Reflector Lamp Electrical Contact for Automated Assembly
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Solution Overview
Problem
The manual and labor-intensive process of assembling reflector lamps, particularly the cementing of light source capsules and electrical wiring, is inefficient and costly, requiring tedious operations to achieve proper electrical coupling.
Innovation Solution
A lamp design featuring a body with a channel and seat for the light source capsule, along with an electrical contact having a depending leg and transverse portion for mechanical and electrical support, allowing for automated assembly and reducing hand labor, using flat stock and simple machine tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual operations are used for cementing light source capsules and electrical wiring, then proper location and electrical coupling can be achieved, but the process becomes very labor intensive and expensive
Solution Approach 1:
The electrical contact structure provides self-aligning features where the depending leg automatically positions itself relative to the lead-in wire during insertion, and the transverse portion with seat engager automatically locates the light source capsule in the correct position within the reflector body, eliminating the need for manual positioning and cementing operations
Solution Approach 2:
The electrical contact is divided into distinct functional segments: a depending leg for electrical connection to the lead-in wire, and a transverse portion with seat engager for mechanical support and positioning of the light source capsule. This segmentation allows each component to be independently manufactured and assembled, enabling automation while maintaining precision
2Reliability
If manual operations are used for welding and soldering electrical wires, then reliable electrical coupling is achieved, but the operations become tedious and expensive
Solution Approach 1:
The electrical contact structure enables self-connection where the depending leg is inserted through the lead-in wire and the transverse portion is engaged with the seat, creating automatic mechanical and electrical connection without requiring manual welding or soldering operations
Solution Approach 2:
The invention replaces the complex thermal processes of welding and soldering with a simple mechanical insertion and engagement system, where the electrical contact is mechanically attached to the lead-in wire and the light source capsule through the depending leg and transverse portion respectively
3Productivity
If automated assembly is implemented, then productivity and manufacturing efficiency are improved, but the electrical contact design must be simplified for automation compatibility
Solution Approach 1:
The electrical contact is formed from flat stock material that is bent into the required shape, changing the manufacturing parameter from complex multi-step fabrication to simple bending operations that are easily automated while maintaining the functional complexity needed for proper electrical and mechanical support
Data Source
AI summary
A lamp (50) has a lamp envelope (10) having a body (12) with a bottom (14) having a lead-in accepting channel (18); a seat (22) formed with the bottom (14) adjacent one of the lead-in accepting channels; a light source capsule (51) having two electrical lead-ins (52, 54) extending therefrom and through the lead-in accepting channel (18; and an electrical contact (24) having a first depending leg (26), an intermediate transverse portion (28) including a seat engager (30) adapted to cooperate with the seat (22), and a projecting leg (32) extending away from the intermediate transverse portion (28) and along a side (34) of the bottom (16), the first depending leg (26) being in mechanical and electrical contact with one of the lead-ins (54).