Lamp on sheet and manufacturing method thereof

• US 20030137839A1
• Filed: 05/20/2002
• Published: 07/24/2003
• Est. Priority Date: 01/24/2002
• Status: Active Grant

• Current Assignee: Lin Yuan
• Original Assignee: Lin Yuan
• Inventors: Lin, Yuan
• Granted Patent: US 6,880,955 B2
• Time in Patent Office: Days
• US Class Current: 362/249
• CPC Class Codes: F21S 4/24 of ribbon or tape form, e.g. LED tapes
• CPC Class Codes: F21V 21/002 making direct electrical contact, e.g. by piercing F21V21/35 takes precedence
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/45144 Gold (Au) as principal constituent
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2201/09236 Parallel layout
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 2203/063 of preperforated insulating layer
• CPC Class Codes: H05K 2203/1545 Continuous processing, i.e. involving rolls moving a band-like or solid carrier along a continuous production path
• CPC Class Codes: H05K 3/0097 Processing two or more printed circuits simultaneously, e.g. made from a common substrate, or temporarily stacked circuit boards H05K3/0052 takes precedence
• CPC Class Codes: H05K 3/202 using self-supporting metal foil pattern
• CPC Class Codes: H05K 3/281 by means of a preformed insulating foil H05K3/284 takes precedence
• CPC Class Codes: H05K 3/305 Affixing by adhesive
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A method of manufacturing lamps on sheets comprises pressing a continuous upper strip, an intermediate conductor assembly, and a continuous lower strip into a continuous strip assembly having a plurality of holes therealong; mounting a light source assembly on the strip assembly to form a continuous strip of lamps; and cutting the continuous strip of lamps into a plurality of sheets each having at least one lamp with a predetermined length of strip wherein the conductor assembly is secured in the strip assembly.

Claims

1. A method of manufacturing lamps on sheets comprising the steps of:

(a) utilizing a laminator to press a continuous upper strip, an intermediate conductor assembly including two parallel continuous strips of foils, and a continuous lower strip into a continuous strip assembly wherein a plurality of equally spaced pairs of holes are formed on the upper strip being communication with the strips of foils;

(b) mounting each one of a plurality of SMD LEDs of a light source assembly across one pair of holes on the upper strip to form a continuous strip of lamps; and

(c) cutting the continuous strip of lamps into a plurality of sheets each having at least one lamp;

whereby a bottom of the conductor assembly is covered by the lower strip, the strips of foils are secured in each sheet so that a short circuit caused by contacting the upper and the lower strips is substantially eliminated, and each sheet is flexible.

2. The method of claim 1, further comprising sequentially performing the steps of (a), (c) and (b).

3. A method of manufacturing lamps on sheets comprising the steps of:

(a) utilizing a laminator to press a continuous upper strip, an intermediate conductor assembly including two parallel continuous strips of foils, and a continuous lower strip into a continuous strip assembly wherein a plurality of equally spaced rounded holes are formed on the upper strip being communication with the strips of foils;

(b) applying an adhesive on one of the strips of foils prior to adhering each one of a plurality of LED dice bondings of a light source assembly onto the adhesive applied point of one of the strips of foils;

(c) bonding one of conducting member wire across one of a plurality of spacings from the LED dice bonding to the other strip of foil by means of a bonding device;

(d) sealing a layer of epoxy resin on each pair of the LED dice bonding and the hole to form a continuous strip of lamps; and

(e) cutting the continuous strip of lamps into a plurality of sheets each having at least one lamp thereon;

whereby a bottom of the conductor assembly is covered by the lower strip, the strips of foils are secured in each sheet so that a short circuit caused by contacting the upper and the lower strips is substantially eliminated, and each sheet is flexible.

4. The method of claim 3, further comprising sequentially performing the steps of (a), (e), (b), (c) and (d).

5. A method of manufacturing lamps on sheets comprising the steps of:

(a) utilizing a laminator to press a continuous upper strip, an intermediate conductor assembly including two parallel continuous strips of foils, and a continuous lower strip into a continuous strip assembly wherein a plurality of equally spaced rounded holes are formed on the upper strip being communication with the strips of foils;

(b) punching a plurality of pairs of holes on the strips of foils respectively in a direction from the upper strip to the lower strip;

(c) inserting a pair of pins of a plurality of mini bulbs (LED lamp) of a light source assembly through the lower strip and the holes prior to securing on the strips of foils by soldering to form a continuous strip of lamps; and

(d) cutting the continuous strip of lamps into a plurality of sheets each having at least one lamp thereon;

whereby a bottom of the conductor assembly is covered by the lower strip, the strips of foils are secured in each sheet so that a short circuit caused by contacting the upper and the lower strips is substantially eliminated, and each sheet is flexible.

6. The method of claim 5, further comprising sequentially performing the steps of (a), (d), (b) and (c).

7. A lamp on sheet comprising:

an intermediate conductor assembly including two parallel continuous strips of foils;

a strip assembly including an upper strip and a lower strip wherein one or more spaced pairs of holes are formed on the upper strip being communication with the strips of foils; and

a light source assembly including one or more SMD LEDs each across one pair of holes;

wherein the strips of foils are secured between the upper and the lower strips.

8. The lamp on sheet of claim 7, wherein the strip assembly is selected from a PP, a PVC, or a thin plastic material.

9. The lamp on sheet of claim 7, wherein the strip assembly is selected from a fireproof fabric, a glass-fiber, or an asbestos.

10. A lamp on sheet comprising:

an intermediate conductor assembly including two parallel continuous strips of foils;

a strip assembly including an upper strip and a lower strip wherein one or more spaced rounded holes are formed on the upper strip being communication with the strips of foils; and

a light source assembly including one or more LED dice bondings each mounted across the strips of foils;

wherein the strips of foils are secured between the upper and the lower strips.

11. The lamp on sheet of claim 10, wherein the strip assembly is selected from a PP, a PVC, or a thin plastic material.

12. The lamp on sheet of claim 10, wherein the strip assembly is selected from a fireproof fabric, a glass-fiber, or an asbestos.

13. A lamp on sheet comprising:

an intermediate conductor assembly including two parallel continuous strips of foils;

a strip assembly including an upper strip and a lower strip wherein one or more spaced rounded holes are formed on the upper strip being communication with the strips of foils, and a plurality of pairs of apertures are formed on the strips of foils respectively in a direction from the upper strip to the lower strip by punching; and

a light source assembly including one or more mini bulbs (LED lamp) each inserted through the lower strip and the apertures prior to securing on the strips of foils by soldering;

wherein the strips of foils are secured between the upper and the lower strips.

14. The lamp on sheet of claim 13, wherein the strip assembly is selected from a PP, a PVC, or a thin plastic material.

15. The lamp on sheet of claim 13, wherein the strip assembly is selected from a fireproof fabric, a glass-fiber, or an asbestos.

16. A method of manufacturing lamps on sheets comprising the steps of:

pressing a continuous upper strip, an intermediate conductor assembly, and a continuous lower strip into a continuous strip assembly having a plurality of holes spaced with a predetermined length therealong being communication with the conductor assembly;

mounting a light source assembly on the strip assembly to form a continuous strip of lamps; and

cutting the continuous strip of lamps into a plurality of sheets each having at least one lamp thereon with a predetermined length of the strip;

wherein the conductor assembly is secured in the strip assembly.