U.S. patent application number 12/758639 was filed with the patent office on 2010-09-02 for shaped led light bulb.
Invention is credited to Anthony DeRose.
Application Number | 20100218406 12/758639 |
Document ID | / |
Family ID | 46329722 |
Filed Date | 2010-09-02 |
United States Patent
Application |
20100218406 |
Kind Code |
A1 |
DeRose; Anthony |
September 2, 2010 |
Shaped LED Light Bulb
Abstract
An LED light bulb where the LED light bulb itself is molded into
various shapes. The plastic lens used to surround the diode is
shaped when manufactured to resemble various items, such as stars,
crosses, hearts, trees, pinecones, bulbs, flat panels with designs,
or any other shape the user desires. Because the entire light bulb
is the LED, uniform and consistent light can be emitted from every
part of the plastic lens that makes up the shaped LED light bulb,
allowing the user to view the shaped LED light bulb from any angle.
The shaped LED light bulb can be used individually, or strung
together to form a strand of shaped lights.
Inventors: |
DeRose; Anthony; (Caledon
East, CA) |
Correspondence
Address: |
ERIC HANSCOM
2141 Palomar Airport Road, Suite 320
CARLSBAD
CA
92011
US
|
Family ID: |
46329722 |
Appl. No.: |
12/758639 |
Filed: |
April 12, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11931891 |
Oct 31, 2007 |
7695166 |
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12758639 |
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11118480 |
May 2, 2005 |
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11931891 |
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09990326 |
Nov 23, 2001 |
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11118480 |
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Current U.S.
Class: |
40/541 ; 315/294;
362/184; 362/231; 362/235; 362/311.02 |
Current CPC
Class: |
G09F 9/33 20130101; B29C
39/10 20130101; B29C 2035/0827 20130101; F21Y 2115/10 20160801;
A47G 33/08 20130101; F21W 2121/00 20130101; G09F 13/04 20130101;
B44F 1/06 20130101; F21Y 2103/37 20160801; F21S 4/10 20160101; F21V
3/062 20180201; F21V 5/04 20130101; F21Y 2113/17 20160801; B44C
5/005 20130101; H01L 33/54 20130101; B29C 35/02 20130101; F21V
3/061 20180201; B29L 2011/00 20130101 |
Class at
Publication: |
40/541 ;
362/311.02; 362/235; 315/294; 362/184; 362/231 |
International
Class: |
G09F 13/00 20060101
G09F013/00; F21V 3/02 20060101 F21V003/02; F21V 1/00 20060101
F21V001/00; H05B 37/02 20060101 H05B037/02; F21L 4/02 20060101
F21L004/02; F21V 9/00 20060101 F21V009/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 26, 2001 |
CA |
2,360,186 |
Claims
1. A shaped light emitting diode comprising a raw light emitting
diode and a plastic lens, where the raw light emitting diode is
surrounded by the plastic lens, where the shape and size of the
plastic lens is determined by a cavity mold that is used to create
the shape of the lens.
2. The shaped light emitting diode of claim 1, where the surface of
the plastic lens comprises one or more grooves or ridges.
3. The shaped light emitting diode of claim 1, where the surface of
the plastic lens is textured.
4. The shaped light emitting diode of claim 1, where the surface of
the plastic lens comprises one or more characters or designs.
5. The shaped light emitting diode of claim 1, where the plastic
lens comprises bubbles or metal shavings.
6. The shaped light emitting diode of claim 1, where the plastic
lens comprises shapes or designs made from steel, glass, or
plastic.
7. The shaped light emitting diode of claim 1, where the plastic
lens comprises electronic circuitry.
8. The shaped light emitting diode of claim 7, where the electronic
circuitry causes the shaped light emitting diode to blink on and
off when connected to a power source.
9. The shaped light emitting diode of claim 1, where the plastic
lens is transparent.
10. The shaped light emitting diode of claim 1, where the shaped
light emitting diode is a sign.
11. The shaped light emitting diode of claim 1, where the plastic
lens has a width of more than 5 mm, a height of more than 5 mm, and
a depth of more than 5 mm.
