Film encapsulated strand of lights

• US 6,945,669 B1
• Filed: 04/14/2003
• Issued: 09/20/2005
• Est. Priority Date: 04/14/2003
• Status: Active Grant

• Current Assignee: Randy D. Jester
• Original Assignee: Randy D. Jester
• Inventors: Jester, Randy D.
• Primary Examiner(s): Tso, Laura K.
• Application Number:
  US10/412,968
• Time in Patent Office: 890 Days
• Field of Search: 362/249, 362/267, 362/227, 362/235, 362/217, 362/223
• US Class Current: 362/227
• CPC Class Codes: F21S 4/20 with light sources held by or within elongate supports
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A method and apparatus providing improved Christmas tree lights. A strand of Christmas tree lights is encapsulated in a thin translucent film of polymer.

Claims

1. An encapsulated strand of lights comprising:

a plurality of insulated electric wires alongside one another,

a plurality of light emitting devices connected in current receiving relation to said wires at predetermined spaced intervals from one another, and

a folded strip of translucent polymer heat shrinkable film with a heat seal layer on the inside of the fold sealed and shrunk by heat tightly around said wires and light emitting devices in an encapsulating manner.

2. The encapsulated strand of claim 1 wherein said film has a thickness between 1 mm and 0.02 mm.

3. The encapsulated strand of claim 2 wherein said film has a thickness between 0.5 mm and 0.02 mm.

4. The encapsulated strand of lights of claim 1 wherein said light emitting devices are light emitting diodes.

5. The encapsulated strand of lights of claim 1 wherein said light emitting devices are elongated bulbs lying parallel to said wires.

6. A method of encapsulating a strand of lights in a translucent film comprising:

providing a strand of lights having a plurality of wires alongside one another and light emitting devices connected to said wires and positioned at spaced intervals to one another,

providing an extrusion die capable of extruding a tube of translucent molten polymer and having a central passageway permitting entry of a strand of lights to said tube as it is formed,

operating said extrusion die to form a tube of thin transparent molten polymer,

passing said strand of lights into said tube by linear movement simultaneous with the formation of said tube,

applying a vacuum to the interior of said tube, said linear movement of said strand and said application of said vacuum causing said tube to form tightly around said strand and

cooling said tube of molten polymer.

7. The method of claim 6 and further comprising adding a flame retardant to said polymer.

8. The method of claim 6 wherein said tube is colored.

9. An encapsulated strand of lights comprising:

a plurality of insulated electric wires alongside one another,

a plurality of light emitting devices connected in current receiving relation to said wires at predetermined spaced intervals from one another, and

a translucent polymer tape spiral wrapped with overlapping spirals and heat shrunk tightly around said wires and light emitting devices in an encapsulating manner, said tape having a heat seal layer on the inside of the spirals sealing said overlapping spirals to one another.