Waterproof Integrated Controller With Replaceable LED Control Board
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Solution Overview
Problem
Existing pre-lit Christmas trees and lighting displays using LEDs lack a waterproof, integrated controller that can efficiently control illumination effects and provide a waterproof connection to outdoor environments.
Innovation Solution
A waterproof, integrated controller with a housing, plug blades, circuit board, U-connectors, and a cap that forms a waterproof seal, allowing for direct electrical connection and wireless control of LED lighting, and enabling replacement controller assemblies for different effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a waterproof seal is added to protect the controller from outdoor environments, then reliability is improved, but device complexity increases due to additional sealing components
Solution Approach 1:
The patent combines the waterproof cap and output connector into a single integrated component. The cap forms a waterproof seal with the housing while simultaneously providing the electrical output connection, eliminating the need for separate sealing components and reducing overall device complexity.
Solution Approach 2:
The cap serves multiple functions: it provides the waterproof seal, acts as the housing closure, and incorporates the output connector for electrical connection. This multi-functionality reduces the number of separate components needed while maintaining reliable waterproof protection.
2Device complexity
If an integrated controller design is used to simplify the system, then device complexity is reduced, but ease of repair worsens because components cannot be easily replaced
Solution Approach 1:
The controller is divided into separable modules: the housing with plug blades, the circuit board with controller assembly, and the cap with output connector. Each module can be independently removed and replaced, maintaining ease of repair while preserving the benefits of an integrated design when assembled.
Solution Approach 2:
The design allows the controller assembly to transition between integrated (assembled) and separable (disassembled) states. The circuit board can be removed from the housing and the cap can be detached, enabling dynamic reconfiguration for repair or replacement while maintaining integrated functionality during operation.
3Ease of operation
If direct electrical connection through plug blades is used to simplify power connection, then ease of operation is improved, but reliability worsens due to potential exposure to moisture at connection points
Solution Approach 1:
The plug blades are nested within the housing structure, with only the essential connection portions exposed. The housing encloses the plug blades to protect them from moisture while maintaining electrical functionality, creating a nested arrangement that balances accessibility with protection.
Solution Approach 2:
The housing provides selective protection: the plug blades are enclosed within the housing for moisture protection, while the cap with output connector provides localized access point. This local quality approach protects vulnerable areas while maintaining necessary electrical connections.
Data Source
AI summary
Disclosed is an integrated controller that is waterproof and can be used in outdoor environments. The integrated controller has a housing which houses a separate controller assembly that is sealed to the housing to provide a waterproof container. Integrated plug blades that are molded into the housing assembly plug directly into a wall socket and U-connectors on a circuit board are used to connect the circuit board to an AC power supply. The system can be used to control the power signal from a wall socket to produce different lighting effects. Replacement circuit boards can be used to provide different lighting effects or to replace a faulty circuit board. Digital control signals can also be transmitted wirelessly to lighting displays, which may be commercial displays, ornamental displays or computer monitor displays.