Substantially inseparable LED lamp assembly
First Claim
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1. A method of assembling a substantially inseparable LED lamp assembly from individual discrete components comprising:
- providing a lamp holder that is formed as an annulus with a first opening on a first end of said annulus and a second opening on a second end of said annulus;
substantially permanently securing a lamp cover to said first end of said annulus so that said lamp cover is substantially inseparable from said lamp holder and forms a watertight seal with said lamp holder;
providing an LED lamp having LED pin leads;
attaching wires directly to said LED pin leads of said LED lamp that have a predetermined size and a predetermined shape;
inserting said LED lamp through said second opening of said second end of said annulus to a position where said LED lamp is oriented to allow light from said LED lamp to be transmitted through said lamp cover;
substantially permanently attaching said LED lamp directly to said annulus so that said LED lamp is substantially inseparable from said annulus;
inserting a plug into said second opening of said second end of said annulus, said plug having indentations along an outer surface that substantially match said predetermined size and said predetermined shape of said wires so that said plug forms a watertight seal with said wires;
substantially permanently sealing said plug in said second opening to form a watertight seal at said second end of said annulus.
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Abstract
Disclosed are LED lamp assemblies that are substantially inseparable. The LED lamp assemblies use discrete components that are individually manufactured and then assembled in a manner that substantially prevents disassembly or disengagement of components. An interference fit can be used to substantially secure components of the LED lamp assemblies. Bonding techniques can also be used, including adhesive and solvent bonds, as well as thermal bonds, including sonic bonds.
212 Citations
39 Claims
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1. A method of assembling a substantially inseparable LED lamp assembly from individual discrete components comprising:
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providing a lamp holder that is formed as an annulus with a first opening on a first end of said annulus and a second opening on a second end of said annulus; substantially permanently securing a lamp cover to said first end of said annulus so that said lamp cover is substantially inseparable from said lamp holder and forms a watertight seal with said lamp holder; providing an LED lamp having LED pin leads; attaching wires directly to said LED pin leads of said LED lamp that have a predetermined size and a predetermined shape; inserting said LED lamp through said second opening of said second end of said annulus to a position where said LED lamp is oriented to allow light from said LED lamp to be transmitted through said lamp cover; substantially permanently attaching said LED lamp directly to said annulus so that said LED lamp is substantially inseparable from said annulus; inserting a plug into said second opening of said second end of said annulus, said plug having indentations along an outer surface that substantially match said predetermined size and said predetermined shape of said wires so that said plug forms a watertight seal with said wires; substantially permanently sealing said plug in said second opening to form a watertight seal at said second end of said annulus. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. An LED lamp assembly that is constructed of individual components that are separately fabricated and are assembled to provide a substantially inseparable LED lamp assembly comprising:
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a lamp holder that is shaped as an annulus, said annulus having a first opening on a first end and a second opening on a second end; a lamp cover substantially permanently attached to said first end of said annulus so that said lamp cover is substantially inseparable from said lamp holder and a watertight seal is formed between said lamp cover and said lamp holder; an LED lamp inserted through said second opening of said annulus and substantially permanently attached in said annulus so that said LED lamp is substantially inseparable from said lamp holder and forms a watertight seal with said lamp holder in a position that orients said LED lamp to allow light to be transmitted through said lamp holder, said LED lamp having LED lead pins attached to said LED lamp; wires that are conductively connected directly to said LED lead pins and extend through said second opening of said second end of said annulus, said wires having a predetermined size and shape; a plug having indentations along an outer surface that substantially match said predetermined size and shape of said wires, said plug substantially permanently inserted in said second opening to prevent disassembly of said LED lamp assembly and to create a watertight seal between said plug and said second opening in said annulus. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39)
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Specification