LED lamp assembly

• US 6,793,371 B2
• Filed: 11/01/2001
• Issued: 09/21/2004
• Est. Priority Date: 03/09/2000
• Status: Expired due to Fees

• Current Assignee: N.I.R., Inc.
• Original Assignee: Mongo Light Co., Inc.
• Inventors: Figura, John, Narzinski, Matt, Dinan, Michael E., Reinhold, Eugene P., Plummer, Robert D., Lamke, Isadore I.
• Primary Examiner(s): TON, ANABEL
• Application Number:
  US10/003,845
• Publication Number:
  US 20020089849A1
• Time in Patent Office: 1,055 Days
• Field of Search: 362/235, 362/800, 362/249, 362/240, 362/241, 362/247
• US Class Current: 362/241
• CPC Class Codes: B60Q 1/2696 Mounting of devices using LEDs
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21V 15/00 Protecting lighting devices from damage protection from thermal damage F21V29/00; gas-tight or water-tight arrangements F21V31/00
• CPC Class Codes: F21V 31/04 Provision of filling media
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 25/13 the devices being of a type provided for in group H01L33/00
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A lamp finding particular application in boat trailers and other vehicular applications is provided with a generally unbreakable lamp structure. The lamp preferably is provided with a plurality of LEDs arranged with rows and columns on a circuit card or board. The lamp is constructed by encapsulating the board and LED arrangement in a moldable lens material, which after removal from a suitable mold at least partially defines the lamp body.

Claims

1. A lamp assembly comprising:

a support circuit board, the circuit board having a first side and a second side, the circuit board defining at least one aperture for communication between the first and second sides of the circuit board;

a plurality of light emitting diodes mounted to the circuit board;

an electrical connection attached to the circuit board and extending outwardly of the lamp assembly;

a mold in place lens formed from material flowable about the circuit board and through the at least one aperture to encapsulate the circuit board and light emitting diodes, to provide a one-piece solid body about said circuit board and light emitting diodes, said solid body being formed into a predetermined shape defining said lamp assembly, the electrical connection extending outwardly of the lens assembly, said body and said lens being formed from the same material.

2. The lamp assembly of claim 1 wherein the circuit board defines a plurality of apertures, the apertures positioned to prevent gasses from being trapped within the material during formation of the mold in place lamp assembly.

3. The lamp assembly of claim 2 wherein the circuit board has a reflector attached thereto.

4. The lamp assembly of claim 3 wherein the circuit board has a plurality of reflector attached thereto.

5. The lamp assembly of claim 1 wherein the LEDs are positioned and arranged in rows and columns.

6. The lamp assembly of claim 5 wherein at lease one of the rows of LEDs emit light having a color different from at least another row of the LEDs.

7. The lamp assembly of claim 6 wherein the lens material has at least one opening formed in it for permitting attachment of the lamp assembly to another structure.

8. The lamp assembly of claim 1 wherein the lamp assembly withstands a force of at least 30 ft.lbs.per square inch of force without damage.

9. A lamp assembly comprising:

a housing formed from a moldable translucent material;

a lens defined by the moldable, translucent material forming the lamp assembly;

a light emitting unit attached to a circuit board wherein the circuit board has been molded within the material, the circuit having at least one aperture formed in it for permitting flow of the translucent material through the circuit board; and

electrical leads attached to circuit board that extend through the material to allow electrical connection to the circuit board, the housing and lens being formed from the same moldable, translucent material, the material defining a predetermined shape for the lamp assembly.

10. The lamp assembly of claim 9 wherein the circuit board has reflector attached thereto.

11. The lamp assembly of claim 10 wherein the circuit board has a plurality of reflectors attached thereto.

12. The lamp assembly of claim 9 wherein the circuit board defines a plurality of apertures positioned to prevent gasses being trapped with the material.

13. The lamp assembly of claim 9 wherein the light emitting unit comprises a plurality of light emitting unit comprising light emitting diodes (LEDs).

14. The lamp assembly of claim 13 wherein the LEDs are positioned and arranged in rows and columns.

15. The lamp assembly of claim 14 wherein at least a portion of one of the rows of LEDs emits light having a color different from at least a portion of another row of the LEDs.

16. The lamp assembly of claim 9 wherein the lens material has at last one opening formed in it for permitting attachment of the lamp assembly to another structure.

17. The lamp assembly of claim 9 wherein the lens material can withstand a force of at least 30ft.lbs.per square inch without damage.

18. A lamp assembly comprising;

a housing;

a circuit board defining a plurality of apertures;

a light emitting unit connected to the circuit board; and

a lens formed from a moldable lens material, said lens material flowable through the aperture plurality;

wherein the circuit board and light emitting unit is submerged within the moldable lens material before hardening and the moldable lens material allowed to harden, such that the circuit board and light emitting unit are encased within the moldable lens material in the substantial absence of air, the housing and lens being formed from the same material, the material defining a predetermined shape for the housing.

19. The lamp assembly of claim 18 wherein the light emitting unit comprise a light emitting diode.