String Light Three-Way Wiring Structure Using Riveted Connections
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Solution Overview
Problem
Manual soldering in three-way line structures for string lights results in low manufacturing efficiency, uncertain yield rates, and inconsistent solder quality due to human factors.
Innovation Solution
A riveting process is used to connect conducting wires with copper strips, enabling automated assembly and ensuring consistent electrical connections, thereby improving manufacturing efficiency and yield rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual soldering is used to connect conducting wire contacts, then the manufacturing process can be performed with simple equipment, but the manufacturing efficiency is low and the yield rate is not guaranteed
Solution Approach 1:
The patent replaces the manual soldering process (thermal/chemical system) with a riveting process (mechanical system). The riveting process uses rivets to mechanically connect wire contacts to conductors, eliminating the need for soldering irons, flux, and heating equipment. This substitution dramatically improves manufacturing efficiency and yield rate while reducing process complexity, as riveting can be performed with simple punching and pressing equipment suitable for automated production.
2Reliability
If manual soldering is used, then equipment requirements are minimal, but personnel changes and temperature variations lead to poor solder contact and inconsistent quality
Solution Approach 1:
The patent replaces the temperature-dependent soldering process with a mechanical riveting process. The riveting process uses standardized rivets that are punched and pressed into predetermined positions, creating consistent mechanical and electrical connections regardless of operator skill or equipment temperature variations. This eliminates the quality inconsistencies associated with manual soldering while maintaining manufacturing simplicity through the use of straightforward riveting equipment.
3Productivity
If automated riveting process is implemented, then manufacturing efficiency and yield rate improve, but the device complexity increases
Solution Approach 1:
The patent divides the wire connection structure into modular components: wire contacts with predetermined connection positions, conductors with matching rivet holes, and rivets. This segmentation allows each component to be manufactured separately using simple processes, then assembled through automated riveting. The modular design enables high-speed automated assembly without requiring complex integrated structures, thus improving manufacturing efficiency while controlling device complexity.
Solution Approach 2:
The wire contacts are designed with predetermined connection positions and built-in rivet holes, allowing them to self-align and self-secure during the riveting process. The rivets themselves serve as both the connecting element and the fastening mechanism, eliminating the need for additional fasteners or complex assembly steps. This self-service design enables simple automated riveting equipment to achieve high manufacturing efficiency without requiring complex positioning or fastening systems.
Data Source
AI summary
The present disclosure relates to a three-way line structure for a string light using a riveting process, and a string light. The three-way line structure for a string light using a riveting process includes: a first power wire for connection to a positive electrode of a power source; a second power wire for connection to a negative electrode of the power source; a first conductor wire electrically connected to the first power wire, an electrical connection between the first conductor wire and the first power wire being riveted with a first copper strip; and a second conductor wire electrically connected to the second power wire, an electrical connection between the second conductor wire and the second power wire being riveted with a second copper strip.