LAMP AND A PROCESS FOR PRODUCING A LAMP
First Claim
1. A process for producing a lamp, including:
- forming an electrically conductive receptacle having a substantially planar base and a substantially planar peripheral region;
forming a substantially planar electrical insulator on said substantially planar peripheral region;
forming a substantially planar electrically conductive contact on said substantially planar electrical insulator;
mounting a light source on said base of said receptacle;
making a first electrical connection between said substantially planar electrically conductive contact and a first contact of said light source, and a second electrical connection between said electrically conductive receptacle and a second contact of said light source; and
encapsulating said light source and said electrical connections to provide a light source assembly for mounting on an electrically conductive support, wherein an unencapsulated portion of said substantially planar electrically conductive contact provides a first electrical contact to said light source mounted in said receptacle, and the electrically conductive receptacle provides a second electrical contact to the light source.
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Accused Products
Abstract
A process for producing a lamp, including forming one or more electrical connectors having a predetermined shape for making electrical connections to one or more light source assemblies mounted at predetermined locations on a non-planar support. The light source assemblies are formed by forming an electrical insulator on a peripheral region of an electrically conductive receptacle, forming an electrically conductive contact adapted to fit the peripheral region, attaching the electrically conductive contact to the electrical insulator, mounting a light source in the receptacle, and making a first electrical connection between a first electrically conductive contact of the receptacle and a first contact of the light source, and a second electrical connection between a second electrically conductive contact of the receptacle and a second contact of the light source. The light sources mounted in the electrically conductive receptacles are light emitting diodes and are encapsulated in transparent medium. An array of electrically conductive receptacles is formed from sheet metal by stamping and cutting. Connected receptacles are subsequently separated from the sheet, The electrical connectors are first and second annular connectors with projections and are formed from a metal sheet and subsequently separated by removing joining portions and tie bars.
68 Citations
18 Claims
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1. A process for producing a lamp, including:
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forming an electrically conductive receptacle having a substantially planar base and a substantially planar peripheral region; forming a substantially planar electrical insulator on said substantially planar peripheral region; forming a substantially planar electrically conductive contact on said substantially planar electrical insulator; mounting a light source on said base of said receptacle; making a first electrical connection between said substantially planar electrically conductive contact and a first contact of said light source, and a second electrical connection between said electrically conductive receptacle and a second contact of said light source; and encapsulating said light source and said electrical connections to provide a light source assembly for mounting on an electrically conductive support, wherein an unencapsulated portion of said substantially planar electrically conductive contact provides a first electrical contact to said light source mounted in said receptacle, and the electrically conductive receptacle provides a second electrical contact to the light source.
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2. A process for producing a lamp, including:
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forming an array of electrically conductive receptacles interconnected by receptacle joining portions, each of said receptacles having a substantially planar base and a substantially planar peripheral region; forming an array of substantially planar electrical insulators on said peripheral regions of said receptacles; forming an array of substantially planar electrically conductive contacts on said electrical insulators; mounting light sources on the bases of said array of receptacles; making first electrical connections between a first contact of each light source and the electrically conductive contact of the corresponding receptacle, and second electrical connections between a second contact of each light source and the corresponding receptacle; and encapsulating said light sources and said electrical connections to form an array of light source assemblies, wherein an unencapsulated portion of the substantially planar electrically conductive contact of each receptacle provides a first electrical contact to the light source mounted in that receptacle, and the electrically conductive receptacle provides a second electrical contact to the light source. - View Dependent Claims (3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. An array of light source assemblies, including:
an array of electrically conductive receptacles for receiving respective light sources, said receptacles interconnected by receptacle joining portions, each of said receptacles having a substantially planar base and a substantially planar peripheral region; an array of substantially planar electrical insulators on said peripheral regions of said electrically conductive receptacles; an array of substantially planar electrically conductive contacts on said electrical insulators; light sources mounted on the bases of said array of electrically conductive receptacles; first electrical connections between said electrically conductive contacts and first contacts of said light sources, and second electrical connections between said electrically conductive receptacles and second contacts of said light sources; and said light sources and said electrical connections being encapsulated, wherein an unencapsulated portion of the substantially planar electrically conductive contact of each receptacle provides a first electrical contact to the light source mounted in that receptacle, and the electrically conductive receptacle provides a second electrical contact to the light source. - View Dependent Claims (18)
Specification