Metal carrier for LEDs in composite lamps

• US 20070259576A1
• Filed: 05/03/2006
• Published: 11/08/2007
• Est. Priority Date: 05/03/2006
• Status: Abandoned Application

• Current Assignee: Grote Industries Incorporated
• Original Assignee: Grote Industries Incorporated
• Inventors: Brandt, Bruce, Brooks, Timothy, Bode, Shane, Branstetter, Cary
• Application Number:
  US11/416,700
• Publication Number:
  US 20070259576A1
• Time in Patent Office: Days
• US Class Current: 439/885
• CPC Class Codes: B60Q 2900/10 Retrofit arrangements
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21S 43/13 characterised by the type of light source
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21S 43/195 Details of lamp holders, terminals or connectors
• CPC Class Codes: F21V 19/001 the light sources being semiconductors devices, e.g. LEDs
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05K 1/184 Components including terminals inserted in holes through the printed circuit board and connected to printed contacts on the walls of the holes or at the edges thereof or protruding over or into the holes
• CPC Class Codes: H05K 2201/0382 Continuously deformed conductors
• CPC Class Codes: H05K 2201/0397 Tab forming integral conductive tabs H05K3/4092
• CPC Class Codes: H05K 2201/09118 Moulded substrate
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 2201/10651 Component having two leads, e.g. resistor, capacitor
• CPC Class Codes: H05K 3/202 using self-supporting metal foil pattern
• CPC Class Codes: H05K 3/326 the printed circuit having integral resilient or deformable parts, e.g. tabs or parts of flexible circuits H05K3/365 takes precedence

Abstract

Novel arrangements are disclosed that provide for replacement of printed circuit boards useful in regulating current for LEDs. In one embodiment, a conductive track is disclosed that forms a pattern for placement of electrical components. The track can be made out of any suitably conductive material and may be stamped, cut, or formed depending on the material type. The conductive track can conduct both electricity and heat. Portions of the conductive track can be removed creating a gap. Electrical components can be placed along the conductive track spanning the gap to create a circuit path. Other embodiments include wiring harnesses that contain embedded electrical components. The harnesses may occupy less space than some embodiments of the conductive track. An electrical connector may be provided to allow easy replacement of the LED.

Claims

1. An electrical circuit comprising:

an unsupported conductor having at least one gap formed therein; and

an electrical component having a first lead and a second lead, the first and second leads being conductively coupled to the unsupported conductor such that the electrical component bridges the gap.

2. The electrical circuit of claim 1 further comprising at least one crimp tab coupling the electrical component to the unsupported conductor.

3. The electrical circuit of claim 1 further comprising at least one fence.

4. The electrical circuit of claim 1 wherein the electrical component comprises a light emitting diode.

5. The electrical circuit of claim 1 wherein the unsupported conductor is composed of material selected from the group consisting of copper and aluminum.

6. The electrical circuit of claim 1 wherein the electrical component is selected from the group consisting of resistor, capacitor, and diode.

7. The electrical circuit of claim 6 wherein the diode is a light emitting diode.

8. An electrical circuit comprising:

an unsupported conductor having a first portion and a second portion;

an electrical component, said electrical component having a first lead and a second lead, the first lead being conductively coupled to the first portion and the second lead being conductively coupled to the second portion;

wherein the first portion and the second portion are coupled only by said at least one electrical component; and

wherein at least one electrical component forms a structural member of said unsupported conductor.

9. The electrical circuit of claim 8 further comprising at least one crimp tab coupling the electrical component to the unsupported conductor.

10. The electrical circuit of claim 8 further comprising at least one fence.

11. The electrical circuit of claim 8 wherein the electrical component comprises a light emitting diode.

12. The electrical circuit of claim 8 wherein the electrical component is selected from the group consisting of resistor, capacitor, and diode.

13. The electrical circuit of claim 12 wherein the diode is a light emitting diode.

14. A conductive device kit comprising:

at least one electrical component; and

an unsupported conductor having at least a portion adapted to be removed thereby forming a gap, the unsupported conductor configured to receive at least one electrical component across the gap thereby forming a circuit path.

15. The conductive device kit of claim 14 wherein the at least one electrical component is selected from the group consisting of resistors, capacitors, and diodes.

16. The conductive device kit of claim 15 wherein the diodes includes a light emitting diode.

17. The conductive device of claim 14 wherein the unsupported conductor further comprises at least one crimp tab.

18. The conductive device of claim 14 further comprising at least one fence.

19. A method of making a conductive device, the method comprising:

providing an operative piece;

shaping the operative piece into an unsupported conductor;

forming a gap in the unsupported conductor; and

placing an electrical component across the gap thereby forming a circuit path.

20. The method of making a conductive device in claim 19 wherein said shaping step is selected from the group consisting of stamping, cutting, forming, and molding.

21. The method of making a conductive device in claim 19 further comprising providing at least one crimp tab on the unsupported conductor.

22. The method of making a conductive device in claim 19 further comprising providing at least one fence on the operative piece.

23. A method of making a conductive device, the method comprising:

providing an unsupported conductor;

forming a gap in the unsupported conductor; and

placing an electrical component across the gap thereby forming a circuit path.

24. The method of making a conductive device in claim 23 further comprising providing at least one crimp tab on the unsupported conductor.

25. The method of making a conductive device in claim 23 further comprising providing at least one fence on the unsupported conductor.

26. A method of retrofitting a lighting device, the method comprising:

providing a lamp assembly;

removing an existing lighting source from the lamp assembly;

providing an unsupported conductor having electrical components forming a circuit; and

placing the unsupported conductor into the lamp assembly.

27. The method of retrofitting a lighting device in claim 26, wherein the step of providing the lamp assembly includes providing an incandescent lamp assembly.

28. The method of retrofitting a lighting device in claim 26, wherein the step of removing the existing lighting source includes removing an incandescent bulb.

29. The method of retrofitting a lighting device in claim 26, wherein said placing step comprises the steps of:

installing a cradle into the lamp assembly; and

placing the unsupported conductor into the cradle.

30. The method of retrofitting a lighting device in claim 29 wherein the unsupported conductor is adapted to be received in the cradle.

31. A wiring assembly embedded with a circuit, the assembly comprising:

an unsupported conductor having a first wire section and a second wire section with a gap therebetween;

an electrical component having a first component end and a second component end, the electrical component coupling the first and second wire sections across the gap; and

a light emitting diode operatively coupled to the unsupported conductor.

32. The wiring assembly of claim 31 further comprising at least one crimp, the at least one crimp connecting the first component end to the first wire path.

33. The wiring assembly of claim 31 wherein the first component end is soldered to the first wire section.

34. The wiring assembly of claim 31 further comprising a protector covering at least a portion of the unsupported conductor.

35. The wiring assembly of claim 34 wherein the protector is selected from the group consisting of a cable shield, shrink tubing, and over-molded protective covering.

36. A wiring assembly embedded with a circuit, the assembly comprising:

an unsupported conductor having a first wire section and a second wire section with a gap therebetween;

an electrical component having a first component end and a second component end, the electrical component coupling the first and second wire sections across the gap;

a connector operatively coupled to the first end; and

a light emitting diode selectively operatively coupled to the connector.

37. The wiring assembly of claim 36 further comprising at least one crimp, the at least one crimp connecting the first component end to the first wire path.

38. The wiring assembly of claim 36 wherein the first component end is soldered to the first wire section.

39. The wiring assembly of claim 36 further comprising a protector covering at least a portion of the unsupported conductor.

40. The wiring assembly of claim 39 wherein the protector is selected from the group consisting of a cable shield, shrink tubing, and over-molded protective covering.