the key is exposed during assembly, then assembly is straightforward, but solder material and misalignment cause key failure
Solution Approach 1:
The key structure is divided into an exposed key body and a protected triggering end located inside the first annular boss. This segmentation allows the key body to remain accessible for assembly while protecting the triggering end from solder material and misalignment issues.
Solution Approach 2:
The push rod serves as an intermediary that connects the button to the key triggering end through the first annular boss. This intermediary structure simplifies assembly by providing a clear insertion path while ensuring the triggering end remains protected from solder material during the dip soldering process.
Data Source
AI summary
A light string power supply includes a housing, an end cover, and a circuit board, where the end cover is fixed to an open end of the housing; the circuit board is disposed inside the housing; the end cover is embedded with a button for triggering a key located on the circuit board; the light string power supply further includes a push rod; a shell of the key is provided with a first annular boss; a triggering end of the key is located inside the first annular boss; one end of the push rod is connected to an inner end of the button, and the other end of the push rod is inserted into the first annular boss and abuts against the triggering end; and when the button is pressed, the push rod pushes the triggering end to trigger the key.