12. The shaped light emitting diode of claim 1, where the plastic
lens has a side that is greater than 20 mm in length.
13. The shaped light emitting diode of claim 1, where the plastic
lens comprises layers of epoxy resin.
14. The shaped light emitting diode of claim 1, where the layers of
epoxy resin are different colors.
15. The shaped light emitting diode of claim 1, where the plastic
lens comprises a battery.
16. A shaped light emitting diode comprising two or more raw light
emitting diodes and a plastic lens, where the raw light emitting
diodes are surrounded by the plastic lens, where the shape and size
of the plastic lens is determined by a cavity mold that is used to
create the shape of the lens.
17. The shaped light emitting diode of claim 16, where the two or
more raw light emitting diodes emit different colors of light.
18. The shaped light emitting diode of claim 16, where the shaped
light emitting diode is a sign.
19. The shaped light emitting diode of claim 16, where the plastic
lens comprises electronic circuitry, and where the electronic
circuitry causes the intensity of each raw light emitting diode to
change, thereby causing the light emitted from the shaped light
emitting diode to change color.
20. A device capable of producing light comprising two or more
shaped light emitting diodes, where the shaped light emitting diode
comprises a raw light emitting diode and a plastic lens, where the
raw light emitting diode is surrounded by the plastic lens where
the shape and size of the plastic lens is determined by a cavity
mold that is used to create the shape of the lens, and where the
two or more shaped light emitting diodes are connected to each
other by means of wires, where these wires supply power from a
power source to each of the shaped light emitting diodes.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/931,891 filed Oct. 31, 2007, which in turn
is a continuation-in-part of U.S. patent application Ser. No.
11/118,480 filed May 2, 2005, which in turn is a divisional of U.S.
patent application Ser. No. 09/990,326 filed Nov. 23, 2001, the
entireties of which are hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was not federally sponsored.
BACKGROUND OF THE INVENTION
Field of the Invention
[0003] This invention relates to the general field of LED lights,
and more specifically toward an LED light bulb where the LED light
bulb itself is molded into various shapes. The plastic lens used to
surround the diode is shaped when manufactured to resemble various
items, such as stars, crosses, hearts, trees, pinecones, bulbs,
flat panels with designs, or any other shape the user desires.
Because the entire light bulb is the LED, uniform and consistent
light can be emitted from every part of the plastic lens that makes
up the shaped LED light bulb, allowing the user to view the shaped
LED light bulb from any angle. The shaped LED light bulb can be
used individually, or strung together to form a strand of shaped
lights.
[0004] LED light bulbs are preferable over florescent or
incandescent light bulbs. They require less power to produce the
same amount of light as florescent or incandescent light bulbs.
Further, LED light bulbs have extremely long life spans, and do not
contain mercury. LEDs are prime candidates for many applications
requiring sources of light.
[0005] An LED, or light emitting diode, is a light-producing object
that produces light by passing electricity through a p-n junction
biased in the forward direction. A plastic lens surrounds the diode
to protect it. The light leaves the diode and travels through the
plastic lens where it exits the LED light bulb. Prior art LED bulbs
are generally small and cylindrical, usually measuring at most
about 5 mm in diameter. The light produced by LEDs can be of
various colors and intensity. The light, however, tends to be a
point source of light. Light exits through the plastic lens in one
direction and at a narrow angle as compared to florescent or
incandescent light bulbs. Further, LED light bulbs with simple
plastic lenses are not pleasing to look at. They can be strung
together to form strands of lights, but they remain point sources
of light.
[0006] Manufacturing LED light bulbs can be a difficult process.
The prior art teaches the use of cap type molds. A liquid resin is
injected into the molds and heated to about 130.degree. C. Because
of the molds used, only cap type shapes have been created;
three-dimensional shapes would be impossible to create using this
method.
[0007] To overcome some of these issues, the prior art has taught
LED light bulbs that are inserted into other materials. These
covers take the light emitted from the LED light bulb and disperse
it. These covers can be made of many different transparent or
translucent materials, such as glass or plastic, and can be of
various shapes, sizes, and colors. The original light source,
however, is still an LED light bulb, which has a small point source
of light. This creates a light-producing object that emits an
inconsistent amount of light over the surface of the object.
