Electrical device having boardless electrical component mounting arrangement
First Claim
Patent Images
1. A light assembly, comprising:
- a sheet metal circuit including at least two electrically conductive circuit elements, each circuit element defining opposite side surfaces;
at least one LED electrically connected to the circuit elements;
at least one electrical component electrically connected to the circuit elements, wherein the one electrical component is selected from the group consisting of a resistor, a diode, a zener diode, a transistor, an integrated circuit, a capacitor, an inductor, a transient voltage suppressor, and a metal oxide varister; and
wherein the electrical component is capable of affecting at least one of the voltage and electrical current supplied to the LED;
a one-piece body comprising thermoplastic polymer material encasing the LED, the one electrical component, and at least a portion of the opposite side surfaces of the circuit elements;
the metal circuit includes at least two cantilevered prongs formed integrally with the electrically conductive circuit elements, the prongs having exposed metal protruding from the thermoplastic polymer material forming the one-piece body, and wherein the thermoplastic polymer material forming the one-piece body includes a cavity having an open end to thereby form a receptacle around the exposed metal of the prongs.
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Accused Products
Abstract
An electrical device such as an LED light assembly includes a conductive circuit and one or more electrical components connected to the circuit. The electrical components and the circuit are at least partially overmolded with a thermoplastic polymer material to encapsulate the components. The material utilized to cover the circuit and/or electrical components may also be utilized to form a housing or other structure of a finished part.
298 Citations
36 Claims
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1. A light assembly, comprising:
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a sheet metal circuit including at least two electrically conductive circuit elements, each circuit element defining opposite side surfaces; at least one LED electrically connected to the circuit elements; at least one electrical component electrically connected to the circuit elements, wherein the one electrical component is selected from the group consisting of a resistor, a diode, a zener diode, a transistor, an integrated circuit, a capacitor, an inductor, a transient voltage suppressor, and a metal oxide varister; and
wherein the electrical component is capable of affecting at least one of the voltage and electrical current supplied to the LED;a one-piece body comprising thermoplastic polymer material encasing the LED, the one electrical component, and at least a portion of the opposite side surfaces of the circuit elements; the metal circuit includes at least two cantilevered prongs formed integrally with the electrically conductive circuit elements, the prongs having exposed metal protruding from the thermoplastic polymer material forming the one-piece body, and wherein the thermoplastic polymer material forming the one-piece body includes a cavity having an open end to thereby form a receptacle around the exposed metal of the prongs.
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2. A light assembly, comprising:
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a sheet metal circuit including at least two electrically conductive circuit elements, each circuit element defining opposite side surfaces; at least one LED electrically connected to the circuit elements; at least one electrical component electrically connected to the circuit elements, wherein the one electrical component is selected from the group consisting of a resistor, a diode, a zener diode, a transistor, an integrated circuit, a capacitor, an inductor, a transient voltage suppressor, and a metal oxide varister; and
wherein the electrical component is capable of affecting at least one of the voltage and electrical current supplied to the LED;a one-piece body comprising thermoplastic polymer material encasing the LED, the one electrical component, and at least a portion of the opposite side surfaces of the circuit elements; and
wherein;the polymer material forms a mounting flange having at least one opening therethrough configured to receive a fastener to mount the light assembly. - View Dependent Claims (3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A light assembly, comprising:
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a metal circuit including at least two electrically conductive circuit elements including opposite side surfaces and opposite edge surfaces extending between the opposite side surfaces and wherein the opposite edge surfaces are spaced-apart to define a plurality of gaps between the opposite edge surfaces; at least one LED electrically connected to the circuit elements and spanning a first one of the gaps; at least one electrical component electrically connected to the circuit elements and spanning a second gap, wherein the electrical component is capable of affecting at least one of the voltage and electrical current supplied to the LED; and a one-piece body comprising thermoplastic polymer material encasing the LED and the one electrical component, wherein the thermoplastic polymer material of the one-piece body is in contact with portions of both of the opposite side surfaces of each circuit element. - View Dependent Claims (14, 15, 16)
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17. A light assembly, comprising:
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a circuit including at least two electrically conductive circuit elements defining an outer peripheral edge portion and a central portion, wherein the electrically conductive circuit elements are spaced apart to define at least one gap in the central portion of the circuit, each circuit element defining first and second opposite side surfaces; at least one LED electrically connected to the circuit elements; at least one electrical component electrically connected to the circuit elements, wherein the one electrical component is capable of affecting at least one of the voltage and electrical current supplied to the LED; a one-piece body comprising thermoplastic polymer material encasing the LED, the one electrical component, and at least a portion of the opposite side surfaces of the circuit elements, the one-piece body including a first portion covering at least a portion of the first opposite side surfaces of the circuit elements, and a second portion covering at least a portion of the second opposite side surfaces of the circuit elements, and wherein the first and second portions of the one-piece body are interconnected by thermoplastic polymer material extending through the one gap in the central portion of the circuit. - View Dependent Claims (18)
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19. A light assembly, comprising:
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a metal circuit including at least two electrically conductive circuit elements, at least a portion of the two circuit elements defining metal upper and lower opposite side surfaces that are spaced-apart a first distance, and edge surfaces extending transversely between the upper and lower opposite side surfaces a second distance that is substantially less than the first distance; at least one LED electrically connected to the circuit elements; at least one electrical component electrically connected to the circuit elements, wherein the one electrical component is selected from the group consisting of a resistor, a diode, a zener diode, a transistor, an integrated circuit, a capacitor, an inductor, a transient voltage suppressor, and a metal oxide varister; and
wherein the electrical component is capable of affecting at least one of the voltage and electrical current supplied to the LED;a one-piece body comprising thermoplastic polymer material encasing the LED, the one electrical component, and at least a portion of the opposite side surfaces of the circuit elements, and wherein at least some of the thermoplastic polymer material of the one-piece body contacts the upper and lower metal opposite side surfaces of the circuit elements. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33)
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34. A light assembly, comprising:
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a sheet metal circuit including at least two electrically conductive circuit elements, each circuit element defining opposite side surfaces; a plurality of LEDs electrically connected to the circuit elements; at least one electrical component electrically connected to the circuit elements, wherein the one electrical component is selected from the group consisting of a resistor, a diode, a zener diode, a transistor, an integrated circuit, a capacitor, an inductor, a transient voltage suppressor, and a metal oxide varister; and
wherein the electrical component is capable of affecting at least one of the voltage and electrical current supplied to the LEDs;a one-piece body comprising thermoplastic polymer material encasing the LEDs, the one electrical component, and at least a portion of the opposite side surfaces of the circuit elements; and
wherein;the thermoplastic polymer material forming the one-piece body includes raised outer surface portions forming a plurality of discrete protrusions over at least some of the LEDs. - View Dependent Claims (35, 36)
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Specification