String Lights Cap Assembly Waterproofing and Automation
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Solution Overview
Problem
Existing string lights have poor waterproof performance and inconvenient assembly, particularly when used outdoors for Christmas decorations.
Innovation Solution
A novel string lights structure featuring a power cord with light bulbs, a cap assembly, and connection terminals made of rigid plastic, where the power cord is tightly clamped between the inner core body and top cover, and the terminals penetrate the lead sheaths for secure electrical connections, facilitating automated assembly and improved waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional string lights structures are used, then assembly is simpler, but waterproof performance deteriorates
Solution Approach 1:
The string light is divided into modular units with male and female connectors that can be assembled separately and then connected. Each module contains isolated electrical components within waterproof housings, allowing individual assembly while maintaining overall waterproof integrity through standardized connection interfaces.
Solution Approach 2:
Waterproof connectors serve as intermediary elements between different string light modules. These connectors contain internal sealing mechanisms and contact structures that establish electrical connections while preventing water ingress, thus mediating between the need for modular assembly and waterproof performance.
2Ease of operation
If traditional string lights structures are used, then manufacturing is simpler, but assembly convenience deteriorates
Solution Approach 1:
Electrical contacts and sealing elements are pre-assembled into connector housings during manufacturing. The connectors are prepared in advance with pre-positioned contacts and pre-applied sealing compounds, so that final assembly requires only simple insertion and connection operations, not complex wiring or sealing procedures.
3Reliability
If connectors are added to improve waterproofing, then device complexity increases, but assembly automation becomes more difficult
Solution Approach 1:
The electrical contact function and waterproof sealing function are merged into a single integrated connector component. The connector housing simultaneously provides mechanical connection, electrical contact transmission, and environmental sealing, eliminating the need for separate sealing elements and simplifying the overall structure despite the multifunctional requirements.
Data Source
AI summary
The present disclosure discloses a novel string lights structure, comprising a power cord, a male connector, and a female connector. The power cord is equipped with a plurality of light bulbs, and comprises a positive lead and a negative lead. The cap assembly comprises a cap inner core and a cap encapsulating part, and the cap inner core comprises an inner core body and an inner core top cover mounted at an upper end portion of the inner core body. The inner core body is internally opened with a body mounting hole, and is equipped with an anode connection terminal and a cathode connection terminal. An upper end portion of the light-emitting light source is embedded in the body mounting hole. The present disclosure has the advantages of novel design, convenient assembly, and good waterproof effect, and is conducive to realize the automated assembly.