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Method of producing an LED hose light

  • US 6,857,924 B2
  • Filed: 06/03/2002
  • Issued: 02/22/2005
  • Est. Priority Date: 06/03/2002
  • Status: Expired due to Fees
First Claim
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1. A method of producing an LED hose light, said LED hose light including a core tube, a plurality of serially connected LED strings directly mounted on said core tube, an intermediate tube enclosing said core tube, and a transparent outer tube enclosing said intermediate tube, comprising the steps of:

  • producing said core tube by drawing a predetermined material into a desired tubular shape;

    cutting one side of said tubular shape to provide a longitudinal groove; and

    forming a plurality of recesses spaced along an opening of said groove;

    producing each of said LED strings by compressing a metal wire at different sections thereof;

    cutting each of said compressed sections into two plate electrodes;

    providing a chip on a first one of said two plate electrodes in each compressed section, and a lead wire on a second plate electrode to overlap a surface of said chip on said first plate electrode, so as to form a light emitting element on each said compressed section of said metal wire;

    positioning said plurality of light emitting elements in said recesses spaced on said core tube;

    using a transparent material to circumferentially enclose said core tube at positions having said recesses and said light emitting elements provided thereat;

    positioning said metal wire in said longitudinal groove while keeping said metal wire in a wavy line; and

    separately extending two outmost ends of said metal wire across a top of said opening of said longitudinal groove of said core tube;

    producing said intermediate tube by serially connecting a plurality of transparent hollow tubular sections to one another with two power cords that have different polarities and are embedded in two opposite sides of walls of said tubular sections, so that said two power cords are exposed from said intermediate tube at joints of any two said tubular sections that are adjacent to each other for said outmost ends of said metal wires of said LED strings to overlap thereat latter; and

    forming an axial opening at one side of the wall of each said tubular section to allow quick positioning of said core tube having said LED strings mounted thereon into said tubular sections of said intermediate tube via said axial openings;

    producing said outer tube with a transparent hollow tubular member that is made of a plastic material and dimensioned to enable easy extending of said intermediate tube therethrough;

    positioning said core tube having said LED strings mounted thereon into said tubular sections of said intermediate tube via said axial openings on said tubular sections to form an assembly of said core tube, said LED strings, and said intermediate tube; and

    overlapping said outmost ends of said metal wire of each said LED string with said power cords exposed from joints of said adjacent tubular sections of said intermediate tube; and

    extending said assembly of said core tube, said LED strings, and said intermediate tube through said outer tube, so as to enclose said assembly in said outer tube to form a complete LED hose light.

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