LED lamp assembly

• US 20040218389A1
• Filed: 02/25/2004
• Published: 11/04/2004
• Est. Priority Date: 03/09/2000
• Status: Active Grant

• Current Assignee: N.I.R., Inc.
• Original Assignee: Mongo Light Co., Inc.
• Inventors: Dinan, Michael E., Reinhold, Eugene P., Lamke, Isidore I., Plummer, Robert D., Figura, John, Narzinski, Matt
• Granted Patent: US 7,040,779 B2
• Time in Patent Office: Days
• US Class Current: 362/241
• CPC Class Codes: B60Q 1/2696 Mounting of devices using LEDs
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21V 15/00 Protecting lighting devices from damage protection from thermal damage F21V29/00; gas-tight or water-tight arrangements F21V31/00
• CPC Class Codes: F21V 31/04 Provision of filling media
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 25/13 the devices being of a type provided for in group H01L33/00
• 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 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A lamp finding particular application in boat trailers and other vehicular applications is provided with a generally unbreakable lamp structure. The lamp preferably is provided with a plurality of LEDs arranged with rows and columns on a circuit card or board. The lamp is constructed by encapsulating the board and LED arrangement in a moldable lens material, which after removal from a suitable mold at least partially defines the lamp body.

Claims

1. A lamp assembly comprising:

a support circuit board defining a plurality of extensions extending from a periphery of the board for attachment to a mold;

a plurality of light emitting diodes mounted to the circuit board;

an electrical connection attached to the circuit board and extending outwardly of the lamp assembly;

a mold in place lens material encapsulating the circuit board and light emitting diodes, and formed to provide a predetermined shape for the lens assembly, the electrical connection extending outwardly of the lens assembly.

2. The lamp assembly of claim 1 wherein the circuit board defines an aperture.

3. The lamp assembly of claim 2 wherein the circuit board defines an aperture.

4. The lamp assembly of claim 1 wherein the circuit board has a reflector attached thereto.

5. The lamp assembly of claim 4 wherein the circuit board has a plurality of reflectors attached thereto.

6. The lamp assembly of claim 1 wherein the LEDs are positioned and arranged in rows and columns.

7. The lamp assembly of claim 6 wherein at least one of the rows of LEDs emit light having a color different from at least another row of the LEDs.

8. The lamp assembly of claim 7 wherein the lens material has at least one opening formed in it for permitting attachment of the lamp assembly to another structure.

9. The lamp assembly of claim 1 wherein the lamp assembly withstands a force of at least 30 ft. lbs. per square inch of force without damage.

10. A lamp assembly comprising:

a moldable, translucent material;

a light emitting unit attached to a circuit board defining a plurality of extension extending from a periphery thereof and wherein the circuit board has been molded within the material; and

electrical leads attached to circuit board that extend through the material to allow electrical connection to the circuit board.

11. The lamp assembly of claim 10 wherein the circuit board has a reflector attached thereto.

12. The lamp assembly of claim 11 wherein the circuit board has a plurality of reflectors attached thereto.

13. The lamp assembly of claim 10 wherein the circuit board defines an aperture.

14. The lamp assembly of claim 13 wherein the circuit board comprises a plurality of apertures.

15. The lamp assembly of claim 10 wherein the light emitting unit comprises a plurality of light emitting units comprising light emitting diodes (LEDs).

16. The lamp assembly of claim 15 wherein the LEDs are positioned and arranged in rows and columns.

17. The lamp assembly of claim 16 wherein at least a portion of one of the rows of LEDs emits light having a color different from at least a portion of another row of the LEDs.

18. The lamp assembly of claim 10 wherein the lens material has at least one opening formed in it for permitting attachment of the lamp assembly to another structure.

19. The lamp assembly of claim 10 wherein the lens material can withstand a force of at least 30 ft. lbs. per square inch without damage.

20. A method of manufacturing a lamp assembly:

providing a circuit board comprising a plurality of extensions extending from a periphery of the circuit board;

attaching a light emitting unit connected to the circuit board; and

injecting a moldable, flowable lens material around substantially all of circuit board and light emitting unit; and

allow the moldable, flowable lens material to harden.

21. The method of claim 20 wherein the step of injecting the lens material is performed such that the circuit board and light emitting unit are encased within the moldable lens material in the substantial absence of air.

22. The method of claim 20 wherein the step of providing a circuit board comprises the step of providing a circuit board comprising a plurality of extensions extending from a periphery of the circuit board and defining a plurality of apertures.