Integrated Plastic Lamp Holder for Automated Insulated Assembly
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Solution Overview
Problem
Existing LED lamp holders require manual assembly of copper components, leading to low automation, high labor costs, and a high failure rate due to the use of metal materials, which increases manufacturing costs and decreases market competitiveness.
Innovation Solution
A high-insulation integrated plastic lamp holder is developed through injection molding, featuring conductive slots and a barrier to facilitate automatic assembly and prevent short circuits, reducing costs and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper components are used for lamp holder, then electrical conductivity is improved, but manufacturing cost increases and reliability decreases
Solution Approach 1:
The patent replaces expensive copper components with plastic materials that can be easily manufactured and replaced. The lamp holder body, insulating parts, and even conductive elements are made from plastic, eliminating the need for costly copper while maintaining functionality through design innovations like conductive paint and integrated molding.
Solution Approach 2:
The patent changes the material parameter from metal (copper) to plastic, fundamentally altering the physical and chemical properties of the lamp holder. This includes changing electrical conductivity through conductive paint application, mechanical strength through plastic formulation, and thermal properties through material selection, thereby reducing cost while maintaining performance.
2Productivity
If manual assembly is used for copper components, then assembly precision is improved, but productivity decreases and labor cost increases
Solution Approach 1:
The patent merges multiple separate copper components (lamp holder body, insulating parts, terminals) into a single integrated plastic structure. The conductive elements, insulating barriers, and mounting features are all formed in one plastic molding process, eliminating the need for manual assembly of multiple parts and enabling fully automated production.
Solution Approach 2:
The patent segments the lamp holder design into functional zones within a single plastic component - conductive areas painted with conductive material, insulating areas left as pure plastic, and structural features molded in place. This segmentation allows automated painting and assembly processes while maintaining precise functional boundaries without manual intervention.
3Ease of manufacture
If copper lamp holder is used, then electrical conductivity is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive copper components with plastic materials that can be easily manufactured and replaced. The lamp holder body, insulating parts, and even conductive elements are made from plastic, eliminating the need for costly copper while maintaining functionality through design innovations like conductive paint and integrated molding.
Solution Approach 2:
The patent uses composite construction by combining plastic base material with conductive paint coatings. The plastic provides structural integrity, insulation, and cost benefits, while the conductive paint layers provide necessary electrical conductivity. This composite approach achieves both low cost and reliable electrical performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables simpler and more efficient automatic production of LED lamp holders with stable power connections, lowering costs and enhancing market competitiveness by using plastic materials instead of metal.
Implementation Method 1
the high-insulation plastic body is integrally formed by injection molding
Implementation Method 2
the barrier are used to prevent the two electrical connectors from colliding with each other
Data Source
AI summary
A high-insulation integrated plastic lamp holder that does not require traditional American and European-standard copper lamp holders, comprising a high-insulation plastic body formed by injection molding. The top of the high-insulation plastic body is provided with a barrier, a first conductive component slot, and a second conductive component slot, and the barrier is located between the first conductive component slot and the second conductive component slot. The first conductive component slot and the second conductive component slot are inserted into positive and negative conductive sheets correspondingly, and the assembly of the lamp holder is simpler, which facilitates automatic production, thereby greatly improving the daily production capacity and insulation, and lowering the cost of production.