End cap substitute for LED-based tube replacement light

• US 8,444,292 B2
• Filed: 10/05/2009
• Issued: 05/21/2013
• Est. Priority Date: 10/24/2008
• Status: Active Grant

• Current Assignee: Ilumisys Incorporated (Altair Engineering Incorporated)
• Original Assignee: Ilumisys Incorporated (Altair Engineering Incorporated)
• Inventors: Ivey, John, Simon, David L
• Primary Examiner(s): Green, Tracie Y
• Application Number:
  US12/573,233
• Publication Number:
  US 20100103673A1
• Time in Patent Office: 1,324 Days
• Field of Search: 362/225, 362/217, 362/116
• US Class Current: 362/225
• CPC Class Codes: B29C 39/10 incorporating preformed parts or layers, e.g. casting around inserts or for coating articles coating a surface by casting in general B05D1/30, B29C39/126 takes precedence
• CPC Class Codes: B29L 2011/00 Optical elements, e.g. lenses, prisms
• CPC Class Codes: F21K 9/272 Details of end parts, i.e. the parts that connect the light source to a fitting; Arrangement of components within end parts F21K9/278 takes precedence
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21V 31/04 Provision of filling media
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 29/4973 Replacing of defective part
• CPC Class Codes: Y10T 29/49746 by applying fluent material, e.g., coating, casting

Abstract

Disclosed herein is a replacement light for a fluorescent tube usable in a fluorescent fixture. The light includes a housing having a first end and a second end opposite the first end. A support structure is disposed within the housing. At least one LED is positioned within the housing and is arranged on the support structure. A first seal has at least one aperture and is disposed within the first end of the housing. The first seal is configured to conform to an inner circumference of the first end of the housing. At least one electrical connector extends through the at least one aperture is and connectable to the fluorescent fixture.

Claims

1. A replacement light for a fluorescent tube usable in a fluorescent fixture, comprising:

a housing having a first end and a second end opposite the first end;

a support structure disposed within the housing;

at least one LED positioned within the housing and arranged on the support structure;

at least one electrical connector connected to the at least one LED; and

a first seal having at least one aperture shaped to receive the at least one electrical connector and disposed within the first end of the housing, the first seal configured to conform to an inner circumference of the first end of the housing and an outer surface of the at least one electrical connector

wherein the at least one electrical connector extends through the at least one aperture and is connectable to the fluorescent fixture.

2. The light of claim 1 wherein the at least one electrical connector is a first connector, further comprising:

a second seal having at least one aperture shaped to receive a second electrical connector and disposed within the second end of the housing, the second seal configured to conform to an inner circumference of the second end of the housing and an outer surface of the second electrical connector.

3. The light of claim 1, wherein the first seal is made of at least one of epoxy, rubber, cork, gel, concrete, glass, clay, wax, a polymer and silicone.

4. The light of claim 1, wherein the first seal has a perimeter that is substantially equal to the inner circumference of the first end.

5. The light of claim 1, wherein the housing has a cylindrical cross-section and the first seal is generally disc-shaped such that the first seal is configured to contact substantially the entire inner circumference of the first end.

6. The light of claim 1, wherein the first seal contacts only a portion of the inner circumference of the first end.

7. The light of claim 1, wherein the first seal has a proximal end and a distal end opposite the proximal end, the proximal end one of flush with the first end and outwardly protruding from the first end.

8. The light of claim 7, wherein the distal end has a groove configured to engage one end of the support structure.

9. The light of claim 1, wherein the at least one aperture is shaped to secure the at least one electrical connector by a friction fit.

10. The light of claim 1, further comprising:

a rubber O-ring disposed around and configured to insulate the at least one electrical connector.

11. A method of manufacturing a seal for a fluorescent tube replacement light for a fluorescent fixture containing at least one LED, comprising:

providing at least one electrical connector;

providing a housing having a first end and a second end opposite the first end;

introducing a hardenable material to at least the first end of the housing;

and hardening the hardenable material such that it conforms to an inner circumference of the first end and an outer surface of the at least one electrical connector to form at least one aperture; and

extending the at least one electrical connector through that at least on aperture.

12. The method of claim 11, wherein the hardenable material is one of an epoxy without a hardener, liquid concrete, a polymer heated to above its melting point and melted wax.

13. The method of claim 11, wherein introducing a hardenable material to the first end of the housing further comprises:

sealing the first end of the housing to a non-stick surface; and

pouring the hardenable material into the second end of housing.

14. The method of claim 13, further comprising:

forming at least one aperture into the hardened material of the first end of the housing;

sealing the second end of the housing to the non-stick surface; and

pouring the hardenable material into the at least one aperture; and

hardening the hardenable material so that it conforms to an inner circumference of the second end.

15. The method of claim 14, further comprising:

inserting the at least one electrical connector through the at least one aperture.

16. The method of claim 11, wherein introducing a hardenable material further comprises:

inserting the first end of the housing into a pool of the hardenable material.

17. The method of claim 16, wherein the housing includes a support structure disposed therein and the at least one electrical connector electrically engaged with the support structure, further comprising:

installing a sleeve over the at least one electrical connector.

18. The method of claim 11, wherein introducing a hardenable material further comprises:

packing the hardenable material into the first end of the housing.

19. A replacement light for a fluorescent tube usable in a fluorescent fixture, comprising:

a housing having a first end and a second end opposite the first end;

a support structure disposed within the housing;

at least one LED positioned within the housing and arranged on the support structure; and

sealing means for replacing a conventional end cap disposed within the first end of the housing wherein the sealing means includes at least one aperture shaped to receive at least one electrical connector.

20. The light of claim 19, further comprising:

at least one electrical connector extending through the sealing means and connectable to the fluorescent fixture.

21. A method of replacing a conventional end-cap for a fluorescent tube replacement light containing at least one LED, comprising;

providing a housing having a first end and a second end opposite the first end;

providing a first seal;

inserting the first seal into one of the first end and the second end of the housing; and

conforming the first seal at the first end in such a manner to include an apeature shaped for receiving at least one electrical connector.

22. The method of claim 21 wherein the first seal is configured to conform to an inner circumference of the first end of the housing.

23. The method of claim 21, further comprising:

forming at least one aperture into the first seal of the housing; and

inserting an electrical connector into the at least one aperture.

24. The method of claim 23, further comprising:

shaping the first seal prior to insertion into the housing.

25. The method of claim 24, wherein the first seal has a proximal end and a distal end opposite the proximal end, and wherein the first seal is shaped have a perimeter transitioning from slightly smaller at the proximal end than an inner circumference of the housing to slightly larger at the distal end than the inner circumference of the housing.

26. The method of claim 21, wherein the first seal is press-fit into the housing.