JP7464322B1 - LED String Lights - Google Patents

Abstract

[Problem] To provide a waterproof LED string light that does not require soldering, which can firmly connect the LED elements and the cable wire, easily set the LED elements, has a good waterproof effect, and effectively prevents the occurrence of short circuits. [Solution] The LED string light includes a cable wire 1 and a plurality of LED elements 2 connected to each other through the cable wire 1. The lead wires of the LED elements 2 are attached to the electric wire portion of the cable wire 1. The LED string light further includes a flexible terminal 3 arranged between the lead wires of the LED elements 2 and the cable wire 1. The flexible terminal 3 is crimped to the lead wires of the LED elements 2 and the cable wire 1. The LED string light further includes a sealing rubber tube 4 that is an outer crimped coating of the LED elements 2. The tip end of the cable wire 1 and the flexible terminal 3 are crimped while being wrapped in the sealing rubber tube 4. [Selected Figure] Figure 1

Description

This application claims priority based on a Chinese utility model application bearing application number 2023209134970.0 and entitled "Solder-free waterproof LED string lights," filed with the China Patent Office on April 21, 2023, the entire contents of which are incorporated herein by reference.

This invention relates to the field of LED lighting technology, and more specifically to LED string lights.

LED string lights are formed by elements and cable wire circuits. By attaching multiple light sources between the cable wire circuits and surrounding the cable wire circuits, LED string lights are formed as a certain linear lighting decoration product. LED string lights are an essential decoration product for lighting up the night view of a place.

LED lighting also has the advantages of low heat generation, low power consumption, and long service life. It saves power resources and meets the demand for night lighting, so LED string lights are being used as lighting in more and more places.

To easily install LED elements into cable circuits, existing manufacturing methods for LED string lights are mainly divided into two types. One manufacturing method involves directly soldering the lead wires of the LED element onto the wire part of the cable, while the other manufacturing method involves using terminals to crimp and fix the overlapping part between the lead wires of the LED element and the wire part of the cable.

Soldering often requires a large amount of lead, and the soldering process often produces toxic gases, making it impossible to meet the demands of environmental protection in the production process. High-temperature soldering can also damage the LED elements and shorten the lifespan of the LED string lights. For these reasons, in the manufacture of LED string lights, terminals are often used to crimp and fix the overlapping parts of the lead wires of the LED elements and the wires of the cable.

However, simply crimping and fixing the overlapping parts of the lead wires of the LED element and the wires of the cable is not strong enough. Therefore, when adjusting the use of the LED string light, such as by enclosing the cable circuit or adjusting the LED element, the lead wires of the LED element may easily fall off the wires of the cable. This may cause the LED element to become disconnected, which may affect the service life of the LED string light.

In addition, since LED string lights are usually used in outdoor locations, they often require good waterproofing to prevent water from getting into the LED string lights due to rainfall, cleaning of the location, etc. For this reason, rubber tubes are often used to perform a press-sealing coating process on the LED elements, LED element lead wires, and cable wire electrical wires. However, during the coating process, the positive and negative lead wires of the LED elements and the positive and negative connection parts of the cable wires are easily brought into contact with each other after being pressed, which may cause a short circuit in the cable wire circuit and affect the normal use of the LED string lights.

For this reason, waterproof LED string lights that do not require soldering, which can firmly connect the LED elements and the cable wires, make it easy to set up the LED elements, have good waterproofing effects, and can effectively prevent the occurrence of short circuits, have great market potential.

In response to the shortcomings of existing technology, one embodiment of the present invention provides a waterproof LED string light that does not require soldering, has a sturdy connection between the LED elements and the cable wire, is easy to set up the LED elements, has good waterproofing, and effectively prevents the occurrence of short circuits.

One embodiment of the present invention provides an LED string light including a cable and a plurality of LED elements interconnected through the cable. The lead wires of the LED elements are attached to the electric wire portion of the cable. The LED string light further includes a flexible terminal disposed between the lead wires of the LED elements and the cable. The flexible terminal is crimped to the lead wires of the LED elements and the cable. The LED string light further includes a sealing rubber tube that is an outer crimp coating of the LED elements. The tip of the cable wire and the flexible terminal are crimped while being wrapped in the sealing rubber tube.

