Supporter for Use During the Overmolding of a Light Engine
First Claim
Patent Images
1. A supporter for a printed circuit board to be included in an LED light engine, said supporter comprising:
- a top surface, a central portion and a bottom surface;
said top surface including mechanical placement means for positioning the printed circuit board;
said central portion including a channel for the placement of wires which supply electrical energy to the printed circuit board;
said central portion also including force spreading columns constructed and arranged to apply pressure to the bottom of the printed circuit board;
said bottom surface including a contact area for receiving pressure from a mold section during the overmolding of the LED light engine.
3 Assignments
0 Petitions
Accused Products
Abstract
A printed circuit board supporter includes a top surface, a bottom surface and a central portion. The top surface enables location of a printed circuit board. The bottom surface enables the force from an injection mold to be distributed across the bottom of the printed circuit board. The central portion of the printed circuit board supporter contains force spreading columns which pass between the top surface of the printed circuit board supporter and the bottom surface of the printed circuit board supporter.
13 Citations
21 Claims
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1. A supporter for a printed circuit board to be included in an LED light engine, said supporter comprising:
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a top surface, a central portion and a bottom surface; said top surface including mechanical placement means for positioning the printed circuit board; said central portion including a channel for the placement of wires which supply electrical energy to the printed circuit board; said central portion also including force spreading columns constructed and arranged to apply pressure to the bottom of the printed circuit board; said bottom surface including a contact area for receiving pressure from a mold section during the overmolding of the LED light engine. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A light engine comprising:
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a printed circuit board having at least one LED mounted thereon, said printed circuit board including the electrical componentry necessary to transform electrical energy into a form usable by said at least one LED, said printed circuit board further being electrically connected to insulated wires supplying said electrical energy to said electrical componentry; a printed circuit board supporter, said printed circuit board supporter including; a top surface, a central portion and a bottom surface; said top surface including mechanical placement means for positioning said printed circuit board; said central portion including a channel for the placement of insulated wires which supply electrical energy to said printed circuit board; said central portion also including force spreading columns constructed and arranged to apply pressure to the bottom of said printed circuit board; said bottom surface including a contact area for receiving pressure from a mold section during the overmolding of the light engine; overmolded material to hold the light engine together and protect said printed circuit board. - View Dependent Claims (8, 9, 10, 11, 12, 13, 14)
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15. A process for manufacturing a light engine comprising:
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placing the cover portion of an LED cover member into sockets located in a mold bottom; affixing a printed circuit board with at least one LED mounted thereon and insulated wires attached thereto to a printed circuit board supporter; placing the combination of said printed circuit with at least one LED mounted thereon and said printed circuit board supporter onto said LED cover member so that said at least one LED is located within said LED cover portion of said LED cover member; placing a mold top onto said mold bottom; injecting sealant material into spaces between said mold top and said mold bottom not occupied by said printed circuit board, said printed circuit board supporter and said LED cover member; separating said mold top from said mold bottom; removing said printed circuit board, said printed circuit board supporter and said lens member now partially enclosed by said sealant material from between said mold top and said mold bottom. - View Dependent Claims (16, 17, 18)
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19. A process for manufacturing a light engine comprising:
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placing the lens portion of an LED lens member into sockets located in a mold bottom; affixing a printed circuit board with at least one LED mounted thereon and insulated wires attached thereto to a printed circuit board supporter; placing the combination of said printed circuit with at least one LED mounted thereon and said printed circuit board supporter onto said LED lens member so that said at least one LED is located within said lens portion of said LED lens member; placing a mold top onto said mold bottom; injecting sealant material into spaces between said mold top and said mold bottom not occupied by said printed circuit board, said printed circuit board supporter and said LED lens member; separating said mold top from said mold bottom; removing said printed circuit board, said printed circuit board supporter and said lens member now partially enclosed by said sealant material from between said mold top and said mold bottom. - View Dependent Claims (20)
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21. A process for overmolding the components of a light engine comprising:
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placing a flexible web member on a mold bottom; affixing a printed circuit board with at least one LED mounted thereon and insulated wires attached thereto to a printed circuit board supporter; said printed circuit board supporter including; a top surface, a central portion and a bottom surface; said top surface including mechanical placement means for positioning said printed circuit board; said central portion including a channel for the placement of wires which supply electrical energy to said printed circuit board; said central portion further including force spreading columns constructed and arranged to apply pressure to the bottom of the printed circuit board; said bottom surface including a contact area for receiving pressure from said mold top during the overmolding of the LED light engine; placing the combination of said printed circuit with at least one LED mounted thereon and said printed circuit board supporter onto said flexible web member so that said at least one LED is located within a hole in said flexible web member; injecting sealant material into spaces between said mold top and said mold bottom not occupied by said printed circuit board, said printed circuit board supporter and said flexible web member; separating said mold top from said mold bottom; removing said printed circuit board, said printed circuit board supporter and said flexible web member now partially enclosed by said sealant material from between said mold top and said mold bottom.
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Specification