SUBSTANTIALLY INSEPARABLE LED LAMP ASSEMBLY
First Claim
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1. A method of assembling a substantially inseparable LED lamp assembly from individual discrete components comprising:
- providing a lamp holder that is formed as an annulus with a first opening on a first end of said annulus and a second opening on a second end of said annulus;
substantially permanently securing a lamp cover to said first end of said annulus;
providing an LED lamp having LED pin leads;
attaching wires to said LED pin leads of said LED lamp that have a predetermined size and a predetermined shape;
inserting said LED lamp through said second opening of said second end of said annulus to a position where said LED lamp is oriented to allow light from said LED lamp to be transmitted through said lamp cover;
substantially permanently attaching said LED lamp to said annulus;
inserting a plug into said second opening of said second end of said annulus, said plug having indentations along an outer surface that substantially match said predetermined size and said predetermined shape of said wires so that said plug forms a watertight seal with said wires;
substantially permanently sealing said plug in said second opening to form a watertight seal at said second end of said annulus.
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Abstract
Disclosed are LED lamp assemblies that are substantially inseparable. The LED lamp assemblies use discrete components that are individually manufactured and then assembled in a manner that substantially prevents disassembly or disengagement of components. An interference fit can be used to substantially secure components of the LED lamp assemblies. Bonding techniques can also be used, including adhesive and solvent bonds, as well as thermal bonds, including sonic bonds.
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Citations
45 Claims
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1. A method of assembling a substantially inseparable LED lamp assembly from individual discrete components comprising:
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providing a lamp holder that is formed as an annulus with a first opening on a first end of said annulus and a second opening on a second end of said annulus; substantially permanently securing a lamp cover to said first end of said annulus; providing an LED lamp having LED pin leads; attaching wires to said LED pin leads of said LED lamp that have a predetermined size and a predetermined shape; inserting said LED lamp through said second opening of said second end of said annulus to a position where said LED lamp is oriented to allow light from said LED lamp to be transmitted through said lamp cover; substantially permanently attaching said LED lamp to said annulus; inserting a plug into said second opening of said second end of said annulus, said plug having indentations along an outer surface that substantially match said predetermined size and said predetermined shape of said wires so that said plug forms a watertight seal with said wires; substantially permanently sealing said plug in said second opening to form a watertight seal at said second end of said annulus. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 10, 11, 12, 13, 14, 15, 16, 17)
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18. An LED lamp assembly that is constructed of individual components that are separately fabricated and are substantially inseparably assembled to provide a fixed LED lamp assembly comprising:
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a lamp holder that is shaped as an annulus, said annulus having a first opening on a first end and a second opening on a second end; a lamp cover substantially permanently attached to said first end of said annulus; an LED lamp inserted through said second opening of said annulus and substantially permanently attached in said annulus in a position that orients said LED lamp to allow light to be transmitted through said lamp holder, said LED lamp having LED lead pins attached to said LED lamp; wires that are conductively connected to said LED lead pins and extending through said second opening of said second end of said annulus, said wires having a predetermined size and shape; a plug having indentations along an outer surface that substantially match said predetermined size and shape of said wires, said plug substantially permanently inserted in said second opening to prevent disassembly of said LED lamp assembly. - View Dependent Claims (9, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39)
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40. A method of assembling a substantially inseparable LED lamp assembly from individual discrete components comprising:
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providing a lamp cover that has a lamp base that has a first opening on a first end of said lamp cover; providing an LED lamp having LED pin leads; attaching wires to said LED pin leads of said LED lamp that have a predetermined size and a predetermined shape; inserting said LED lamp through said first opening of said first end of said lamp base to a position where said LED lamp is oriented to allow light from said LED lamp to be transmitted through said lamp cover; substantially permanently attaching said LED lamp to said lamp base; inserting a plug into said first opening of said first end of said lamp base, said plug having grooves along an outer surface that substantially match said predetermined size and said predetermined shape of said wires so that said plug forms a watertight seal with said wires; substantially permanently sealing said plug in said first opening to form a watertight seal at said first end of said lamp base. - View Dependent Claims (41, 42, 43, 44)
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45. An LED lamp assembly that is constructed of discrete components that are separately fabricated and are substantially inseparably assembled to provide a fixed LED lamp assembly comprising:
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a lamp cover having a lamp base that has a first opening at a first end of said lamp base; an LED lamp inserted through said first opening of said lamp base and substantially permanently attached in said lamp base in a position that orients said LED lamp to allow light to be transmitted through said lamp cover; LED lead pins attached to said LED lamp; wires that are conductively connected to said LED lead pins and extending through said first opening of said lamp base, said wires having a predetermined size and shape; a plug having grooves along an outer surface that substantially match said predetermined size and shape of said wires, said plug substantially permanently sealed in said first opening of said lamp base to prevent disassembly of said LED lamp assembly.
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Specification