In one embodiment of the invention, the flexible terminal includes a plate-shaped coating portion having a longitudinal direction, a cable wire pressing portion for pressing the cable wire against the coating portion, an electric wire pressing portion for pressing an overlapping portion of the cable wire and the electric wire portion of the cable wire against the coating portion, and a lead wire pressing portion for pressing the lead wire of the LED element against the coating portion, as an integral structure. The lead wire pressing portion includes two stopper plates facing each other in the longitudinal direction of the coating portion, and two flexible pressing plates formed on the two stopper plates, respectively. The two flexible pressing plates are disposed between the two stopper plates. The tip of one of the flexible pressing plates is pressed against the ceiling surface of the tip of the other flexible pressing plate. The lead wire of the LED element is pressed onto the coating portion by the tip of the other flexible pressing plate.

In one embodiment of the present invention, the cable wire pressing portion includes two cable wire pressing plates formed on the coating portion so as to face each other in the width direction of the coating portion. The two cable wire pressing plates have a top. The top of the cable wire pressing plate adopts a triangular plate structure. The cable wire is crimped and fixed onto the coating portion by the cable wire pressing plates.

In one embodiment of the present invention, the electric wire pressing portion includes two electric wire pressing plates. The two electric wire pressing plates are formed to face each other in the width direction of the coating portion. The electric wire pressing plates adopt a V-shaped plate structure. The overlapping portion between the lead wire of the LED element and the electric wire portion of the cable wire is crimped and fixed to the coating portion by the electric wire pressing plates.

In one embodiment of the invention, the sealing rubber tube has a tubular structure made of insulating rubber. The sealing rubber tube includes an inner rubber tube and an outer rubber tube as an integral structure. The flexible terminal and the cable wire are enclosed in the inner rubber tube. The LED element is fitted into the outer rubber tube. The sealing rubber tube further includes an isolation post enclosed in the inner rubber tube. The isolation post and the flexible terminal are in contact with each other, and the isolation post is crimped and fixed by the inner rubber tube.

In one embodiment of the present invention, the sealing rubber tube has a tubular structure made of insulating rubber. The sealing rubber tube is filled with a sealant.

According to one embodiment of the invention, first, a plurality of LED elements connected to each other through several cable wires are included, the lead wires of the LED elements are attached to the electric wire portion of the cable wire, and a flexible terminal is provided between the lead wires of the LED elements and the cable wire, and the flexible terminal is crimped and coated on the lead wires of the LED elements and the cable wire, and a sealing rubber tube is provided on the outer crimp coating of the LED elements, and one side of the cable wire and the flexible terminal are crimped and coated inside the sealing rubber tube. In one embodiment of the invention, the lead wires of the LED elements and the cable wire are crimped and fixed through the provided flexible terminals, and specifically, the lead wires of the LED elements are crimped onto the coating portion through the provided lead wire pressing portion, thereby allowing the lead wires of the LED elements to be easily and quickly inserted into the electric wire portion of the cable wire, and enhancing the fixing effect of the crimped lead wires of the LED elements.

According to one embodiment of the present invention, the cable wire can be crimped to the coating portion through the cable wire holder, thereby improving the fixing efficiency of the cable wire. The overlapping portion of the lead wire of the LED element and the electric wire portion of the cable wire is reinforced through the electric wire holder, thereby ensuring the fixation of the lead wire of the LED element and the electric wire portion of the cable wire, thereby satisfying the requirements. In other words, the stability of the current flow of the LED element can be ensured, and the lead wire of the LED element can be prevented from easily falling off the electric wire portion of the cable wire. Also, the LED element can be easily attached to the cable wire. Specifically, by crimping the cable wire to a flexible terminal, the lead wire of the LED element is inserted into the flexible terminal, the lead wire of the LED element and the electric wire portion of the cable wire are overlapped with each other, and then the overlapping portion of the lead wire of the LED element and the electric wire portion of the cable wire are crimped in the flexible terminal, thereby completing the installation work of the LED element and the cable wire.

