String Light Assembly With Riveted Wiring and Internal Frame
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Solution Overview
Problem
Existing string lights face issues with poor electrical conductivity and defective lamp caps due to welding connections and lack of internal frames, leading to fall-off and deformation problems.
Innovation Solution
A novel string light design featuring riveting connections for hanging wires, a round internal frame with guide grooves and serrated notches for improved assembly, and a waterproof ring to enhance electrical contact and structural integrity, combined with injection molding for increased production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding connection is used to connect base and hanging wires, then electrical conductivity is improved, but the connection reliability deteriorates causing parts to fall off
Solution Approach 1:
The connection structure is segmented into multiple components: the base with through holes, the hanging wires with connection ends, and the adhesive material. This segmentation allows each component to be optimized independently while improving overall connection reliability through the combination of mechanical insertion and adhesive bonding, eliminating the fall-off problem of traditional welding connections.
2Manufacturing precision
If internal frame is added to lamp holder, then structural integrity is improved preventing deformation, but device complexity increases
Solution Approach 1:
The round internal frame is pre-installed inside the lamp holder before the injection molding process. This preliminary action provides structural support during molding, preventing deformation of the lamp holder. The frame serves as a preliminary structural framework that guides the molding process and ensures dimensional accuracy without requiring complex post-processing or additional structural elements in the final product.
3Productivity
If traditional injection molding is used without internal frame, then production efficiency is maintained, but manufacturing precision deteriorates causing high defect rate
Solution Approach 1:
The round internal frame acts as an intermediary element during the injection molding process. It provides a stable structural foundation that mediates between the molding pressure and the lamp holder material, preventing deformation and ensuring dimensional accuracy. This intermediary structure enables high-precision molding without compromising production efficiency, as the frame remains in place during molding and is subsequently removed or integrated into the final product.
Data Source
AI summary
The present disclosure relates to a string light of a novel structure. On a main wire, multiple string light bodies are connected in series, each string light body includes a lamp holder (1) and a lamp cap (8), a bulb is installed in the lamp cap (8), and the lamp cap (8) is connected to the lamp holder (1). One end of each of two hanging wires (3) is connected to the lamp holder (1) in a riveting mode through double riveting ports (2), and the other ends thereof are connected to positive and negative electrodes of the main wire, respectively. It is not only saves the cost and reduces the defective rate, but also is more solid and less likely to cause a fall-off problem compared with the traditional spot welding connection, reducing the problems of poor electrical conductivity and poor contact of a single lamp cap.