Strip Lamp End Cover Assembly for Waterproof Solder-Free Wiring
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Solution Overview
Problem
Existing strip-shaped LED lamps require complex and labor-intensive assembly processes, particularly for waterproofing, due to separate end covers and manual soldering of electric wires, which hinders automated production.
Innovation Solution
A strip-shaped lamp design featuring slots for easy assembly of lampshade, light board, and end cover, utilizing resiliently biased terminals for electrical connection without soldering, and a waterproof structure achieved through glue injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate end covers with manual wire soldering are used, then electrical connections can be established, but assembly productivity is very low and complex structure is required
Solution Approach 1:
The patent merges the end cover, electrical connection terminals, and sealing functions into a single integrated component. The end cover assembly includes a cover body with integrated terminal electrodes and sealing structures, eliminating the need for separate wire soldering operations and reducing assembly complexity while maintaining electrical connectivity and waterproofing functions.
Solution Approach 2:
The end cover is designed with self-aligning and self-positioning features including guide rails, positioning protrusions, and snap-fit mechanisms that enable automated assembly without manual intervention. The resilient sealing elements automatically adjust to ensure proper sealing, and the terminal electrodes are pre-positioned to accept wire connections without complex alignment procedures.
2Reliability
If complex end cover structures are used for waterproofing, then sealing performance is improved, but manual soldering is required and assembly becomes difficult
Solution Approach 1:
The patent employs resilient sealing elements including elastic sealing rings and flexible membrane structures that conform to the mating surfaces of the lamp holder and end cover. These flexible sealing components provide reliable waterproofing while being easily installable through simple snap-fit or press-fit mechanisms, eliminating the need for complex assembly procedures.
Solution Approach 2:
The end cover assembly is segmented into modular functional elements: the cover body, integrated terminals, sealing rings, and mounting features. This segmentation allows each component to be optimized independently for its specific function while enabling straightforward assembly through standardized interfaces and connection mechanisms.
3Productivity
If automated production is implemented, then productivity increases, but precise positioning and electrical contact reliability become critical challenges
Solution Approach 1:
The end cover and lamp holder are designed with pre-formed positioning features including guide rails, positioning protrusions, and locating surfaces that ensure precise alignment before final assembly. These preliminary positioning structures guide the automated assembly equipment and ensure consistent electrical contact between terminal electrodes and wire connections, eliminating the need for complex precision control systems.
Solution Approach 2:
The patent replaces manual soldering operations with mechanical connection mechanisms including spring-loaded terminal electrodes, snap-fit connectors, and press-fit interfaces. These mechanical connection systems provide reliable electrical contact through elastic force and precise geometric fitting, enabling automated assembly without requiring skilled soldering operations or complex inspection systems.
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
Facilitates automated assembly, simplifies the assembly process, and provides a waterproof seal, enhancing production efficiency and reliability.
Implementation Method 1
a resiliently biased terminal, which comprises an overlapping connecting portion in electric contact with the conductive layer of the light board for electric power supply
Implementation Method 2
the bracket is provided on both sides with guiding blocks configured to be positively accommodated in the second slots of the lamp holder
Implementation Method 3
the snap-in portions are positively accommodated in the first slots so that the lampshade and the lamp holder are connected to each other and form the inner cavity
Data Source
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AI summary
In a strip-shaped lamp, comprising a lamp holder 1, a lampshade 2 mounted on the lamp holder 1, a light emitting module 3 disposed in an inner cavity 14 formed by the lamp holder 1 and the lampshade 2, and an end cover 4, and end cover 4 is provided to cover a mounting port 13 at an axial end of the lamp holder 1. The end cover 4 comprises an outer cover 41 and a bracket 42, wherein the bracket 42 is provided on both sides with guiding blocks 421 configured to be positively accommodated in slots 122 of the lamp holder 1, and is provided with a resiliently biased terminal 43, a resiliently biased terminal 43 is provided that comprises an overlapping connecting portion 431 in electric contact with a conductive layer 33 of the light emitting module 3 for electric power supply, and an interface 411 is provided in the outer cover 41 for electrical connection of an external wiring harness 5 to the resiliently biased terminal 43. The end cover structure provides a good waterproof structure, a simple end connection structure, simplifies the assembly process, and is suitable for automated production.