In one embodiment of the invention, the LED element and the wire part of the cable are sealed and protected through a sealing rubber tube, and the thermal contraction properties of the rubber are used to press and coat the LED element and the cable. A waterproof effect is achieved, and the two lead wires of the LED element are separated through the attached isolation pole, thereby separating the cable wires and preventing the positive and negative lead wires of the LED element and the positive and negative wire parts of the cable wire from coming into contact after being pressed. This prevents the occurrence of a short circuit. Then, a sealing process is performed on the flexible terminal and the wire part of the cable wire through filling with a sealant, further enhancing the waterproof effect of one embodiment of the invention. This is a product with good social and economic efficiency and easy to popularize.

One embodiment of the present invention addresses the shortcomings of existing technology by providing an LED string light that has a sturdy connection between the LED elements and the cable and allows for easy installation of the LED elements.

FIG. 1 is a diagram for explaining an LED string light according to an embodiment of the present invention. FIG. 2 is a perspective view of a flexible terminal included in the LED string light.

Figure 1 is a diagram for explaining an LED string light according to one embodiment of the present invention. Figure 2 is a perspective view of a flexible terminal 3 included in the LED string light.

The LED string light according to one embodiment of the present invention is a waterproof LED string light that does not require soldering. As shown in FIG. 1 and FIG. 2, the LED string light includes a plurality of cable wires 1 and a plurality of LED elements 2 connected to each other through the cable wires 1. The cable wires 1 include an electric wire portion. The electric wire portion is, for example, a core wire. The core wire is made of a metal wire such as copper. The cable wires 1 further include a tubular covering portion that covers the electric wire portion. The covering portion is, for example, made of synthetic resin. The lead wires of the LED elements 2 are attached to the electric wire portion of the cable wires 1. The LED string light further includes a flexible terminal 3. The flexible terminal 3 is disposed between the lead wires of the LED elements 2 and the cable wires 1. The flexible terminal 3 is a terminal for connecting the lead wires of the LED elements 2 and the electric wire portion of the cable wires 1. The flexible terminal 3 is crimped and coated on the lead wires of the LED elements 2 and the cable wires 1. The flexible terminal 3 is used to crimp and fix the lead wires of the LED elements 2 to the cable wires 1. The flexible terminal 3 ensures the interconnection between the LED element 2 and the cable wire 1 and provides protection for the connection between the LED element 2 and the cable wire 1. The LED string light further includes a sealing rubber tube 4 which is an outer crimped coating of the LED element 2. The sealing rubber tube 4 encases the LED element 2 and the two cable wires 1. One side (tip) of the cable wire 1 and the flexible terminal 3 are crimped while being encased within the sealing rubber tube 4. The sealing rubber tube 4 is used to seal and protect the lead wire of the LED element 2 and the electric wire portion of the cable wire 1.

The flexible terminal 3 includes a cable wire pressing portion 31, an electric wire pressing portion 32, a lead wire pressing portion 33, and a coating portion 34 (a long, thin plate-like base portion (terminal body)) as an integral structure. The flexible terminal 3 has a length in a predetermined longitudinal direction (the vertical direction in FIG. 2). The coating portion 34 is plate-like and extends along the longitudinal direction. The coating portion 34 has a U-shaped plate structure, and the cable wire pressing portion 31, the electric wire pressing portion 32, and the lead wire pressing portion 33 are formed on the open end of the coating portion 34.

The lead wire pressing portion 33 has a plate-like structure that is roughly M-shaped when viewed from the side (side view seen in the direction along the width direction (direction connecting the upper left and lower right in Figure 2) described below). The lead wire pressing portion 33 has two stopper plates 332 each equipped with a flexible pressing plate 331, and two flexible pressing plates 331. Each stopper plate 332 and the corresponding flexible pressing plate 331 are formed integrally. The two stopper plates 332 and the two flexible pressing plates 331 are formed integrally with the coating portion 34.

The two stopper plates 332 face each other in the longitudinal direction. Each stopper plate 332 has a pair of side walls that rise in the height direction (to the right side in FIG. 2) from both ends in the width direction of the flexible terminal 3 (the direction connecting the upper left and lower right in FIG. 2) in the coating portion 34, and an upper wall that connects the upper ends of the pair of side walls. The pair of side walls and the upper wall are formed integrally. Each stopper plate 332 has a U-shape that is turned 90° when viewed from the side along the longitudinal direction. The two stopper plates 332 are elastically deformable with respect to the coating portion 34. The stopper plate 332 adopts an N-shaped plate structure.

