Jacketed LED assemblies and light strings containing same
A jacketed light emitting diode assembly is provided, which includes a light emitting diode including a set of positive and negative contacts, and a lens body containing a semiconductor chip and end portions of the contacts. An electrical wire set of first and second electrical wires are connected to the positive contact and the negative contact, respectively. A light transmissive cover receives the lens body, and has an opening through which at least one of the contact set and the electrical wire set passes. An integrally molded plastic jacket at the opening of the light transmissive cover provides a seal at the opening against moisture and airborne contaminants. A waterproof light string including one or more of the jacketed light emitting diode assemblies is also provided, as are related methods.
1 . A jacketed light emitting diode assembly, comprising:
a light emitting diode comprising
a contact set comprising a positive contact and a negative contact, each of the contacts having a first end portion and a second end portion; and
a lens body containing a semiconductor chip and the first end portions of the positive and negative contacts;
an electrical wire set comprising a first electrical wire and a second electrical wire electrically connected to the second end portions of the positive contact and the negative contact, respectively;
a light transmissive cover having a cavity with an opening, the cavity receiving the lens body, the opening having at least one of the contact set and the electrical wire set passing therethrough; and
an injection molded thermoplastic jacket sealing and encasing the opening of the light transmissive cover to provide a seal at the opening against moisture and airborne contaminants;
wherein the jacket is formed in a single molding operation; and
wherein the light transmissive cover is at least partially encased by the injection molded thermoplastic jacket.
2 . A jacketed light emitting diode assembly according to claim 1 , wherein electrically connected portions of the contact set and the electrical wire set are directly encased by the injection molded thermoplastic jacket to provide a seal against moisture and airborne contaminants.
3 . A jacketed light emitting diode assembly according to claim 1 , wherein the electrical wire set passes through the opening, and wherein the injection molded plastic jacket encases respective regions of the electrical wire set passing through the opening.
4 . A jacketed light emitting diode assembly according to claim 1 , wherein the contact set passes through the opening, and wherein the injection molded thermoplastic jacket encases electrical connections between the contact set and the electrical wire set.
5 . A jacketed light emitting diode assembly according to claim 1 , wherein the injection molded thermoplastic jacket comprises at least one of polycarbonate, polystyrene, and other moldable thermoplastic material.
6 . A jacketed light emitting diode assembly according to claim 1 , wherein the injection molded thermoplastic jacket comprises a thermoplastic selected from poly(vinyl chloride).
7 . A jacketed light emitting diode assembly according to claim 1 , wherein the injection molded thermoplastic jacket comprises polypropylene.
8 . A jacketed light emitting diode assembly according to claim 1 , wherein the contact set and/or the electrical connections and/or a portion of the electrical wire set are separated by a contact separator to isolate them during the molding operation.
9 . A method for making a jacketed light emitting diode assembly, comprising:
providing a light emitting diode comprising a positive contact and a negative contact of a contact set, each of the contacts having a first end portion and a second end portion, and a lens body containing a semiconductor chip and the first end portions of the positive and negative contacts;
electrically connecting a first electrical wire and a second electrical wire of an electrical wire set to the second end portions of the positive contact and the negative contact, respectively;
inserting the light emitting diode through an opening and into a cavity of a light transmissive cover, the opening having at least one of the contact set and the electrical wire set passing therethrough; and
injection molding a thermoplastic jacket integrally at the opening of the light transmissive cover to provide a seal at the opening against moisture and airborne contaminants.
10 . A method according to claim 9 , wherein electrically connected portions of the contact set and the electrical wire set are encased by the injection molded plastic jacket to provide a seal against moisture and airborne contaminants.
11 . A method according to claim 9 , wherein the electrical wire set passes through the opening, and wherein the plastic jacket encases respective regions of the electrical wire set passing through the opening.
12 . A method according to claim 9 , wherein the contact set passes through the opening, and wherein the plastic jacket encases electrical connections between the contact set and the electrical wire set.
13 . A method according to claim 9 , wherein the plastic jacket comprises at least one of polycarbonate, polystyrene, or other moldable thermoplastic material.
14 . A method according to claim 9 , wherein the plastic jacket comprises a thermoplastic selected from poly(vinyl chloride).
15 . A method according to claim 9 , wherein the thermoplastic jacket comprises polypropylene.
16 . A method according to claim 9 , wherein the light transmissive cover is at least partially encased by the integrally molded plastic jacket.
