Waterproof Plug Injection Molding for Outdoor Lamp Sealing
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Solution Overview
Problem
Traditional outdoor lamps are not waterproof due to the siphon phenomenon that occurs when they cool down, leading to a negative pressure state inside the lamp housing, which allows water vapor to enter, resulting in a short service life.
Innovation Solution
A reinforced waterproof outdoor lamp design featuring a waterproof plug formed through injection molding on the electric conductors, a lamp holder with a mounting groove, and a lamp housing connected with waterproof glue, creating multiple sealed connections to prevent water vapor ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the lamp housing is opened to allow heat dissipation during operation, then the heat accumulation problem is solved, but water vapor enters the lamp housing due to negative pressure formed during cooling
Solution Approach 1:
The lamp housing is divided into an upper housing and a lower housing that can be separated. The upper housing can be removed to allow heat dissipation during operation, while the lower housing remains in place to maintain the waterproof seal. This segmentation allows the system to address both heat dissipation and waterproofing requirements without compromise.
Solution Approach 2:
A waterproof plug is introduced as an intermediary component at the connection between the upper and lower housings. The waterproof plug includes a waterproof layer that prevents water vapor from entering the lamp housing while allowing the upper housing to be removed for heat dissipation. This intermediary component resolves the contradiction by maintaining the seal during cooling while permitting thermal management during operation.
2Ease of manufacture
If a simple lamp housing structure is used, then the manufacturing cost is reduced, but the waterproof performance is insufficient
Solution Approach 1:
The lamp housing is segmented into upper and lower housings that can be manufactured separately using conventional molding techniques, then assembled together. This segmentation allows each part to be manufactured independently with standard processes, keeping manufacturing costs reasonable while enabling the assembly to achieve superior waterproof performance through the integrated seal design.
Solution Approach 2:
The waterproof plug incorporates a waterproof layer made of waterproof material that is composite with the plug structure. This composite construction provides effective waterproofing at the critical connection point between housings, achieving reliable waterproof performance without requiring complex overall structure or excessive manufacturing cost.
3Reliability
If the lamp housing is sealed to prevent water vapor ingress, then the waterproof performance is improved, but the heat dissipation capability is reduced
Solution Approach 1:
The lamp housing is divided into separable upper and lower housings, allowing the upper housing to be removed when heat dissipation is needed. During normal operation, the housing remains sealed for waterproofing. When heat accumulation occurs, the upper housing can be detached to provide ventilation pathways for heat dissipation, while the lower housing and waterproof plug maintain the seal integrity. This temporal separation of sealing and venting functions resolves the contradiction.
Solution Approach 2:
The waterproof plug acts as an intermediary that maintains the waterproof seal even when the upper housing is removed. The waterproof layer in the plug ensures that water vapor cannot enter the lamp housing through the connection point, allowing the system to maintain waterproofing during both sealed and vented states of operation.
4Ease of manufacture
If traditional molding methods are used for the lamp housing, then the manufacturing process is simple, but the waterproof seal at connection gaps is insufficient
Solution Approach 1:
The lamp housing is segmented into upper and lower housings that are molded separately using traditional molding methods. The segmentation allows each housing to be manufactured independently with conventional processes, maintaining manufacturing simplicity. The waterproof performance is enhanced through the integrated seal design at the connection point between the segmented parts.
Solution Approach 2:
The waterproof plug serves as an intermediary component that is molded with a waterproof layer to create an effective seal at the connection gap between the upper and lower housings. This intermediary component addresses the waterproofing requirement without complicating the overall molding process, as the plug can be molded as a separate part and then assembled with the housings.
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
The design enhances the waterproof performance, preventing siphon phenomena and extending the service life of the outdoor lamp by ensuring effective sealing and stability.
Implementation Method 1
after being powered off, the outdoor lamp is cooled, the interior of the lamp housing may be in an atmospheric negative pressure state, water vapor in the air may be sucked into the lamp housing due to a siphon phenomenon
Implementation Method 2
waterproof glue which fills a connection gap between the lower end of the lamp housing and the upper end of the waterproof plug and a connection gap between the lower end of the waterproof plug and the mounting embedding groove
Data Source
AI summary
A reinforced waterproof outdoor lamp, including a first electric conductor, a second electric conductor, a light emitting source, a waterproof plug, a lamp holder, a lamp housing and waterproof glue. The waterproof plug is formed on the first electric conductor and the second electric conductor by means of a mold through plastic filling or injection molding.