The two flexible pressing plates 331 are arranged between the two stopper plates 332 so as to be sandwiched in the longitudinal direction. The base end of each flexible pressing plate 331 is connected to the upper wall of the corresponding stopper plate 332. Each flexible pressing plate 331 is supported by a cantilever on the corresponding stopper plate 332. Each flexible pressing plate 331 is elastically supported by the corresponding stopper plate 332. Each flexible pressing plate 331 is inclined so as to approach the coating portion 34 side as it moves away from the corresponding stopper plate 332. The tip portions of the flexible pressing plates 331 overlap in the vertical direction (the left-right direction in FIG. 2). The tip portions of the flexible pressing plates 331 are attached on the side walls of the stopper plates 332. The tip portion of one flexible pressing plate 331 (the lower flexible pressing plate 331 shown in FIG. 2) is pressed against the ceiling surface (the surface opposite the coating portion 34 side) of the tip portion of the other flexible pressing plate 331 (the upper flexible pressing plate 331 shown in FIG. 2).

The lead wire of the LED element 2 inserted into the flexible terminal 3 is sandwiched between the other flexible pressing plate 331 (the upper flexible pressing plate 331 shown in FIG. 2) and the coating 34. This causes the lead wire of the LED element 2 to be crimped onto the coating 34. That is, the flexibility of the two flexible pressing plates 331 is utilized to crimp and fix the lead wire of the LED element 2. This allows the lead wire of the LED element 2 to be easily and quickly inserted into the wire portion of the cable wire 1, and the lead wire of the LED element 2 to be easily crimped and fixed into the flexible terminal 3. The flexible terminal 3 is formed using flexible soft metal, and the deformability and flexibility of the soft metal are utilized to crimp and fix the LED element 2 and the cable wire 1.

The cable wire pressing portion 31 includes two cable wire pressing plates 311. The two cable wire pressing plates 311 rise in the height direction (right side of FIG. 2) from both ends of the flexible terminal 3 in the width direction (direction connecting the upper left and lower right in FIG. 2) in the coating portion 34. The two cable wire pressing plates 311 face each other in the width direction. Each cable wire pressing plate 311 has a rising portion rising from both ends in the width direction in the coating portion 34 and a top portion connected to the tip of the rising portion. The rising portion and the top portion are formed by bending. The two cable wire pressing plates 311 are elastically deformable with respect to the coating portion 34. The top portion of the cable wire pressing plate 311 is elastically supported by the rising portion of the cable wire pressing plate 311. The two cable wire pressing plates 311 are attached to both sides of one end of the coating portion 34. The top portion of each cable wire pressing plate 311 adopts a triangular plate-shaped structure. Specifically, the shape of the top of the cable wire pressing plate 311 when viewed from the normal direction of the top is triangular. The cable wire 1 is crimped and fixed onto the coating portion 34 by the cable wire pressing plate 311. This allows the cable wire 1 to be easily crimped and fixed inside the flexible terminal 3.

The wire pressing portion 32 includes two wire pressing plates 321. The two wire pressing plates 321 rise in the height direction (right side in FIG. 2) from both ends of the flexible terminal 3 in the width direction (direction connecting the lower right and upper left in FIG. 2) in the coating portion 34. The two wire pressing plates 321 face each other in the width direction. The two wire pressing plates 321 are attached to both sides of the coating portion 34. Each wire pressing plate 321 adopts a V-shaped plate structure (a V-shaped plate structure turned 180°). Each wire pressing plate 321 has a rising portion rising from the coating portion 34 and a connecting portion connected to the tip of the rising portion in the coating portion 34. The rising portion and the connecting portion are formed by bending. The two wire pressing plates 321 are elastically deformable with respect to the coating portion 34. The connecting portion of the electric wire pressing plate 321 is elastically supported by the rising portion of the electric wire pressing plate 321. The overlapping portion between the lead wire of the LED element 2 and the electric wire portion of the cable wire 1 is crimped and fixed onto the coating portion 34 by the electric wire pressing plate 321. As a result, the overlapping portion between the LED element 2 and the electric wire portion of the cable wire 1 is fixed within the flexible terminal 3, thus ensuring stable electrical current flow to the LED element 2.

