Flexible light emitting diode lighting process and assembly

• US 20120099326A1
• Filed: 10/26/2010
• Published: 04/26/2012
• Est. Priority Date: 10/26/2010
• Status: Active Grant

• Current Assignee: Truck-Lite Company LLC (Truck-Lite Holdings 2 Corp.)
• Original Assignee: Truck-Lite Company Incorporated (Truck-Lite)
• Inventors: Hammond, Steven G., Hefright, Craig W.
• Granted Patent: US 10,024,510 B2
• Time in Patent Office: Days
• US Class Current: 362/311.02
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21S 43/19 Attachment of light sources or lamp holders
• CPC Class Codes: F21S 43/27 Attachment thereof
• CPC Class Codes: F21S 43/51 Attachment thereof

Abstract

A light emitting diode lighting assembly for mounting to a curved mounting surface, such as a vehicle surface, includes a plurality of light emitting diodes, a circuit board, and a molded polymer section for surrounding and insulating the LEDs against the circuit board. The lighting assembly also includes a lens and a flexible molded housing surrounding a perimeter of the lens and the circuit board for sealing the lens to the circuit board.

Claims

1. A light emitting diode lighting assembly comprising:

at least one light emitting diode;

a circuit board for providing electrical current to said at least one light emitting diode;

a molded polymer section surrounding and insulating said at least one light emitting diode against said circuit board;

a lens in which said molded polymer section and circuit board are positioned such that an air gap is present between a top surface of said at least one light emitting diode and said lens;

a flexible molded housing surrounding a perimeter of said lens and said circuit board for sealing said lens to said circuit board, while maintaining the air gap between said top surface of said at least one light emitting diode and said lens; and

an adhesive material positioned against a back portion of said flexible molded housing for attaching said light emitting diode lighting assembly to a surface.

3. The light emitting diode lighting assembly of claim 1 further comprising a second molded polymer section for sealing a bottom surface of said circuit board.

4. The light emitting diode lighting assembly of claim 1 wherein said molded polymer section and said flexible molded housing are formed of polyamide.

5. The light emitting diode lighting assembly of claim 1 wherein the adhesive material is a double sided foam tape.

6. The light emitting diode lighting assembly of claim 1 wherein the lens includes an outer surface and an inner surface having at least one optical element corresponding to one of said at least one light emitting diode.

7. The light emitting diode lighting assembly of claim 6 wherein the lens includes pillow optical elements on an internal surface and a protruding optical element on an outer surface.

8. The light emitting diode lighting assembly of claim 7 wherein the lens is configured to meet the photometric requirements for use as a Clearance lamp, Side Marker lamp, Identification Lamp, or Combination Clearance and Side Marker lamp.

9. The light emitting diode lighting assembly of claim 1 wherein the flexible molded housing includes flexible extension wings for curving such that said light emitting diode lighting assembly may be adhesively attached to a curved surface.

10. The light emitting diode lighting assembly of claim 1 wherein said molded polymer section further includes an encasing portion for containing wires extending from said circuit board and said flexible molded housing further includes a plug for covering said encasing portion of said molded polymer section, wherein said plug is adapted to fit within an opening in a mounting surface.

11. A light emitting diode lighting assembly comprising:

at least one light emitting diode;

a circuit board for provides electrical current to said at least one light emitting diode;

a molded polymer section surrounding and insulating said at least one light emitting diode against said circuit board;

a lens positioned over said molded polymer section such that an air gap is present between a top surface of said at least one light emitting diode and said lens;

a flexible molded housing surrounding a perimeter of said lens and said circuit board for sealing said lens to said circuit board, while maintaining the air gap between said top surface of said at least one light emitting diode and said lens, said flexible molded housing having flexible extension wings extending outward from said circuit board; and

an adhesive material positioned against a back portion of said flexible molded housing for attaching said light emitting diode lighting assembly to a surface;

wherein said flexible molded housing having flexible wing portions which curve such that said light emitting diode lighting assembly may be adhesively attached to a curved surface.

12. The light emitting diode lighting assembly of claim 11 further comprising a second molded polymer section for sealing a bottom surface of said circuit board.

13. The light emitting diode lighting assembly of claim 11 wherein said molded polymer section and said flexible molded housing are formed of polyamide.

14. The light emitting diode lighting assembly of claim 11 wherein the adhesive material is a double sided foam tape.

15. The light emitting diode lighting assembly of claim 11 wherein the lens includes an outer surface and an inner surface having at least one optical element corresponding to one of said at least one light emitting diode.

16. The light emitting diode lighting assembly of claim 15 wherein the lens includes pillow optical elements on an internal surface and a protruding optical element on an outer surface.

17. The light emitting diode lighting assembly of claim 16 wherein the lens is configured to meet the photometric requirements for use as a Clearance lamp, Side Marker lamp, Identification Lamp, or Combination Clearance and Side Marker lamp.

18. The light emitting diode lighting assembly of claim 11 wherein said molded polymer section further includes an encasing portion for containing wires extending from said circuit board and said flexible molded housing further includes a plug for covering said encasing portion of said molded polymer section, wherein said plug is adapted to fit within an opening in a mounting surface.

19. Method of producing a light emitting diode lighting assembly, comprising:

providing a circuit board having at least one light emitting diode electrically connected thereto;

positioning said circuit board in a mold;

introducing a polymer material into said mold such that said at least one light emitting diode is surrounded by a polymer material to affix the at least one light emitting diode to said circuit board, wherein the polymer material is prevented from covering a top surface of said least one light emitting diode;

curing said polymer material in said mold to form a molded polymer section;

positioning a lens over said molded polymer section such that an air gap is present between said top surface of said at least one light emitting diode and said lens;

positioning said circuit board and said lens in a mold;

introducing a polymer material into said mold such that said polymer material surrounds a perimeter of said lens and said circuit board for sealing said lens to said circuit board, while maintaining the air gap between said top surface of said at least one light emitting diode and said lens; and

curing said polymer material in said mold to form a flexible molded housing; and

applying an adhesive material positioned against a back portion of said flexible molded housing for attaching said light emitting diode lighting assembly to a surface without the use of fasteners.

20. The method of producing the light emitting diode lighting assembly of claim 19 wherein said molded polymer section further includes an encasing portion for containing wires extending from said circuit board and said flexible molded housing further includes a plug for covering said encasing portion of said molded polymer section, wherein said plug is adapted to fit within an opening in a mounting surface.

21. The method of producing the light emitting diode lighting assembly of claim 19 wherein the flexible molded housing includes flexible extension wings for curving such that said light emitting diode lighting assembly may be adhesively attached to a curved surface.