String Light Structure Weld-Free Electrical Connection
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Solution Overview
Problem
Current string light production processes are complex and inefficient, requiring injection molding, shell fastening, and welding, which result in high production costs.
Innovation Solution
A string lamp structure that includes a light bulb component, a lamp holder with positive and negative electrode elastic sheets, a wire, and a lamp cover. The lamp cover presses against the lamp holder, causing the elastic sheets to puncture the wire, thereby forming a conductive state without the need for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding processes are used to connect the wire to the lamp holder, then reliable electrical connection is achieved, but the production process becomes complex and inefficient with high production costs
Solution Approach 1:
The patent extracts and eliminates the welding process from the production line, replacing it with a mechanical pressing mechanism. The lamp cover pressing structure directly compresses the wire between contact points, removing the need for separate welding equipment and operations, thus simplifying the production process while maintaining electrical connection reliability
Solution Approach 2:
The patent replaces the thermal-mechanical welding system with a purely mechanical pressing system. The lamp cover pressing structure uses mechanical force to create direct contact between the wire and contact points, substituting the welding process with a simpler mechanical operation that is easier to control and implement in mass production
2Strength
If injection molding and shell fastening processes are used to assemble the lamp holder components, then structural integrity is achieved, but production efficiency decreases and costs increase
Solution Approach 1:
The patent merges multiple assembly operations into a single integrated lamp holder structure. The lamp holder is designed as a unified component that incorporates the wire retention features and contact points, eliminating the need for separate injection molding and fastening operations. This integration allows for simpler assembly and higher production efficiency while maintaining structural integrity
Solution Approach 2:
The patent employs a flexible lamp cover that can be elastically deformed during assembly and then maintains continuous contact pressure on the wire. This flexible shell approach replaces rigid fastening methods, allowing for simpler assembly operations and improved production efficiency while ensuring reliable electrical connection through continuous contact pressure
3Manufacturing precision
If multiple separate production steps are used for assembling string lights, then component precision is maintained, but overall production time increases
Solution Approach 1:
The patent incorporates preliminary action by pre-forming the wire retention features and contact points into the lamp holder structure during its initial manufacturing. The lamp cover is also pre-designed with the appropriate pressing geometry. These preliminary preparations eliminate the need for multiple subsequent adjustment and assembly steps, reducing production time while maintaining assembly precision
Solution Approach 2:
The patent introduces dynamic elements by using an elastic lamp cover that can be deformed during assembly and then automatically maintains contact pressure. The elastic deformation allows for tolerance compensation and self-adjustment during assembly, ensuring precise component alignment and electrical contact without requiring multiple separate adjustment steps, thus reducing overall production time
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the production process, reduces costs, and improves efficiency by eliminating the need for welding, while ensuring a reliable and stable electrical connection.
Implementation Method 1
the lamp cover is configured to press the wire, so that the positive and negative elastic sheets puncture the wire
Implementation Method 2
the lamp cover squeezes the wire, the positive electrode elastic sheet and the negative electrode elastic sheet are caused to puncture the wire
Data Source
AI summary
A string lamp structure is provided, which includes a light bulb component, a lamp holder, a wire, and a lamp cover. The lamp holder is provided with a positive electrode elastic sheet and a negative electrode elastic sheet, the light bulb component is moveably connected to the lamp holder and electrically connected to the positive electrode and negative electrode elastic sheets. The wire horizontally passes through the lamp holder and abuts against the positive electrode and negative electrode elastic sheets, the lamp cover is movably connected to the lamp holder; when the lamp cover presses against the lamp holder, the lamp cover squeezes the wire, the positive electrode and negative electrode elastic sheets are caused to puncture the wire, thereby forming a conductive state. This way achieves a welding free process, significantly simplifies a production process, improves an overall production efficiency, reduces a production cost, and has strong practicality.