A light module includes one or more LEDs that are encapsulated in a thermoplastic polymer material. Metal conductors and electrical components providing a power supply circuit for the LED are also encapsulated in the thermoplastic polymer material. The conductive material may include a pair of relatively rigid portions that project outwardly from the thermoplastic polymer material to provide for electrical connection of the light module. The body may include connecting surface portions that permit the light module to be connected to a conventional electrical receptacle or the like, such that the light module can be mechanically and electrically connected to a socket or other connector previously utilized for incandescent bulbs.
1. A light module, comprising:
an electrically conductive assembly comprising at least a pair of metal conductors, the pair of metal conductors together forming a generally planar mounting area, the pair of metal conductors including first and second rigid prongs;
at least one LED mounted to the mounting area of the metal conductors;
at least one electrical component mounted to the pair of metal conductors to form an electrical circuit controlling at least one of a voltage and a current applied to the prongs;
a body made of a light-transmitting thermoplastic polymer material encapsulating the one LED and the one electrical component, the body including mounting surface portions adjacent the first and second prongs that form a mechanical connector whereby the light module can be electrically and mechanically connected to an electrical receptacle by movement of the light module relative to an electrical connector.
2. The light module of claim 1 , wherein:
the first and second prongs extend transversely away from the planar mounting area; and:
the mounting surface portions are parallel to the first and second prongs.
3. The light module of claim 2 , wherein:
the mounting surface portions from a cavity, and the first and second prongs are disposed in the cavity.
4. The light module of claim 1 , wherein:
the mounting surface portions comprise a quarter-turn connector.
5. The light module of claim 4 , wherein:
the body includes a generally cylindrical portion and a flange portion projecting outwardly from the cylindrical portion.
6. The light module of claim 5 , wherein:
the flange portion includes a generally circular peripheral outer edge surface.
7. The light module of claim 5 , wherein:
the cylindrical portion defines a first end and includes a convex surface at the first end forming a lens.
8. The light module of claim 1 , including:
a lens having a cavity on a first side of the lens, wherein the lens is connected to the light module with the cavity in registry with the LED.
9. The light module of claim 8 , wherein:
the lens includes a plurality of concentric raised ridges on a second side of the lens opposite the first side of the lens.
10. The light module of claim 8 , wherein:
the lens includes a plurality of flexible arms having barbed connectors connecting the lens to the light module.
11. The light module of claim 1 , wherein:
the body includes a first lens facing a first direction, and a second lens facing in a second direction that is transverse to the first direction.
12. The light module of claim 11 , wherein:
the first lens comprises a first convex surface portion of the body.
13. The light module of claim 12 , wherein:
the second lens comprises a second convex surface portion of the body.
14. The light module of claim 13 , wherein:
the first and second convex surface portions face outwardly at substantially right angles relative to one another.
15. The light module of claim 11 , wherein:
the LED comprises a side-emitting LED.
16. The light module of claim 11 , wherein:
the LED comprises a front-emitting LED.