Method of manufacturing LED light string

• US 7,340,830 B2
• Filed: 10/28/2003
• Issued: 03/11/2008
• Est. Priority Date: 10/28/2003
• Status: Expired due to Fees

• Current Assignee: Li-Wen Liu, Wei-Jen Liu
• Original Assignee: Li-Wen Liu, Wei-Jen Liu
• Inventors: Liu, Wei-Jen, Liu, Li-Wen
• Primary Examiner(s): Till; Terrence R.
• Assistant Examiner(s): Zilberman; Jossef
• Application Number:
  US10/694,015
• Publication Number:
  US 20050086801A1
• Time in Patent Office: 1,596 Days
• Field of Search: 298/54, 298/29, 298/30, 298/76, 362/555, 362/249
• US Class Current: 29/854
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21S 4/10 with light sources attached to loose electric cables, e.g. Christmas tree lights
• CPC Class Codes: F21W 2121/04 for Christmas trees
• CPC Class Codes: F21Y 2107/40 on the sides of polyhedrons, e.g. cubes or pyramids
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01R 25/16 Rails or bus-bars provided with a plurality of discrete connecting locations for counterparts
• CPC Class Codes: H05K 1/148 Arrangements of two or more hingeably connected rigid printed circuit boards, i.e. connected by flexible means
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: Y10T 29/49124 On flat or curved insulated base, e.g., printed circuit, etc.
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/49208 by assembling plural parts

Abstract

A method of manufacturing LED light string includes the steps of forming an LED light body from multiple serially connected printed circuit boards, fixing the LED light body to a base, and connecting a light-transmissible shell to the light body to form a cluster lamp; preparing a power cord, to which multiple lamp sockets are serially connected; fitting multiple cluster lamps to the lamp sockets on the power cord, so that the LED light bodies are made to emit light. A lampshade is detachably engaged with each lamp socket. The lampshade and the lamp socket may be differently designed to create romantic feeling. The number of LED light bodies on each cluster lamp and the number of cluster lamps on one LED light string may be varied as desired to increase the brightness of the light string while reduce the manufacturing cost of the LED light string.

Claims

1. A method of manufacturing LED light string, comprising the steps of:

(a) Preparing a plurality of printed circuit boards that may be folded toward one another in a predetermined manner, each of said printed circuit boards being provided with a positive and a negative electrode that are in square and round shapes, respectively, to enable easy identification thereof, and two connecting legs being separately connected to one predetermined positive and one predetermined negative electrode for connecting to a base later;

(b) Folding said printed circuit boards to form a light body, disposing said light body into a light-transmissible shell, and then connecting said light body with said shell to a base to form a cluster lamp;

(c) Preparing a plurality of lamp sockets, into each of which one said cluster lamp may be inserted;

a plurality of conductors, each of which has two electrically terminals connected to two ends thereof;

a power cord, an end of which is provided with a connector having a plug end and a socket end; and

a plurality of top caps, each of which may be fitly closed to a rear bottom of each said lamp socket;

(d) Separately inserting said two terminals at two ends of each said conductor into two insertion holes on two adjacent lamp sockets, so that said a plurality of lamp sockets are serially connected; and

(e) Connecting a lampshade to an opening of each said lamp socket.

2. The method of manufacturing LED light string as claimed in claim 1, wherein the number of said printed circuit boards prepared in the step (a) for folding into one said light body in the step (b) may be two, three, five, or more than five, and wherein said light body formed from said folded printed circuit boards in the step (b) may have a configuration selected from the group consisting of rectangle, flat plane, semi-sphere, and sphere.

3. The method of manufacturing LED light string as claimed in claim 1, wherein the step (a) further includes mounting of LED chips of different light colors on said printed circuit boards, so that each of said light body formed in the step (b) is able to emit light showing more than one color.

4. The method of manufacturing LED light string as claimed in claim 1, wherein said base in the step (b) is externally provided at one side with an error protection groove, and said lamp socket prepared in the step (c) is internally provided with a rib corresponding to and adapted to engage with said error protection groove, so as to enable easy distinction said position electrode from said negative electrode during the manufacturing of said LED light string.

5. The method of manufacturing LED light string as claimed in claim 1, wherein said light-transmissible shell used in the step (b) is substantially round in shape, and defines an inner space that is adapted to fitly receive said light body therein and divides said light-transmissible shell into a plurality of convex lenses.

6. The method of manufacturing LED light string as claimed in claim 1, wherein each of said lamp sockets prepared in the step (c) is provided along an inner side close to an opening thereof with an annular groove, and each said lampshade used in the step (e) is provided along an outer side close to an opening thereof with an annular rib for fitly and firmly engaging with said annular groove of said lamp socket, preventing said lampshade from separating from said lamp socket.