17 . A method according to claim 9 , wherein the light transmissive cover is not a portion of the thermoplastic jacket seal.
18 . A light string comprising a plurality of light emitting diode assemblies connected to one another, the light emitting diode assemblies comprising a plurality of jacketed light emitting diode assemblies, comprising:
a light emitting diode comprising
a contact set comprising a positive contact and a negative contact, each of the contacts having a first end portion and a second end portion; and
a lens body containing a semiconductor chip and the first end portions of the positive and negative contacts;
an electrical wire set comprising a first electrical wire and a second electrical wire electrically connected to the second end portions of the positive contact and the negative contact, respectively;
a light transmissive cover having a cavity with an opening, the cavity receiving the lens body, the cavity having at least one of the contact set and the electrical wire set passing therethrough; and
an injection molded thermoplastic jacket at the opening of the light transmissive cover to provide a seal at the opening against moisture and airborne contaminants along a length of the light string.
wherein the jacket is formed in a single molding operation; and
wherein the light transmissive cover is at least partially encased by the injection molded thermoplastic jacket.
19 . A light string according to claim 18 , wherein electrically connected portions of the contact set and the electrical wire set are encased by the injection molded thermoplastic jacket to provide a seal against moisture and airborne contaminants.
20 . A light string according to claim 18 , wherein the electrical wire set passes through the opening, and wherein the injection molded thermoplastic jacket encases respective regions of the electrical wire set passing through the opening.
21 . A light string according to claim 18 , wherein the contact set passes through the opening, and wherein the injection molded thermoplastic jacket encases electrical connections between the contact set and the electrical wire set.
22 . A light string according to claim 18 , wherein the injection molded plastic jacket comprises at least one of polycarbonate, polystyrene, or other moldable thermoplastic material.
23 . A light string according to claim 18 , wherein the injection molded plastic jacket comprises a thermoplastic selected from poly(vinyl chloride).
24 . A light string according to claim 18 , wherein the injection molded thermoplastic jacket comprises polypropylene.
25 . A light string according to claim 18 , wherein the contact set and/or the electrical connections and/or a portion of the electrical wire set are separated by a contact separator to isolate them during the molding operation.
26 . A method for moisture sealing a light-emitting diode elements of a light string, comprising:
providing a light string comprising a plurality of light emitting diodes, the plurality of light emitting diodes comprising a positive contact and a negative contact of a contact set, each of the contacts having a first end portion and a second end portion, and a lens body containing a semiconductor chip and the first end portions of the positive and negative contacts;
electrically connecting a first electrical wire and a second electrical wire of an electrical wire set to the second end portions of the positive contact and the negative contact, respectively;
inserting the light emitting diode through an opening and into a cavity of a light transmissive cover, the opening having at least one of the contact set and the electrical wire set passing therethrough; and
injection molding a thermoplastic jacket integrally at the opening of the light transmissive cover to provide a seal at the opening against moisture and airborne contaminants.
27 . A method according to claim 26 , wherein electrically connected portions of the contact set and the electrical wire set are encased by the injection molded thermoplastic jacket to provide a seal against moisture and airborne contaminants.
28 . A method according to claim 26 , wherein the plastic jacket comprises at least one of polycarbonate, polystyrene, or other moldable thermoplastic material.
29 . A method according to claim 26 , wherein the plastic jacket comprises a thermoplastic selected from poly(vinyl chloride).
30 . A method according to claim 26 , wherein the thermoplastic jacket comprises polypropylene.
31 . A method according to claim 26 , wherein the light transmissive cover is at least partially encased by the injection molded thermoplastic jacket.
32 . A method according to claim 26 , wherein said molding comprises injection molding the thermoplastic jacket in a mold cavity.
33 . A jacketed light emitting diode assembly, comprising:
a light emitting diode comprising
a contact set comprising a positive contact and a negative contact, each of the contacts having a first end portion and a second end portion; and
a lens body containing a semiconductor chip and the first end portions of the positive and negative contacts;
an electrical wire set comprising a first electrical wire and a second electrical wire electrically connected to the second end portions of the positive contact and the negative contact, respectively and,
an injection molded thermoplastic jacket directly molded onto at least one of the lens body, contact set, electrical connections and a portion of the electrical wire set to seal and encase against moisture and airborne contaminants.
34 . A jacketed light emitting diode assembly according to claim 33 , wherein the contact set and/or the electrical connections and/or a portion of the electrical wire set are separated by a contact separator to isolate them during the direct molding process.