System and method for increasing the surface mounting stability of a lamp
View Patent ↗In one embodiment, an LED is constructed with its entire contact structure stamped and inserted into the molded lamp as a single structure. A portion of the contact structure is imbedded in the molded lamp such that the bottom surface of the contacts do not extend below the base of the molded lamp. The base of the molded lamp is made wide enough to give support to the entire structure. Using this concept, any excess contact structure is cutoff and there is no need for bending of the contact structure to form the contact portions. In some embodiments, the cross-sectional area of the lamp base is extended to increase stability of the lamp when the lamp base is mounted on a flat surface.
1. An LED comprising:
a premolded lamp shell having contained therein at least one LED structure adapted for mating with electrical contacts, said lamp shell having a base which comprises a lower surface and an area for receiving said electrical contacts; and
at least one set of contacts formed on a single structure and adapted to be inserted inside said lamp shell via said lamp base, said set of contacts having at least one laterally extending portion, said laterally extending portion for extending circumferentially outward of said lamp base and said laterally extending portion having a bottom surface adapted to not extend below the lower surface of said lamp base.
2. The LED of claim 1 wherein said lamp shell is circular.
3. The LED of claim 2 wherein said lamp base has a portion with a circumference larger than the circumference of the main portion of said lamp shell.
4. The LED of claim 3 wherein said wider circumference is large enough to provide stability for mounting said LED to a substrate.
5. The LED of claim 1 wherein said premolded lamp shell base has constructed thereon at least one protruded leg for providing stability for mounting said LED to a substrate.
6. The LED of claim 5 wherein the base of said protruded leg is on the same plane as the base of said laterally extending portion.
7. A lamp shell comprising:
a cylindrical portion having a top for allowing light to escape;
a base portion for mounting on a substrate, said base portion having a lower surface having a cross-sectional area large enough to maintain said cylindrical portion stable when said base portion is in contact with a flat surface, said base portion comprising:
means for receiving a contact structure, said contact structure having a proximal end for mating with light producing elements within said cylindrical portion of said lamp shell and externally extending portions for extending circumferentially outward from said base portion for receiving electrical power from an external source, said externally extending portions each comprising a bottom edge; and
at least two areas positioned to receive and support said externally extending portions such that the bottom edge of each of said externally extending portions does not extend below said lower surface of said base portion.
8. The lamp shell of claim 7 wherein said bottom edge of each of said externally extending portions operates in conjunction with said lower surface of said base portion to cause said cylindrical portion of said lamp shell to experience an increase in stability when said base portion is in contact with said flat surface.
9. The lamp shell of claim 8 wherein said receiving means comprises at least a pair of slits on opposite circumferentially edges of said lamp base.
10. An LED comprising:
a premolded lamp shell having contained therein at least one LED structure adapted for mating with electrical contacts, said lamp shell having a base which comprises a lower surface and an area for receiving said electrical contacts; and
at least one set of contacts formed on a single structure and adapted to be inserted inside said lamp shell via said lamp base, said single structure comprising at least one section thereof which, when cut, will separate said set of contacts into two separate contact members, said set of contacts having at least one laterally extending portion, said laterally extending portion for extending circumferentially outward of said lamp base and said laterally extending portion having a bottom surface adapted to not extend below the lower surface of said lamp base.