Further, the LED can become dislodged from the cover, or the cover
can break.
[0008] U.S. Pat. No. 5,743,616, to Giuliano et al., discloses an
LED illuminated image display. It uses LED lights imbedded in the
edge of a flat panel to light up the panel. However, in this
patent, the LED light bulb is separate from the panel. A standard
LED light bulb is inserted into the edge of the flat panel, and the
panel merely redirects light emitted by the LED light bulb.
Giuliano does not teach of a display where the LED light bulb and
the display are in fact one and the same. Further, the etched
panels disclosed in Giuliano cannot be viewed from all angles.
[0009] U.S. Pat. No. 4,965,701, to Voland, discloses an illuminated
curtain, where the curtain has strands of lights. These strands
have light bulbs that produce light, and these light bulbs are
placed inside of other members, where these members can be
different shapes, sizes, and colors. The light bulb, and the
surrounding member are, however, two distinct objects. The
surrounding member can be broken separately from the light, or the
light can become separated from the surrounding member, leaving a
simple point source of light. Voland does not teach a strand of
lights where the light bulbs themselves are various shapes, sizes
and colors and do not require a surround member to achieve such a
purpose.
[0010] U.S. Pat. No. 5,217,286, to Ming-ho, discloses a variety of
ornaments and structures. Ming-ho, however, does not disclose an
LED light bulb where the LED light bulb itself is the ornament or
structure. U.S. Pat. No. 5,151,679, to Dimmick, discloses the use
of light scattering elements such as metal shavings or bubbles.
However, Dimmick does not teach the use of scattering elements such
as metal shavings or bubbles in the plastic lens of the LED light
bulb itself.
[0011] Thus there has existed a long-felt need for a an object that
produces light that can be a particular shape, size and color,
where the entire object can emit a uniform and consistent amount of
light as well as be viewed from any angle. The light source should
be efficient to operate as well as be durable and have an extremely
long useful lifespan.
SUMMARY OF THE INVENTION
[0012] The current invention provides just such a solution by
having an LED light bulb where the LED light bulb itself is molded
into various shapes. The plastic lens used to surround the diode is
shaped when manufactured to resemble various items, such as stars,
crosses, hearts, trees, pinecones, bulbs, flat panels with designs,
or any other shape the user desires. Because the entire light bulb
is the LED, uniform and consistent light can be emitted from every
part of the plastic lens that makes up the shaped LED light bulb,
allowing the user to view the shaped LED light bulb from any angle.
The shaped LED light bulbs can be used individually, or strung
together to form a strand of shaped lights.
[0013] This invention is simply an LED light bulb, where the LED
light bulb itself can be of different shapes, colors, and sizes.
These LED light bulbs can be used individually, or strung together
to form a strand of shaped lights. The key difference over the
prior art is that this invention can have a larger plastic lens
where the lens is shaped to anything the user desires.
[0014] To make the LED light bulb, a mold must first be created.
The mold determines the shape and size of the LED light bulb, as
well as any surface effects that the LED light bulb may have.
Stars, crosses, hearts, trees, pinecones, bulbs, flat panels with
designs, or any other shape the user desires can be manufactured.
Preferably, a cavity mold with two halves should be created with
the desired three-dimensional design of the LED light bulb. The
cavity mold is created by means of an injection mold. Grooves,
ridges, etching, or other surface effects are built directly into
the walls of the injection mold to create the opposite effect in
the cavity mold. The cavity mold itself should be made from a
plastic material that epoxy resin or silicon will not stick to,
such as polyethylene terephthalate (PET), nylon, polymethylpentene
(TPX.RTM.), and polycarbonate (PC). Further, the cavity mold itself
must be able to withstand temperatures of at least 130.degree. C.
without distorting the shape of the mold. The plastic material of
the cavity mold should also be durable so that the cavity mold can
be used repeatedly without the need of repair. Finally, the top of
the cavity mold should have an opening that is slightly tapered.
The opening allows the epoxy resin to be poured into the mold. The
tapered opening allows for a wire connector to easily slide onto
the LED light bulb.
