Serial LED Lamp String with Block Pins and Insulation
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Solution Overview
Problem
Existing LED decoration lamp strings and hose lamps face material waste and increased weight due to parallel electric connections, and complex manufacturing processes when using enameled wires in serial structures, which require multiple wire arrangements and welding steps.
Innovation Solution
A serial LED lamp string with insulation-coated connection wires and LED chips welded between them, where the connection wire ends are welded to flat surfaces and wrapped with block pins formed by bending or cutting, enhancing firmness and simplifying the manufacturing process by using a tight, serial structure with insulation plastic packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If parallel electric connection manner is adopted for LED lamp strings, then electrical connection is achieved, but material waste is caused and weight of the hose lamp is increased
Solution Approach 1:
The connection wire is segmented into multiple sections with insulation layers removed at specific positions to expose conductive portions for welding LED chips, while retaining insulation at other portions. This segmentation allows efficient material utilization in serial connection structure, reducing overall material waste compared to parallel connection methods.
Solution Approach 2:
Multiple functional elements are merged into a single connection wire structure: the conductive portion for electrical connection, the insulation portion for protection, and the block pin for mechanical fixation. This merging creates a compact serial connection structure that reduces total material usage compared to separate components required in parallel connections.
2Reliability
If enameled wires are used in serial structure with chips placed transversely, then serial connection is formed, but manufacturing process becomes complex with multiple wire arrangements and welding steps
Solution Approach 1:
The insulation layers are pre-removed from specific portions of the connection wire before assembly, and block pins are pre-formed at designated positions. This preliminary preparation simplifies the manufacturing process by eliminating the need for complex in-process wire arrangement and multiple welding steps, making serial connection easier to manufacture.
Solution Approach 2:
The connection wire structure is designed to be self-sufficient with integrated insulation portions and block pins that automatically provide mechanical fixation and electrical insulation functions during assembly, reducing the need for additional manufacturing steps and external components.
3Strength
If connection wires are tightly structured with block pins and plastic packaging, then firmness between wires and lighting chip is enhanced, but device complexity increases
Solution Approach 1:
The block pin and insulation portions are merged into an integrated connection wire structure, where the block pin is formed as part of the wire itself rather than a separate component. This merging enhances firmness through tight plastic packaging while avoiding the complexity of additional separate parts.
Solution Approach 2:
The connection wire structure provides its own mechanical fixation through the integrated block pin and insulation portions that work together during plastic packaging, eliminating the need for separate fixation mechanisms and reducing overall structural complexity.
Data Source
AI summary
The invention discloses a novel LED lamp string and a hose lamp therewith, wherein, the serial lighting LED lamp string is formed by serial connection of a plurality of connection wires and a plurality of LED lighting chips, the front ends of the connection wires at two sides are respectively welded on the lower end surface electrifying welding areas, block pins facing the outside are formed at the tails of the front ends of the connection wires, each LED lighting chip, the welded points of the connection wires at two corresponding sides thereof and the corresponding block pins are tightly wrapped and plastic-packaged by small insulation plastic bodies. The hose lamp saves materials and is firm and reliable and simple in machining process.