Light emitting diode lamp and method for producing thereof

• US 4,630,183 A
• Filed: 10/20/1982
• Issued: 12/16/1986
• Est. Priority Date: 10/23/1981
• Status: Expired due to Fees

• Current Assignee: Izumi Denki Corporation
• Original Assignee: Izumi Denki Corporation
• Inventors: Fujita, Teizo
• Primary Examiner(s): Lall, Parshotam S.
• Application Number:
  US06/435,591
• Time in Patent Office: 1,518 Days
• Field of Search: 362/95, 362/226, 362/254, 362/311, 362/800, 340/815.03, 29/854, 29/855, 29/856, 29/884, 350/96.17, 350/96.2, 313/499, 313/500, 313/512, 339/157 R, 357/74, 445/23, 445/24, 445/27, 445/28
• US Class Current: 362/311.05
• CPC Class Codes: F21K 9/23 Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2224/49113 the connectors connecting different bonding areas on the semiconductor or solid-state body to a common bonding area outside the body, e.g. converging wires
• CPC Class Codes: H01L 24/97 the devices being connected to a common substrate, e.g. interposer, said common substrate being separable into individual assemblies after connecting
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/12041 LED
• CPC Class Codes: H01L 33/483 Containers
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

Disclosed is a light emitting diode lamp and a method for producing thereof, in which at least one light emitting diode is connected between at least a pair of conductive members at their upper end portions, the light emitting diode is embedded together with the conductive members in a molding of a light transmissible resin material, with the respective lower end portions of the conductive members being left exposed, and the respective exposed lower end portions of the conductive members are connected to a lamp base or cap and a contact member supported at the lower end of the lamp base or cap and insulated from the lamp base or cap.

Claims

1. A light emitting diode lamp comprising:

(A) a light emitting diode assembly unit including,

(a) at least three spaced apart conductive means, one of said conductive means being central to the remaining two conductive means, and two remaining conducive means having radially extending portions at their lower end portions;

(b) at least one light emitting diode element electrically connected between one of the outer of said conductive means and the central of said conductive means at their upper end portions;

(c) a molding of a light-transmissible material which embeds said light emitting diode element and the upper portions of said conductive means, leaving lower end portions of said conductive means exposed;

(B) a lamp cap or base assembly unit including,

(d) a substantially cylindrical cap or base member having openings at its axially opposite end portions, said light emitting diode assembly unit being attached to said cap or base unit so as to seal one of the opposite openings of said cap or base member with the exposed lower end portion of said remaining two conductive means, said remaining two conductive means electrically connected at said radially extending portions to the rim of said remaining opening of said cap or base member; and

(e) an electrical contact means supported by an electrical insulating member which seals the other opening of said cap or base member and insulates said contact means from said cap or base member, the exposed lower end portion of the central conductive means being electrically connected to said contact means.

2. A light emitting diode lamp according to claim 1, wherein said cap or base member is of the swan type.

3. A light emitting diode lamp according to claim 2, wherein the exposed lower end portion of said central conductive means is connected to said contact means through a resistor means.

4. A light emitting diode lamp according to claim 1, wherein said cap or base member is of the Edison type.

5. A light emitting diode lamp according to claim 4, wherein the exposed lower end portion of said central conductive means is connected to said contact means through a resistor means.

6. A method of producing a light emitting diode lamp comprising the steps:

electrically connecting at least one light emitting diode element between a central conductive means and at least one of two outer conductive means at their respective upper end portions, said two outer conductive means having at the lower end portions thereof a radially extending portion;

preparing a light emitting diode assembly unit by embedding said at least one light emitting diode element together with said upper end portions of said central conductive means and said two conductive means in a molding of a light transmissible resin material leaving lower end portions of said conductive means left exposed;

preparing a lamp cap or base assembly unit including a substantially cylindrical lamp cap or base member having openings at its axially opposite ends, one opening being sealed by an electrical insulator material which supports an electrical contact means and insulates said contact means from said cap or base member; and

electrically connecting the radially extending portions of said two lower conductive means end portions to the rim of said remaining opening of said cap or base member and said central conductive means to said contact means, respectively, with the other opening of said cap or base member being sealed by said light emitting diode assembly unit.

7. The method according to claim 6, in which the exposed lower portion of said central conductive means is connected through a resistor to said contact means.

