Note: Descriptions are shown in the official language in which they were submitted.
CA 02426529 2003-04-24
FLEXIBLE ROD LIGHT AND MANUFACTURING METHOD THEREOF
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to LED (Light Emitting Diode) means and more
particularly to a flexible rod light device containing a string of LED lamps
and
manufacturing method thereof.
2. Description of Related Art
A process of manufacturing a conventional flexible rod light is shown in FIG.
1. First, solder a terminal 2a of a LED lamp 2 to one end of a conductor
section
3. Next, pull the conductor section 3 to pass a side of the LED lamp 2. Then,
solder a terminal 2b of a second LED lamp 2 to the other end of the conductor
section 3. Then, repeat above three processes to~ form a string of LED lamps.
Next, put a continuous sleeve 1 around the string of LED lamps. Then, wrapping
the sleeve 1 with a plastic material (not shown) by extrusion to form a
jacket. As
a result, the flexible rod light is formed.
However, the prior art suffered from several disadvantages. For example,
there is no support means between any two adjacent LED lamps 2 with the
conductor section 3 bent therebetween. Further, the LED lamps 2 and the
conductor sections 3 tend to be stuck within the sleeve 1 during the
manufacturing process. This is particularly true when the sleeve 1 has a
length
longer than a predetermined one, resulting in an interrupt of the
manufacturing
process. In a less serious case, a distance between two adjacent LED lamps 2
may be different from that of another two adjacent LED lamps 2. And in turn,
the
already bent conductor section 3 is further bent or extended. As an end, a
desired configuration of equal spaced apart LEI) lamps 2 is not obtainable.
Consequently, a uniform light emitted from the light device is made
impossible.
Furthermore, an excessive pulling of one LED lamp 2 from an adjacent LED
lamp 2 may break the conductor section 3, thus disconnecting the electrical
connection of the light device. Also, LED lamps 2 tend to displace slightly in
the
sleeve 1, i.e., not reliably secured. As such, light emitted from a displaced
LED
Tamp 2 may not concentrate in a direction parallel tea, for example, X-Z
plane, i.e.,
being oblique relative to the X-Z plane.
Thus, it is desirable to provide an improved flexible rod light and
manufacturing method thereof in order to overcome the above drawbacks of the
prior art.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a flexible rod light
device
wherein light emitted from LED lamps can concentrate in a direction
perpendicular to the top surface thereof to thereby increase illumination.
It is another object of the present invention to provide a flexible rod light
device wherein a string of LED lamps enhances flexibility of the conductor
section when used.
!t is further object of the present invention to provide a flexible rod light
device wherein the components of LED lamps and resistors are protected from
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damage.
It is still further object of the present invention to provide a flexible rod
light
device wherein the LED lamps are readily fastened and installed when
assembling, and each of lamps has a same orientation.
It is still further object of the present invention to provide a flexible rod
light
device wherein a string of LED lamps and resistors is easily installed due to
flat
top and bottom surface of jacket.
In one aspect of the present invention to provide a flexible rod light device,
comprising a substantially H-shaped inner layer formed of a flexible elongate
transparent or half transparent plastic material and comprising lengthwise top
and bottom grooves and a plurality of equally spaced apart dents on the top
groove; a string of LED lamps comprising a plurality of series connected units
each including a LED lamp, two substantially 90 degrees bent conductor
sections with the LED lamp received in a substantially tt section of the
conductor
sections and electrically connected thereto by connecting terminals of the LED
lamp to one ends of adjacent conductor sections, and a resistor
interconnecting
the other end of the conductor section and the other end of the conductor
section
of an adjacent unit wherein straight portions of the conductor sections and
the
LED lamp of each unit are rested on the dent and two wing portions of the
conductor sections are rested on the top groove; a pair of main wires parallel
disposed in the inner layer proximate sides wherein front most and rearmost
conductor sections are rested on the main wires in front and rear sides of the
inner layer respectively; and a jacket, formed of the same material as the
inner
layer, wrapped up the inner layer and the string of LED lamps. By utilizing
this, a
number of advantages are obtained. For example, the LED lamps are fastened
and have the same orientation. Enhanced flexibility of the conductor sections
on,
for example, X-Y plane to withstand a pulling of the light. Protection
resistors
against damage. Easy installation is effected due to the flat top and bottom
surfaces of the jacket.
It is another aspect of the present invention to provide a method of
manufacturing a flexible rod light device comprising the steps of (a) wrapping
a
parallel pair of main wires in a substantially H-shaped inner layer formed of
a
flexible elongate plastic material proximate sides by molding; (b) soldering
one
end of a resistor to the other end of one conductor section and the other end
thereof to the other end of another adjacent conductor section and soldering
terminals of a LED lamp to one ends of the adjacent conductor sections for a
unit
including the LED lamp, two conductor sections, and the resistor; (c)
continuing
step (b) to form a string of LED lamps including a plurality of units; (d)
bending
the conductor sections of each unit and inserting straight portions of the
conductor sections and the LED lamp of each unit into one of a plurality of
dents
on a top of the inner layer with two wing portions of the conductor sections
rested
on a top groove of the inner layer; (e) disposing front most and rearmost
conductor sections on the main wire in front and rear sides of the inner layer
respectively; and (f) wrapping up the inner layer and the string of LED lamps
by
the same material as the inner layer by extruding to form a jacket.