[0015] It is important to understand that the process for making
the LED light bulbs themselves does not require the use of
injection molds. After an injection mold has been used over
1,000,000 times, it must be replaced. A cavity mold must be
replaced after approximately the same number of uses. However,
since over 1,000 LED light bulbs can be made with each cavity mold,
as opposed to the single LED light bulb per injection mold, the
cavity mold can create 1,000 times as many LED light bulbs per mold
compared to the injection mold. Further, the cavity molds are less
expensive to create than injection molds, and can be reused to
create new cast molds. The injection mold is used to create the
cavity mold, which in turn can be used to create millions of LED
light bulbs.
[0016] The two halves of the cavity mold are aligned together by
the use of guide rods. These rods ensure that each half of the
cavity mold aligns properly with the other half. Each half of the
cavity mold must fit securely together to form a sealed cast mold
so that the epoxy resin will not leak out. Clamps can be used to
secure the two halves of the cavity mold together. The halves of
the cavity mold can also be secured together by enclosing the
cavity mold within another structure. This structure surrounds the
outside of the cavity mold leaving an opening in the top so that
the cavity molds can be inserted and removed from the structure, as
well as allowing the raw LEDs and resin to be inserted into the
cavity mold.
[0017] Multiple cavity molds can also be used at the same time.
They can be aligned with each other using the same guide rods used
to align each half. The cavity molds can be secured together by
various means, including by using clamps or enclosing the cavity
molds in a structure. This structure is similar to the one
described above, but is designed to accommodate multiple cavity
molds at the same time.
[0018] The raw LED comprises a diode that must be surrounded by a
protective cover, such as a plastic lens. The raw light emitting
diode is coated with an epoxy resin to protect it when it is
inserted into the mold. The raw LEDs are connected to upper and
lower guide wires to aid in orienting and holding the raw LEDs in
the mold. Before being placed in the mold, however, each diode,
individually or in groups, should be tested to make sure the diodes
are working properly.
[0019] The resin chosen for the plastic lens determines the color
and clarity of the lens, but not necessarily the color of the light
that is emitted from the LED light bulb. For example, a clear
plastic lens could be created whereby red light is emitted from the
diode. The material used for the plastic lens can be an epoxy
resin, polymethylmethacrylate, acrylic, engineered thermoplastic
polycarbonate, silicon, or other like materials. The plastic lens
can be transparent or translucent. Further, other additives, such
as metal particles and bubbles, can be added to the resin before it
is poured to create different lighting effects.
[0020] Once the cavity mold is created, the cavity mold is secured
in place and heated to a temperature of at least 120.degree. C.,
but preferable 130.degree. C., for one hour. The cavity mold is
then filled with the epoxy resin and the raw LEDs are inserted
through the opening at the top of the cavity mold. The cavity mold
is then once again heated to at least 120.degree. C., but
preferably 130.degree. C., for one to one and a half hours. At this
time, the epoxy resin becomes solid and is formed into the desired
shape. An alternative method for curing the epoxy resin is to use
ultraviolet lighting. Instead using heating the epoxy resin, the
epoxy resin is cured by irradiating it with ultraviolet light,
generally for a period of seconds.
[0021] After the resin has cured, the cavity molds are separated
and the three dimensionally shaped LED light bulb is removed. If
the molds are secured together by use of clamps, the clamps need
not be removed, but rather only loosened to allow the two halves of
the cavity mold to separate. If the cavity molds are secured
together by being placed in a structure, they also need not be
removed from the structure to remove the shaped LED light bulb.
Rather, the cavity molds can be separated while remaining in the
structure. By leaving the molds in the clamps or in the structure,
valuable manufacturing time can be saved. Also, the cavity mold
need not be cooled down before the LED light bulb is removed. This
also removes the requirement of preheating the cavity mold, as the
cavity mold is already at the desired temperature for creating the
LED light bulb. Therefore, the cavity mold can be used continuously
without cooling and reheating the mold. Once the shaped LED light
bulb has been created, no cleaning or polishing is required.