8. The method according to claim 6, wherein the exposed lower end portion of said central conductive means is connected to said contact means through a resistor means.

9. A method of producing a light emitting diode lamp comprising the steps of:

electrically connecting at least two light emitting diode elements between a central one and one of the outer two of three conductive means which are aligned and extending parallel to each other, and between said central conductive means and the other outer conductive means, respectively, at their upper end portions the outer two of said conductive means having at a lower end thereof radially extending portions;

preparing a light emitting diode assembly unit by embedding said at least two light emitting diode elements together with said upper end portions of said three conductive means in a molding of a light transmissible resin material, with lower end portions of said three conductive means left exposed;

preparing a lamp cap or base assembly unit including a substantially cylindrical lamp cap or base member having openings at its axially opposite ends, one opening being sealed by an electrical insulating material which supports an electrical contact means and insulates said contact means from said cap or base member; and

electrically connecting the respective exposed lower radially extending end portions of said outer two conductive means to the top rim of said remaining opening of said cap or base member and the exposed lower end portion of said central conductive means to said contact means, with the other opening of said cap or base member being sealed by said light emitting diode assembly unit.

10. The method according to claim 9, wherein the exposed free end portion of said central conductive means is connected to said contact means through a resistor means.

11. A method of successively producing a plurality of light emitting diode lamps comprising the steps of:

preparing a train of serially connected plural sets of conductive means each extending perpendicularly from a linearly extending conductive connection means, each set including at least three parallel conductive means, the outer two of said conductive means having at a lower end thereof radially extending portions, by punching out from an electrically conductive sheet;

electrically connecting at least one light emitting diode element between respective free end portions of a central of said parallel conductive means and one of the remaining conductive means of each of said plural sets;

embedding said at least one light emitting diode element together with the respective free end portions of said at least three conductive means of each of said plural sets in a molding of a light-transmissible resin material, with lower end portions of said two conductive means and said connection means being left exposed;

cutting off connecting portions of said connection means between respective adjacent sets of conductive means to prepare a plurality of individual light emitting diode assembly units each including said at least one light emitting diode element and said at least two conductive means with their free lower ends exposed;

preparing a plurality of lamp cap or base assembly units of the same number as said plurality of light emitting diode assembly units, each of said lamp cap or base assembly units including a substantially cylindrical lamp case or base member having openings at its axially opposite ends, one opening being sealed by an electrical insulating material which supports an electrical contact means and insulates said contact means from said cap or base member; and

electrically connecting the exposed free end portions of said two outer conductive means radially extending portions of each of said light emitting diode assembly units to the rim of said remaining opening of said cap or base member and the remaining central conductive means to said contact means of corresponding one of said cap or base assembly units, with the other opening of said cap or base member being sealed by said light emitting diode assembly unit.

12. The method according to claim 11, wherein the exposed free end of the central one of said three conductive means is connected to said conductive means through a resistor means.

13. A method of successively producing a plurality of light emitting diode lamps comprising the steps of:

preparing a train of serially connected plural sets of conductive means, each extending perpendicularly from a linearly extending conductive connection means, each set including three aligned conductive means, the outer two of said conductive means having at the lower ends radially extending portions, by punching out from an electrically conductive sheet;

electrically connecting at least two light emitting diodes between a central conductive means and one of two outer conductive means, and between the central conductive means the other conductive means, respectively, at their respective free end portions, of each of said plural sets;

embedding said at least two light emitting diode elements together with the respective free end portions of said three conductive means of each of said plural sets in a molding of a light transmissible resin material, with lower end portions of said three conductive means and said connection means being left exposed;

cutting off connecting portions of said connection means between respective adjacent two conductive means to prepare a plurality of individual light emitting diode assembly units each including said at least two light emitting diode elements and said three conductive means with their free lower ends exposed;

preparing a plurality of lamp cap or base assembly units in the same number as said plurality of light emitting diode assembly units, each of said lamp cap or base assembly units including a substantially cylindrical lamp case or base member having openings at its axially opposite ends, one opening being sealed by an electrical insulator material which supports an electrical contact means and insulates said contact means from said cap or base member; and

electrically connecting the respective exposed radially extending portions of said outer two of said three conductive means to the rim of the remaining opening of said cap or base member, and the exposed free end portion of central one of said three conductive means to said contact means, of corresponding one of said cap or base assembly, with the other opening of said cap or base member being sealed by said light emitting diode assembly unit.