Wire Joint Tin Impregnation Prevents Siphon in LED Lamps
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Solution Overview
Problem
Existing outdoor LED lamps are prone to the siphon phenomenon due to gaps between core wires, leading to water vapor or liquid ingress, which affects lighting quality and safety.
Innovation Solution
A wire joint with a plurality of core wires wrapped in a first wire skin, subjected to tin-impregnation treatment, and an insulating wire fastener is used to block gaps, along with a breathing channel and film to manage atmospheric pressure differences, and a sealing ring for enhanced waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gaps between core wires are left open for electrical connection, then electrical connectivity is improved, but water vapor and liquid water can enter the lamp body causing siphon phenomenon
Solution Approach 1:
A waterproof coating layer is applied to the surface of the core wires within the sealing section, forming a flexible barrier that prevents water vapor and liquid water from penetrating through the gaps between wires while maintaining electrical connectivity. The coating acts as a thin film seal that conforms to the wire arrangement.
Solution Approach 2:
The waterproof coating serves as an intermediary substance between the core wires and the external environment, blocking the harmful effects of moisture while allowing the electrical function to continue uninterrupted. The coating mediates between the need for wire proximity (electrical connectivity) and the need for water protection.
2Object-affected harmful factors
If core wires are tightly packed to prevent water ingress, then waterproofing is improved, but manufacturing precision and assembly difficulty increase
Solution Approach 1:
The waterproof coating provides a flexible sealing solution that does not require precise wire arrangement or tight packing. The coating can be applied uniformly across the sealing section regardless of minor variations in wire positioning, thereby maintaining manufacturing simplicity while achieving effective waterproofing.
3Object-affected harmful factors
If a rigid seal is used to block all gaps, then waterproofing is improved, but the structure becomes more complex and harder to manufacture
Solution Approach 1:
The waterproof coating layer replaces complex rigid sealing structures with a simple, flexible film application. This single-layer coating solution is much simpler to manufacture and install than multi-component rigid seals, while providing effective protection against water vapor and liquid water ingress.
4Reliability
If wire skin is stripped completely for connection, then electrical connection is improved, but gaps between strands become more exposed to water
Solution Approach 1:
The waterproof coating is applied specifically to the exposed core wires in the sealing section after the wire skin has been stripped for electrical connection. This coating restores the protective barrier that was removed during stripping, preventing water vapor and liquid water from entering through the now-exposed gaps between strands while maintaining electrical connectivity.
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 solution effectively prevents siphon phenomena, improving lighting quality and safety by blocking water ingress and maintaining atmospheric pressure balance within the lamp.
Implementation Method 1
a first breathing channel is provided in the extraposition section, one port of the first breathing channel is in communication with the notch, and the other port is located on a surface of the extraposition section, and a first breathing film is provided in the first breathing channel
Implementation Method 2
each strand of the core wires in the threshold interval is subjected to a tin-impregnation treatment
Data Source
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AI summary
The embodiment of the present disclosure discloses a wire joint and a manufacturing method thereof. The wire joint includes a wire and a joint; the wire includes a plurality of strands of core wires and a first wire skin, each strand of the core wires is respectively wrapped by the first wire skin, the first wire skin outside the each strand of the core wires is stripped within a threshold interval, the each strand of the core wires in the threshold interval is subjected to a tin-impregnation treatment, and an insulating wire fastener is provided between the each strand of the core wires in the threshold interval; the joint includes a connection section and an extraposition section, the insulating wire fastener is wrapped in the extraposition section, and the connection section is connected at one end of the extraposition section and wraps around the outer circumference of the first wire skin of the plurality of strands of core wires. The wire joint provided by the present disclosure may block the gaps between the plurality of strands of core wires and the gaps between a plurality of core wires of each strand of core wires, thereby avoiding the siphon phenomenon when the lamp is used, and improving the lighting effect and the safe use of the lamp.