Various types of incandescent lights have been developed for use in a wide range of applications. For example, incandescent lights may be used for vehicle interior and/or exterior lighting. Incandescent vehicle lights are typically connected to a 12-volt DC power source.
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
With reference to
With further reference to
With further reference to
As described in detail in the 11/842,606 application, a relatively small amount of polymer material 20 is initially molded around the LED 6 and electrical components. Because a relatively small amount of polymer material 20 is initially formed around the LED 6 and electrical components, the pressures, forces, and/or temperatures to which these components are exposed can be controlled to avoid damage. The polymer material 20 formed during the first molding step thereby provides a protective envelope that encapsulates the electrical components to provide for one or more additional molding steps.
With further reference to
The second mold cavity (not shown) is configured to form an extension 25 that, in combination with the prongs 14 and 15, forms the first connector 3 that can be utilized to connect the light module 1 to a conventional plug-in type electrical receptacle. Transverse protrusions 16 and 17 (see also
With further reference to
The light modules 1 and 40 of the present invention provide an LED light module that can be connected to a conventional incandescent receptacle or ¼-turn connector. The light modules 1 and 40 include a circuit that provides the proper voltage and current to drive the LEDs from a 12-volt DC or 120-volt AC power source, such that additional circuits or the like are not required to power the LED light. Furthermore, because the LED, electrical circuit elements, and electrical components are substantially encapsulated in the polymer material, the polymer material substantially protects the LED and/other electrical components from ambient moisture and the like.
With further reference to
With further reference to
With further reference to
After the first polymer material 60 (
With further reference to
During fabrication of base 71 of light assembly 70, a metal circuit 85 (
One or more additional molding shots are then utilized to form a one-piece polymer layer or body 96 of the base 71 as shown in
In addition to the bulb/connectors described above in connection with
In general, in each case the light module may be formed utilizing conductors forming a lattice such as the metal lattice 10 described in more detail above in connection with
In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.
This application claims the benefit of U.S. Provisional Application No. 61/019,988, filed on Jan. 9, 2008, entitled LIGHT MODULE, the entire contents of which are incorporated herein by reference.
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