LIGHTING APPARATUS AND METHOD OF MANUFACTURE

• US 20100014308A1
• Filed: 07/15/2008
• Published: 01/21/2010
• Est. Priority Date: 07/15/2008
• Status: Abandoned Application

• Current Assignee: Triplex Manufacturing Co.
• Original Assignee: Triplex Manufacturing Co.
• Inventors: Katz, Paul, Robin, Gary, Heidegger, Michael
• Application Number:
  US12/173,071
• Publication Number:
  US 20100014308A1
• Time in Patent Office: Days
• US Class Current: 362/545
• CPC Class Codes: B29C 45/14 incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles B29C45/1671 takes precedence
• CPC Class Codes: B29L 2031/747 Lightning equipment
• CPC Class Codes: B60Q 1/2696 Mounting of devices using LEDs
• 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 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21S 43/195 Details of lamp holders, terminals or connectors
• CPC Class Codes: F21S 45/50 Waterproofing
• CPC Class Codes: F21V 19/005 by permanent fixing means, e.g. gluing, riveting or embedding in a potting compound
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 31/00 Gas-tight or water-tight arrangements
• CPC Class Codes: F21V 31/04 Provision of filling media
• CPC Class Codes: F21W 2106/00 Interior vehicle lighting devices
• 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]

Abstract

A lighting subassembly includes at least one light emitting device, a solid, light transmitting material, and a mating arrangement. The solid, light-transmitting material at least partially surrounds the at least one light emitting device. The mating arrangement communicates with the solid, light transmitting material and is configured to be attachable to a corresponding base assembly. In some examples, the lighting subassembly further includes a frame and the frame is integral with the solid, light-transmitting material.

Claims

1. A lighting apparatus, comprising:

a lighting subassembly including at least one light emitting device that is embedded in a solid, light-transmitting material, the at least one light emitting device and the solid, light-transmitting material forming a separate and distinct structure;

an electrical coupler configured and arranged to supply energy to the at least one light emitting device from an energy source;

a base portion attached to the lighting subassembly;

a lens portion coupled to the base portion and at least partially covering the lighting subassembly.

2. The lighting apparatus of claim 1 wherein the lighting subassembly further comprises a frame, the frame being integral with the solid, light-transmitting material.

3. The lighting apparatus of claim 1 wherein the at least one light emitting device comprises at least one light emitting diode (LED).

4. The lighting apparatus of claim 1 wherein the lighting apparatus is configured and sized to be disposed in a vehicle.

5. The lighting apparatus of claim 1 wherein the lighting apparatus is configured to be a lamp selected from a group consisting of:

an out door lighting device;

a clearance lamp;

a stopping lamp;

a tail lamp;

a back-up lamp;

a turning lamp;

a utility lamp;

a reading lamp;

a license plate lamp; and

an interior lamp.

6. The lighting apparatus of claim 1 wherein the lighting subassembly further includes a printed circuit board that is embedded in the solid, light-transmitting material and wherein the at least one light emitting device is coupled to the printed circuit board.

7. The lighting apparatus of claim 1 wherein the assembled lens portion and base portion provide a seal to prevent intrusion of external environmental elements from entering the lighting apparatus.

8. The lighting apparatus of claim 1 wherein the solid, light-transmitting material comprises a resin.

9. A method of manufacturing a lighting apparatus comprising:

providing at least one light emitting device, a base portion, and a lens portion;

positioning the at least one light emitting device in a mold;

injecting the mold with a formable material to form a single-piece subassembly that includes and is formed around the at least one light emitting device;

curing the single-piece subassembly;

removing the single-piece subassembly from the mold;

attaching the subassembly to the base portion; and

attaching the lens portion to the base portion such that the lens portion at least partially covers the subassembly.

10. The method of claim 9 further comprising providing a frame and positioning the light emitting device so as to be secured by the frame.

11. The method of claim 9 further comprising coupling an electrical connector to the light emitting device and extending the connector through the base portion and from the subassembly.

12. The method of claim 9 wherein providing the at least one light emitting device comprises providing at least one light emitting device on a printed circuit board.

13. The method of claim 9 further comprising installing the completed lighting apparatus within or on a vehicle.

14. The method of claim 13 wherein the lighting apparatus is configured to operate as a lamp selected from a group consisting of:

a clearance lamp;

a stopping lamp;

a tail lamp;

a back-up lamp;

a turning lamp;

a utility lamp;

a reading lamp;

a license plate lamp; and

an interior lamp.

15. A vehicular lighting apparatus comprising:

a base portion;

a lighting subassembly coupled to the base portion, the lighting subassembly being formed of a solid, light-transmitting material surrounding an embedded printed circuit board, the embedded printed circuit board including at least one light emitting device;

an electrical coupler coupled to the printed circuit board and configured and arranged to supply energy to the printed circuit board from a vehicular power source;

a lens portion, the lens portion attached to the base portion and at least partially covering the lighting subassembly; and

wherein the vehicular lighting apparatus is configured and sized to be disposed within or on a vehicle.

16. The vehicular lighting apparatus of claim 15 wherein the lighting subassembly further comprises a frame, the frame being integral with the solid, light-transmitting material.

17. The vehicular lighting apparatus of claim 15 wherein the vehicular lighting apparatus is configured and arranged to be used as a vehicular lamp selected from a group consisting of:

a clearance lamp;

a stopping lamp;

a tail lamp;

a back-up lamp;

a turning lamp;

a utility lamp;

a reading lamp;

a license plate lamp; and

an interior lamp.

18. The vehicular lighting apparatus of claim 15 wherein the assembled lens portion and base portion provide a seal to at least partially prevent the intrusion of external environmental elements into the lighting apparatus.

19. The vehicular lighting apparatus of claim 15 wherein the solid, light-transmitting material comprises a resin.

20. A lighting subassembly, comprising:

at least one light emitting device;

a solid, light-transmitting material that at least partially surrounds the at least one light emitting device; and

a mating arrangement, the mating arrangement communicating with the solid, light transmitting material, the mating arrangement configured to be attachable to a corresponding base assembly.

21. The lighting subassembly of claim 20 further comprising a frame, the frame being integral with the solid, light-transmitting material.

22. The lighting subassembly of claim 20 wherein the at least one light emitting device comprises at least one light emitting diode (LED).

23. The lighting subassembly of claim 20 wherein the lighting subassembly is configured to be disposed within a lamp selected from a group consisting of:

an out door lighting device, a clearance lamp;

a stopping lamp;

a tail lamp;

a back-up lamp;

a turning lamp;

a utility lamp;

a reading lamp;

a license plate lamp; and

an interior lamp.

24. The lighting subassembly of claim 20 further comprising a printed circuit board that is embedded in the solid, light-transmitting material and wherein the at least one light emitting device is coupled to the printed circuit board.

25. The lighting subassembly of claim 20 wherein the solid, light-transmitting material comprises a resin.