Light emitting diode light bar module with electrical connectors formed by injection molding
First Claim
1. A method of forming an electrical connector of a light emitting diode (LED) light bar comprising:
- determining a coefficient of thermal expansion (CTE) of materials of a heat sink, wherein the heat sink has a channel with an opening;
selecting injection molding materials having a CTE that is substantially the same as the CTE of materials of the heat sink;
placing the opening of the channel of the heat sink into an injection mold;
clamping a set of conductor pins into the injection mold at the opening of the channel of the heat sink;
injecting the injection molding materials in molten state into the injection mold to fill cavities between the set of conductor pins and the heat sink;
allowing the injection molding materials to solidify inside the injection mold to form the electrical connector, wherein the electrical connector includes the injection molding materials and the set of conductor pins surrounded radially by the injection molding materials; and
removing the electrical connector and the heat sink from the injection mold.
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Accused Products
Abstract
The present disclosure relates to methods for fabricating electrical connectors of a waterproof connector-heat sink assembly of a LED light bar module using injection molding. The methods include matching the coefficient of thermal expansion (CTE) of injection molding materials for the connectors and heat sinks. A heat sink and conductor pins are inserted into an injection mold and the injection molding materials are injected into the injection mold. An integrated connector-heat sink assembly is formed when the injection molding materials of the connectors form a waterproof seal with the heat sink when the injection molding materials solidify. Placement of the heat sink and conductor pins inside the injection mold is controlled to ensure that adhesive bonding between the injection molding materials and the heat sink is stronger than a maximum shear force.
9 Citations
16 Claims
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1. A method of forming an electrical connector of a light emitting diode (LED) light bar comprising:
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determining a coefficient of thermal expansion (CTE) of materials of a heat sink, wherein the heat sink has a channel with an opening; selecting injection molding materials having a CTE that is substantially the same as the CTE of materials of the heat sink; placing the opening of the channel of the heat sink into an injection mold; clamping a set of conductor pins into the injection mold at the opening of the channel of the heat sink; injecting the injection molding materials in molten state into the injection mold to fill cavities between the set of conductor pins and the heat sink; allowing the injection molding materials to solidify inside the injection mold to form the electrical connector, wherein the electrical connector includes the injection molding materials and the set of conductor pins surrounded radially by the injection molding materials; and removing the electrical connector and the heat sink from the injection mold. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 14)
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9. A method of forming an electrical connector of a light emitting diode (LED) light bar module comprising:
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selecting a heat sink, wherein the heat sink has a channel with an opening; selecting injection molding materials, wherein the injection molding materials are waterproof; placing the opening of the channel of the heat sink into an injection mold; clamping a set of conductor pins into the injection mold at the opening of the channel of the heat sink; injecting the injection molding materials in molten state into the injection mold to fill cavities between the set of conductor pins and the heat sink to form the electrical connector, wherein the electrical connector includes the injection molding materials and the set of conductor pins surrounded radially by the injection molding materials; forming a waterproof seal between the injection molding materials and the channel of the heat sink by allowing the injection molding materials to solidify; and removing the electrical connector and the heat sink from the injection mold. - View Dependent Claims (10, 11, 12, 13, 15, 16)
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Specification