Overmolded low voltage lamp assembly

• US 6,910,795 B2
• Filed: 04/18/2003
• Issued: 06/28/2005
• Est. Priority Date: 04/18/2003
• Status: Expired due to Fees

• Current Assignee: Tyco Electronics Canada ULC (TE Connectivity Limited)
• Original Assignee: Tyco Electronics Ltd. (TE Connectivity Limited)
• Inventors: Robichaud, Roger E., Luca, Dragos N., Du Pont, Ronal, Goto, Kazuhiro, Albino, Alan, Gyimes, Andras
• Primary Examiner(s): LEE, Y MY QUACH
• Application Number:
  US10/418,776
• Publication Number:
  US 20040208005A1
• Time in Patent Office: 802 Days
• Field of Search: 362/267, 362/391, 362/551, 362/554, 362/555, 362/556, 362/558, 362/562, 362/573, 362/574, 362/581, 362/583
• US Class Current: 362/555
• CPC Class Codes: B60Q 3/64 for a single lighting device
• CPC Class Codes: B60Q 3/78 for generating luminous strips, e.g. for marking trim component edges
• CPC Class Codes: F21L 14/02 capable of hand-held use, e.g. inspection lamps
• CPC Class Codes: F21V 15/01 Housings, e.g. material or assembling of housing parts F21V15/02 takes precedence housings forming signs or letters G09F13/04
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A low voltage lamp assembly includes a lamp housing having an illumination bore extending along an optical axis and that receives a light transmission member. A low voltage light source is situated within the bore and is axially aligned with the optical axis. A bushing is positioned within the bore and surrounds a portion of the light source. First and second wires extending from the lamp assembly for establishing an electrical connection to the light source. The wires are received by a strain relief pod separated from the lamp housing. The strain relief pod includes a current limiter therein.

Claims

1. A low voltage lamp assembly comprising:

a lamp housing having an optical axis and an illumination bore extending along said optical axis, said housing adapted for receiving a light transmission member; and

a low voltage light source situated within said bore and axially aligned with said optical axis, wherein said lamp housing constitutes an overmolded elastomer enclosing said light source and defining an alignment key extending from an outer surface thereof.

2. A lamp assembly in accordance with claim 1 wherein said light source comprises a light emitting diode.

3. A lamp assembly in accordance with claim 1 further comprising a bushing positioned within said bore and surrounding a portion of said light source.

4. A lamp assembly in accordance with claim 1 further comprising wires extending from said lamp assembly for establishing an electrical connection to said light source, being bonded to said lamp housing to create a seal therewith.

5. A lamp assembly in accordance with claim 1 further comprising wires extending from said lamp assembly for establishing an electrical connection to said light source, and a strain relief pod provided separate from said housing and bonded to said wires.

6. A lamp assembly in accordance with claim 1 further comprising a strain relief pod connected in series with said light source through a flexible wire.

7. A lamp assembly in accordance with claim 1 further comprising a current limiting resistor connected in series with said light source through an intermediate section of wire, said wire being flexible with respect to said housing.

8. A lamp assembly in accordance with claim 1 further comprising a strain relief pod distanced from said housing and attached in series with said light source through wires, said strain relief pod comprising a tube encasing overmolded portions of said wire.

9. A lamp assembly in accordance with claim 1 further comprising a color filter element disposed adjacent said low voltage light source.

10. A low voltage lamp assembly comprising:

a lamp housing comprising an illumination bore extending along an optical axis and adapted for receiving a light transmission member, said bore comprising a shelf;

a bushing situated within said bore, said bushing comprising a collar and sealingly engaged to said shelf; and

a low voltage light source situated within said bushing and axially aligned with said optical axis.

11. A low voltage lamp assembly in accordance with claim 10 wherein said light source comprises a light emitting diode.

12. A low voltage lamp assembly in accordance with claim 10 further comprising wires joining said light source with a strain relief pod separated from said lamp housing.

13. A low voltage lamp assembly in accordance with claim 10 further comprising a current limiter connected in series with said light source, said current limiter being held in strain relief pod located remote from said lamp housing.

14. A low voltage lamp assembly in accordance with claim 10, said lamp housing comprising an outer surface, said outer surface comprising an alignment key extending therefrom.

15. A distributed lighting assembly comprising:

at least one low voltage lamp assembly comprising a lamp housing, said lamp housing having a bore extending along an optical axis;

a light emitting diode situated within said bore and axially centered and aligned along said optical axis; and

a strain relief pod located remote from said housing, said strain relief pod comprising a current limiter therein connected in series with said light emitting diode.

16. A lighting assembly in accordance with claim 15 further comprising wires extending from said light emitting diode and coupled to respective contact leads extending therefrom, said wires being received in said strain relief pod, one of said wires being electrically coupled to said current limiter.

17. A lighting assembly in accordance with claim 16 wherein said lamp housing is overmolded upon said light emitting diode and bonded to said wires.

18. A lighting assembly in accordance with claim 15 wherein said strain relief pod comprises a rigid tube that is overmolded with a thermoplastic material.

19. A lighting assembly in accordance with claim 15 further comprising a light transmission member coupled to said lamp assembly and extending from said bore.