The above and other objects, features and advantages of the present
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invention will become apparent from the following detailed description taken
with
the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of flexible rod light
according to the invention;
FIG. 2 is an exploded perspective view of the string of LED lamps and the
inner layer with the jacket removed for clarity;
FIG. 3 is a perspective view in part section of the assembled string of LED
lamps and the inner layer according to the invention;
FIG. 4 is a cross-sectional view of another embodiment of the flexible rod
light according to the invention;
FIG. 5 is a view similar to FIG. 4, showing still another embodiment of the
flexible rod light according to the invention;
I5 FIG. 6 is a side plan view of the light;
FIG. 6A is a view similar to FIG. f, showing another embodiment of the
jacket; and
FIG. 7 is a side view in part section for illustrating a process of
manufacturing a conventional flexible rod light.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1, 2 and 3, there is shown a flexible rod light device in
accordance with the invention. The light device comprises an inner layer 10, a
string of LED lamps 20, a pair of main wires 30 and 31, and a jacket 40. Each
of
above components will now be described in detail k>elow.
The inner layer 10 is a flexible elongate transparent (or half-transparent)
plastic material and comprises lengthwise grooves 12 and 14 on top and bottom
respectively and a plurality of equally spaced apart dents 11 on the groove
12.
Thus, a substantially H-shaped cross-section of the inner layer 10 is formed.
The
string of LED lamps 20 comprises a plurality of units each including a LED
lamp
21, two substantially 90 degrees bent conductor sections 23 with the LED lamp
21 received in a tJ section of the conductor sections 23 and electrically
connected thereto by connecting the terminals of the LED lamp 21 to one ends
of the adjacent conductor sections 23 by soldering, and a resistor 22
interconnecting the other end of the conductor section 23 and the other end of
the conductor section 23 of an adjacent unit by soldering. Thus, LED lamps 21
are series connected one by one. Further, straight portions of the conductor
sections 23 and the LED lamp 21 of each unit are rested on the dent 11 and two
wing portions of the conductor sections 23 are resi:ed on the top groove 12.
The
pair of main wires 30 and 31 are parallel disposed in the inner layer 10
proximate
the sides. A front most conductor section 230 is rested on the main wire 30 in
a
front side of the inner layer 10 by a tool. Likewise, a rearmost conductor
section
231 is rested on the main wire 31 in a rear side of the inner layer 10 by a
tool. As
such, the main wires 30 and 31 interconnect a power source (not sh~wn) and the
string of LED lamps 20 to form an electric circuit. The jacket 40, having the
same
plastic material as the inner layer 10, is formed to wrap up the inner layer
10 and
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the string of LED lamps 20 by extrusion. The jacket 40 has flat top and bottom
surfaces 41 and 42.
A process of manufacturing the flexible rod light device of the invention
comprises the steps of:
Step 1: Wrap the parallel pair of main wires 30 and 31 in the inner layer 10
proximate the sides by molding.
Step 2: Solder one end of the resistor 22 to the other end of one conductor
section 23 and the other end thereof to the other end of another adjacent
conductor section 23. Solder the terminals of the LED lamp 21 to one ends of
the
adjacent conductor sections 23. Continue above two sub-steps to form a string
of
LED tamps 20 including a plurality of units each including a LED lamp 21, two
conductor sections 23, and the resistor 22.
Step 3: Bend the conductor sections 23 of each unit and insert the straight
portions of the conductor sections 23 and the LED lamp 21 of each unit into
the
dent 11 with two wing portions of the conductor sections 23 rested on the top
groove 12.
Step 4: Dispose front most and rearmost ccmductor sections 230 on the
main wire 30 in front and rear sides of the inner layer 10 respectively by a
tool.
As such, the main wires 30 and 31 interconnect a power source (not shown) and
2Q the string of LED lamps 20 to form an electric circuit.
Step 5: Wrap up the inner layer 10 and the string of LED lamps 20 by a
plastic material the same as the inner layer 10 by extruding to form a jacket
40.
Referring to FIG. 4, there is shown another embodiment of the flexible rod
light wherein a plurality of slots 13 are formed in the inner layer 10 so that
an
excess length of conductor section 23 can be inserted into the slot 13. This
has
the benefit of permitting a pulling of the resistor 22 without disengaging the
conductor section 23 from the adjacent resistor 22 and the LED lamp 21.
Referring to FIG. 5, there is shown still another embodiment of the flexible
rod light wherein one or more dents 11 are used to receive one or more second
resistors having a large resistance 25. Moreover, an excess length of a
coupled
conductor section 23a can be inserted into the same dent 11 as the second
resistor 25. This also has the benefit of enhancing flexibility of the
conductor
section 23a.
Referring to FIG. 6, there is shown a side plan view of the light. A
smoothness of the top and bottom surface 41 and 42 of the jacket 40 can be
seen clearly. Also, light emitted from the LED lamp 21 (as indicated by arrow)
concentrates in a direction perpendicular to the top surface 41, thus
obtaining an
increased illumination.
Referring to FIG. 6A, there is shown another embodiment of the jacket 40
wherein a plurality of parallel troughs 410 and 42t) are formed on the top and
bottom surfaces 41 and 42 respectively.
Also, side surfaces 43 and 44 of the jacket 40 can be made flat. Thus, a
substantially rectangular or square cross-section of the light is obtained.
The benefits of this invention include: The LED lamps 21 are fastened and
have the same orientation. Enhanced flexibility of the conductor sections 23
on,
for example, X-Y plane. Protection resistors 22 against damage. Easy
installation
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due to the flat top and bottom surfaces 41 and 42 of the jacket 40. Light
emitted
from LED lamps 21 can concentrate in a direction perpendicular to the top
surface 41, i.e., increased illumination.
While the invention herein disclosed has been described by means of
specific embodiments, numerous modifications aind variations could be made
thereto by those skilled in the art without departing from the scope and
spirit of
the invention set forth in the claims.
