Plug-In String Lamp Structure for Low-Cost Bulb Replacement
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Solution Overview
Problem
Existing string lamps have complex structures and high manufacturing costs due to their copper head bulb design, making them difficult to install and maintain.
Innovation Solution
A novel plug-in string lamp structure featuring a string lamp connecting line with bulb components comprising a plastic inner core, luminescent light source, and light-transmitting lampshade, where the luminescent light source is inserted into the inner core accommodating cavity and connected via positive and negative pins, and a plug-in plastic head for easy installation and replacement, along with a protective resistor for stable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper head bulb structure is used, then light emission function is achieved, but structure becomes complicated and manufacturing cost increases
Solution Approach 1:
The bulb is divided into separate functional modules: the lamp cap (housing), the copper head (connector), and the light source assembly. This segmentation allows each component to be optimized independently and simplifies the overall structure by eliminating unnecessary integrations.
Solution Approach 2:
The copper head connector is extracted from the traditional integrated bulb structure and positioned separately on the connecting line. The light source is then separately inserted into the lamp cap, eliminating the need for complex threaded connections and reducing structural complexity.
2Reliability
If copper head bulb structure is used, then light emission function is achieved, but manufacturing cost increases
Solution Approach 1:
By segmenting the bulb into separate components (lamp cap, copper head, light source), each part can be manufactured using simpler, more cost-effective processes. The light source module can be produced through standard SMT techniques, while the lamp cap can be molded separately, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The invention uses a standardized light source module that can be easily replaced if failed, rather than requiring replacement of the entire bulb assembly. This modular approach reduces the cost of individual components and simplifies the manufacturing process for each part.
3Stability of the object's composition
If threaded connection is used, then bulb is fixed to lamp cap, but installation becomes complicated and time-consuming
Solution Approach 1:
The bulb structure is segmented into a lamp cap and a separate light source assembly with a distinct insertion interface. This segmentation enables a simple plug-in connection mechanism that eliminates the need for threading operations, making installation quick and tool-free while maintaining secure fixation.
Solution Approach 2:
The copper head on the connecting line acts as an intermediary component that provides both electrical connection and mechanical positioning. The light source inserts directly into the lamp cap with the copper head serving as the interface, creating a stable connection without requiring threaded fastening.
4Reliability
If complex bulb structure is used, then light emission function is achieved, but replacement and maintenance become difficult
Solution Approach 1:
The bulb is segmented into a reusable lamp cap and a replaceable light source module. When the light source fails, only the small light source module needs to be removed and replaced, while the lamp cap remains in place. This segmentation dramatically simplifies maintenance compared to replacing the entire traditional bulb assembly.
Solution Approach 2:
The light source is extracted as a separate, independently replaceable component from the lamp cap. The extraction design includes standardized electrical contacts and mechanical interfaces that allow the light source to be quickly removed and replaced without affecting the lamp cap or requiring complex disassembly procedures.
Data Source
AI summary
The present disclosure discloses a novel plug-in string lamp structure, which comprises a string lamp connecting line, a male connector and a female connector, wherein the string lamp connecting line is provided with a plurality of bulb components arranged in sequence, each bulb component comprises a lamp cap, a luminescent light source and a light-transmitting lampshade; the lamp cap comprises a plastic inner core which is formed with an inner core accommodating cavity, the string lamp connecting line is provided with positive and negative leads, and a positive contact terminal of the positive lead and a negative contact terminal of the negative lead are located in the inner core accommodating cavity; the lamp cap further comprises a rubber-coated member which is injection-molded into an integrated structure with the upper end of the plastic inner core, the outer skin of the positive lead and the outer skin of the negative lead.