The sealed rubber tube 4 includes an inner rubber tube 41 and an outer rubber tube 42 as an integral structure. The flexible terminal 3 and the cable wire 1 are wrapped in the inner rubber tube 41 (both are coated). The LED element 2 is fitted into the outer rubber tube 42. An isolating post 43 is housed in the inner rubber tube 41 as a spacer. The isolating post 43 and the flexible terminal 3 are in contact with each other. The isolating post 43 is crimped and fixed by the inner rubber tube 41. The LED element 2 has two leads wrapped in the inner rubber tube 41, and the two leads of the LED element 2 are divided into a positive lead and a negative lead. The isolating post 43 is disposed between the positive lead and the negative lead of the LED element 2. The isolating post 43 is used to insulate (isolate) the positive lead of the LED element 2 from the negative lead of the LED element 2. This makes it possible to prevent the occurrence of a short circuit phenomenon.

The sealing rubber tube 4 has a tubular structure made of insulating rubber. The sealing rubber tube 4 is filled with a sealant 44. Taking advantage of the thermal shrinkage and discharge properties of rubber, the sealing rubber tube 4 is heated to 200-250°C, whereupon it forms a shrink coating. At this time, a large amount of sealant 44 is discharged due to the thermal shrinkage and discharge properties of rubber, and the sealing process is performed. As a result, the LED element 2, flexible terminal 3, and cable wire 1 are fixed inside the sealing rubber tube 4. This satisfies the demand for waterproof sealing.

This product is used as follows. As shown in Figures 1 and 2, first, the two lead wires of the two LED elements 2 are attached to the electric wire portion of the cable wire 1 using the flexible terminal 3. Specifically, the cable wire 1 is inserted into the flexible terminal 3, and the cable wire 1 is placed on the coating portion 34. At this time, the cable wire 1 is placed on the cable wire pressing portion 31, and the electric wire portion of the cable wire 1 is placed on the electric wire pressing portion 32. In this state, the top of the cable wire pressing plate 311 of the cable wire pressing portion 31 is further bent from the state shown in Figure 2 toward the coating portion 34. As a result, the cable wire 1 inserted into the flexible terminal 3 is sandwiched between the top of the cable wire pressing plate 311 and the coating portion 34. As a result, the cable wire 1 is crimped and fixed onto the coating portion 34.

Next, the lead wire of the LED element 2 is inserted into the lead wire pressing portion 33 of the flexible terminal 3, and the lead wire of the LED element 2 is overlapped with the wire portion of the cable line 1 at the wire pressing portion 32. By inserting the lead wire of the LED element 2 into the wire pressing portion 32, the lead wire of the LED element 2 is crimped onto the coating portion 34 by the other flexible pressing plate 331.

The lead wire of the LED element 2 is also crimped and fixed onto the coating portion 34, and the connecting portion of the two wire pressing plates 321 of the wire pressing portion 32 is further bent from the state shown in FIG. 2 towards the coating portion 34. As a result, the overlapping portion of the lead wire of the LED element 2 and the wire portion of the cable wire 1 is sandwiched between the connecting portion of the wire pressing plate 321 and the coating portion 34. As a result, the overlapping portion of the lead wire of the LED element 2 and the wire portion of the cable wire 1 is crimped and fixed onto the coating portion 34 by the wire pressing plate 321. As a result, the flexible terminal 3 can maintain electrical continuity between the LED element 2 and the cable wire 1 while achieving a strong connection between the lead wire of the LED element 2 and the cable wire 1.

Then, the LED element 2 and the cable wire 1 are wrapped in the sealing rubber tube 4. Specifically, first, the isolating post 43 is placed between the two lead wires of the LED element 2, so that the flexible terminal 3 and the isolating post 43 come into contact with each other. The LED element 2 is wrapped in the rubber outer tube 42, and the isolating post 43, the cable wire 1, and the isolating post 43 are wrapped in the rubber inner tube 41. After that, a heat gun is used to heat-seal the sealing rubber tube 4. The sealing rubber tube 4 is heat-shrunk onto the LED element 2 and the flexible terminal 3. At this time, the inner rubber tube 41 receives heat and expels a large amount of sealant 44, sealing the product. This makes it possible to satisfy the requirement for waterproof sealing.

