LED lamp assembly

• US 7,172,315 B2
• Filed: 02/25/2004
• Issued: 02/06/2007
• Est. Priority Date: 03/09/2000
• Status: Expired due to Fees

• Current Assignee: N.I.R., Inc.
• Original Assignee: Mongo Light Co., Inc.
• Inventors: Dinan, Michael E., Reinhold, Eugene P., Lamke, Isidore I., Plummer, Robert D.
• Primary Examiner(s): O'Shea; Sandra
• Assistant Examiner(s): Ton; Anabel
• Application Number:
  US10/787,494
• Publication Number:
  US 20040174705A1
• Time in Patent Office: 1,077 Days
• Field of Search: 362/226, 362/800, 362/249, 362/267, 362/310, 362/235, 362/240, 362/61, 362/241, 313/512, 445/22, 445/26, 257/25, 257/100
• 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 31/04 Provision of filling media
• 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 lens 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 housing.

Claims

1. A method for forming a lamp assembly, comprising:

providing a mold having a predetermined shape corresponding to the desired shape of said lamp assembly;

positioning a circuit board having a plurality of light emitting diodes (“

LEDs”

) mounted thereto in said mold;

filling the mold with a flowable lens material to immerse the LEDs within the material and such that the flowable lens material itself forms the exterior of the lamp assembly;

hardening the lens material such that the flowable material forming the exterior of the lamp assembly provides a rigid exterior of the lamp assembly; and

removing the lamp assembly from the mold;

reusing said mold for molding subsequent lamp assemblies.

2. The method of claim 1 further including the steps of adding a color pigment to the lens material.

3. The method of claim 2 further including the step of attaching an electrical connection to the light emitting diodes.

4. The method of claim 3 further including the step of placing the electrical connection in said mold.

5. The method of claim 4 wherein said LEDs are arranged in rows and columns.

6. The method of claim 5 wherein at least one LED emits a light color different from the other LEDs.

7. A method for forming a lamp assembly comprising:

providing a mold having a shape corresponding to the desired shape of said lamp assembly;

positioning a circuit board having a plurality of light emitting diodes (“

LEDs”

) mounted thereto in said mold;

filling the mold with a flowable lens material to immerse the LEDs and the circuit board within the material and such that the flowable lens material itself forms the exterior of the lamp assembly;

hardening the lens material such that the flowable material forming the exterior of the lamp assembly provides a rigid exterior of the lamp assembly; and

reusing said mold for molding subsequent lamp assemblies.

8. The method of claim 7 further including the steps of adding a color pigment to the lens material.

9. The method of claim 8 further including the step of attaching an electrical connection to the light emitting diodes.

10. The method of claim 9 further including the step of placing the electrical connection in said mold.

11. The method of claim 10 wherein said LEDs are arranged in rows and columns.

12. The method of claim 11 wherein at least one LED emits a light color different from the other LEDs.

13. A method for forming a lamp assembly comprising:

providing a mold corresponding to the desired shape of said lamp assembly;

positioning a plurality of light emitting diodes (“

LEDs”

) in said mold;

interconnecting the LEDs to an electrical lead;

filling the mold with a flowable lens material to immerse the LEDs within the material and such that the flowable lens material itself forms the exterior of the lamp assembly;

hardening the lens material such that the flowable material forming the exterior of the lamp assembly provides a rigid exterior of the lamp assembly; and

reusing said mold for molding subsequent lamp assemblies.

14. The method of claim 13 further including the steps of adding a color pigment to the lens material.

15. The method of claim 14 further including the step of attaching an electrical connection to the light emitting diodes.

16. The method of claim 15 further including the step of placing the electrical connection in said mold.

17. The method of claim 16 wherein said LEDs are arranged in rows and columns.

18. The method of claim 17 wherein at least one LED emits a light color different from the other LEDs.