Wire-piercing light-emitting diode lamps
A wire-piercing light-emitting diode (LED) a lead frame having a first lead and a second lead. The first lead has a first transition portion and a first bottom portion with a first cutting member, and the second lead having a second transition portion and a second bottom portion with a second cutting member.
1. A light-emitting diode lamp for piercing insulated wires of a lighting device so as to make electrical contact between the lamp and the wires of the lighting device, the lamp comprising:
a light-emitting diode lead frame including a conductive first lead and a conductive second lead, the first lead having a first cutting member and a second cutting member;
a light-emitting diode mounted to the lead frame, the light-emitting diode electrically connected to the first lead and electrically connected the second lead; and
a lens adjacent the light-emitting diode and covering at least a portion of the first lead and a portion of the second lead so as to fix a position of the portion of the first lead relative to the portion of the second lead.
2. The light-emitting diode lamp of claim 1 , wherein the first lead light-emitting defines a wire-receiving recess adjacent the first cutting member.
3. The light-emitting diode lamp of claim 1 , wherein the second lead includes a first cutting member.
4. The light-emitting diode lamp of claim 3 , wherein the second lead further includes a second cutting member and defines a wire-receiving recess.
5. The light-emitting diode lamp of claim 1 , wherein the first lead further includes a transition portion adjacent the cutting member, the transition portion forming a step having a transition surface adapted to contact a top surface of an insulated wire.
6. The light-emitting diode lamp of claim 5 , wherein the transition surface defines a plane generally perpendicular to the cutting member of the first lead.
7. The light-emitting diode lamp of claim 1 , wherein the first lead and the second lead are substantially coplanar.
8. The light-emitting diode lamp of claim 1 , the first lead further including a top portion, a middle portion, and a bottom portion, the bottom portion comprising the cutting member, and the second lead further including a top portion, a middle portion, and a bottom portion, the bottom portion comprising a cutting member, and wherein the middle portion of the first lead and the bottom portion of the first lead project away from a center of the light-emitting diode lead frame in a forward direction such that a distance from the middle portion of the first lead to the center of the light-emitting diode lead frame defines a first offset, and wherein the middle portion of the second lead and the bottom portion of the second lead project away from the center of the LED lead frame in a rearward direction such that a distance from the middle portion of the second lead to the center of the LED lead frame defines a second offset.
9. The light-emitting diode lamp of claim 8 , wherein the first offset is substantially the same as the second offset.
10. The light-emitting diode lamp of claim 1 , wherein the lead frame forms a Z shape and the first lead further includes a top portion and an end portion coupled to a bottom portion comprising the cutting member of the first lead, the top portion of the first lead forming a first angle with the end portion of the first lead; and
the second lead further includes a top portion and an end portion coupled to a bottom comprising a cutting member of the second lead, the top portion of the second lead forming a second angle with the end portion of the second lead.
11. The light-emitting diode lamp of claim 10 , wherein the first angle and the second angle are substantially 45 degree angles.
12. The light-emitting diode lamp of claim 1 , the first lead further including a top portion and a bottom portion, the second lead further including a top portion and a bottom portion, wherein the top portion of the first lead and the top portion of the second lead define a horizontal plane, the bottom portion of the first lead forms a first vertical plane, the bottom portion of the second lead forms a second vertical plane, and wherein the top horizontal plane is substantially perpendicular to the first vertical plane and the second vertical plane.
13. The light-emitting diode lamp of claim 12 , wherein the bottom portion of the first lead and the bottom portion of the second lead are directly opposite one another.
14. The light-emitting diode lamp of claim 1 , wherein the first lead further includes a twisted portion and the second lead further includes a twisted portion.
15. The light-emitting diode lamp of claim 1 , the lamp further comprising a chip carrier and the light-emitting diode comprising a light-emitting diode chip, wherein the light-emitting diode chip is mounted to the chip carrier, and the chip carrier is mounted to the lead frame.
16. The light-emitting diode lamp of claim 15 , wherein the chip carrier comprises a reflective cavity.
17. The light-emitting diode lamp of claim 1 , wherein the first lead further includes an integral chip carrier.
18. The light-emitting diode lamp of claim 1 , wherein the light-emitting diode is electrically connected to the second lead by a wire bond.
19. The light-emitting diode lamp of claim 1 , wherein the lens encapsulates the entire light-emitting diode and a portion of each of the first lead and the second lead.
20. The light-emitting diode lamp of claim 19 , wherein the lens comprises an epoxy material.