According to one embodiment of the present invention, a waterproof LED string light that does not require soldering is provided, which strengthens the connection between the LED element 2 and the cable wire 1, makes it easy to set up the LED element 2, improves the waterproof effect, and effectively prevents the occurrence of short circuits. One embodiment of the present invention has great market potential.

Although the embodiments of the present invention have been described in detail, these are merely examples used to clarify the technical content of the present invention, and the present invention should not be interpreted as being limited to these examples, and the scope of the present invention is limited only by the scope of the attached claims.

1: Cable wire
2: LED element
3: Flexible terminal
4: Sealing rubber tube
31: Cable wire holder
32: Wire clamp
33: Lead wire holder
34: Coating
41: Rubber inner tube
42: Rubber outer tube
43: Isolation Pillar
44: Sealant
311: Cable wire retaining plate
321: Wire retaining plate
331: Flexible pressure plate
332: Stopper plate

Claims (5)

Cable lines and
A LED string light including a plurality of LED elements interconnected through the cable line,
The lead wire of the LED element is attached to the electric wire portion of the cable wire,
The LED element further includes a flexible terminal disposed between the lead wire and the cable wire,
the flexible terminal is crimped to the lead wire and the cable wire of the LED element,
The LED element further includes a sealing rubber tube which is an outer crimp coating of the LED element.
the tip end of the cable and the flexible terminal are crimped while being enclosed in the sealing rubber tube ,
the flexible terminal includes, as an integral structure, a plate-shaped coating portion having a longitudinal axis, a cable wire pressing portion for pressing the cable wire against the coating portion, an electric wire pressing portion for pressing an overlapping portion of the cable wire and an electric wire portion of the cable wire against the coating portion, and a lead wire pressing portion for pressing the lead wire of the LED element against the coating portion;
the lead wire pressing portion includes two stopper plates facing each other in the longitudinal direction of the coating portion, and two flexible pressing plates respectively provided on the two stopper plates, the two flexible pressing plates being disposed between the two stopper plates,
a tip end of one of the flexible pressure plates is pressed against a ceiling surface of a tip end of the other flexible pressure plate,
An LED string light , wherein the lead wires of the LED elements are crimped onto the coating portion by the tip portion of the other flexible pressing plate . the cable wire pressing portion includes two cable wire pressing plates formed on the covering portion so as to face each other in a width direction of the covering portion, the two cable wire pressing plates have apexes, and the apexes of the cable wire pressing plates have a triangular plate structure;
The LED string light according to claim 1 , wherein the cable is crimped and fixed onto the covering portion by the cable pressing plate. The electric wire pressing portion includes two electric wire pressing plates,
2. The LED string light of claim 1, wherein the two wire pressing plates are formed to face each other in the width direction of the coating portion, the wire pressing plates have a V-shaped plate structure, and the overlapping portion between the lead wire of the LED element and the wire portion of the cable line is crimped and fixed to the coating portion by the wire pressing plates. Cable lines and
A LED string light including a plurality of LED elements interconnected through the cable line,
The lead wire of the LED element is attached to the electric wire portion of the cable wire,
The LED element further includes a flexible terminal disposed between the lead wire and the cable wire,
the flexible terminal is crimped to the lead wire and the cable wire of the LED element,
The LED element further includes a sealing rubber tube which is an outer crimp coating of the LED element.
the tip end of the cable and the flexible terminal are crimped while being enclosed in the sealing rubber tube,
The sealing rubber tube is made of insulating rubber and has a tubular structure. The sealing rubber tube includes an inner rubber tube and an outer rubber tube as an integral structure.
the flexible terminal and the cable are enclosed in the inner rubber tube, and the LED element is fitted into the outer rubber tube;
The LED string light further includes an isolation post enclosed within the inner rubber tube, the isolation post and the flexible terminal are in contact with each other, and the isolation post is crimped and fixed by the inner rubber tube. 5. The LED string light according to claim 1 or 4 , wherein the sealing rubber tube adopts a tubular structure made of insulating rubber, and the sealing rubber tube is filled with a sealant.