Plastic Light Bulb Socket Segmentation for Cost Reduction
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Solution Overview
Problem
The manufacturing cost of plastic light bulb sockets is high due to the need for large-sized sockets and bases, which increases the size of the lamp housing and socket, making the components more expensive to produce.
Innovation Solution
A plastic light bulb design featuring a socket with a mounting part and a plug-in part of different diameters, where the light chip is installed on the mounting part, and the base is sleeved on the plug-in part, allowing for a smaller base and socket size, along with a PC bulb housing made by blow molding with a large through hole to support the light chip, reducing the overall size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large-sized bulb socket is used to accommodate the light chip, then the light chip can be securely installed, but the manufacturing cost of the bulb socket increases
Solution Approach 1:
The bulb socket is divided into two distinct parts: a mounting part with a larger diameter for securely installing the light chip, and a plug-in part with a smaller diameter for insertion into the lamp holder. This segmentation allows each part to be optimized for its specific function, reducing overall manufacturing cost while maintaining secure light chip installation.
Solution Approach 2:
Different parts of the bulb socket have different diameters tailored to their specific functions. The mounting part has a larger diameter to securely hold the light chip, while the plug-in part has a smaller diameter for cost-effective manufacturing and easy insertion. This local differentiation of quality resolves the contradiction between secure installation and manufacturing cost.
2Reliability
If a large-sized base is used to support the socket, then the socket can be properly mounted, but the overall size of the light bulb increases
Solution Approach 1:
The socket's segmented design with a smaller plug-in part allows the base to be more compact. The mounting part maintains sufficient size for reliable light chip attachment, while the reduced diameter of the plug-in part enables a smaller base configuration, thereby reducing the overall bulb volume.
Solution Approach 2:
The socket structure is designed to nest efficiently within the base and lamp holder. The smaller plug-in part fits into the base, while the mounting part extends to hold the light chip. This nested arrangement maximizes space utilization and minimizes the overall footprint of the light bulb.
3Ease of manufacture
If a large through hole is made in the PC bulb housing for blow molding, then the housing can be properly formed, but the base must be made larger to adapt to the housing
Solution Approach 1:
The socket's segmented structure with a smaller plug-in part compensates for the large through hole required for PC blow molding. The mounting part maintains the necessary size for light chip support, while the reduced plug-in part allows for a more compact base design, offsetting the space occupied by the large housing opening.
Data Source
AI summary
Disclosed is a plastic light bulb, comprising a light chip, a socket, a housing, a base and a PC bulb housing. The socket comprises a mounting part and a plug-in part, an external diameter of the plug-in part is smaller than that of the mounting part, and the light chip is installed on the mounting part; the PC bulb housing comprises a housing body and a plug, the housing body is provided with an internal space, and the plug is provided with a through hole; the mounting part is installed in the through hole, and the light chip is positioned in the internal space; and the housing is sleeved on the plug, the base is sleeved on the plug-in part, a negative electrode of the light chip is electrically connected with the housing, and a positive electrode of the light chip is electrically connected with a contact of the base.