[0022] For more complex designs, the cavity mold cavity can be
filled with shapes or designs made from steel, glass, plastic, or
other suitable materials before the resin is poured. A reflective
surface can be placed on one side of the mold so that light is
emitted from only part of the entire bulb. Integrated circuits,
switches, batteries, or other electronic components can also be
placed in the mold cavity along with the raw LED, allowing for a
wide range of lighting options. For example, a full wave rectifier
or a current controller can be located inside of the plastic lens.
A battery, including a rechargeable battery, could be located
inside of the plastic lens to create a stand alone self-powered LED
light bulb. Alternatively, the wires from the LED could be
connected directly or indirectly to a solar panel.
[0023] Multiple raw LEDs can also be used in one bulb, and when
these are combined with other electronic components, a bright
shaped LED light bulb or one that changes colors can be created. A
shaped LED light bulb with multiple raw LEDs and an integrated
circuit can create a color changing light bulb without the costly
use of multiple bulbs or color changing controllers. Another design
possibility is to partially fill the cavity mold with different
colored epoxy resin or silicon at different times. For example,
part of the cavity mold could be filled with a red epoxy resin and
allowed to cure. Then another portion of the cavity mold could be
filled with a white epoxy resin and allowed to cure. Finally, the
rest of the cavity mold could be filled with a blue epoxy resin and
allowed to cure. This would create a red, white, and blue colored
LED light bulb. Alternatively, a shaped LED light bulb can located
inside of an additional plastic lens, which itself can be shaped,
include light scattering elements on the surface, or include light
scattering elements internally. These processes can be used to
create multicolored, layered, shaped LED light bulbs.
[0024] A string of shaped LED light bulbs can also be easily
created from this process. The wires connecting the shaped LED
light bulbs can be secured to the raw LEDs before the molding
process. These wires can even be encapsulated inside the shaped LED
light bulb making the shaped LED light bulb waterproof and more
resistant to high temperatures. These shaped LED light bulbs can be
wired in series or run in parallel. A group of shaped LED light
bulbs can be run in parallel, and then this group can be run in
series, allowing a greater number of shaped LED light bulbs to be
strung together without increasing the voltage requirements. It is
possible to run 2,000 or more shaped LED light bulbs together using
a single 110-volt power source.
[0025] It is also contemplated that the LED light bulb itself can
be a sign where the sign itself should have a design and emit
light. Examples of this would be an emergency exit sign, an
open/closed sign for a business, an advertising sign, or even a car
nameplate. The body of the LED light bulb can contain holes or
other means to mount the LED Light bulb directly to a wall or other
apparatus.
[0026] It is further contemplated by the inventor that the LEDs
could be used to create a flat LED display panel. Because of the
ability of diodes to sense light instead of emit light, it is also
possible to use the shaped LED light bulbs to sense light. If the
LED light bulbs are used to create a flat LED panel, this panel
could be a sensor panel instead of a display panel.
[0027] This invention has many benefits over the prior art. One
benefit is that there is no restriction as to the size of the LED
light bulb--it can be as thin as two mm or as thick as 100 mm or
more. There is no need to drill a hole and insert an LED into the
bulb. Further, there is no need for potting liquid to bond the LED
in place. Since the shape of the bulb is completely finished by the
time it is removed from the mold, there is no need to etch the
design after molding, nor is there a need to clean or polish the
bulb after molding. Additionally, the process for creating the
current shaped LED light bulb requires the same amount of energy as
the prior art process to create a small 3 mm LED, while at the same
time producing less chemical pollution to create the plastic lens
than the prior art processes.
[0028] It is a principal object of the invention to provide an
object capable of producing light that can be of various shapes,
sizes, and colors.
[0029] It is another object of the invention to provide an object
capable of producing light where the light that is produced can be
uniform and consistent over the entire surface of the bulb.
[0030] It is an additional object of the invention to provide an
object capable of producing light that its sculptured look and
shape can be viewed from all angles.
[0031] It is a further object of the invention to provide an object
capable of producing light where there is no need to drill the
object and then place an LED inside of the object.
[0032] It is a final object of this invention to provide an object
capable of producing light that is durable, efficient, long
lasting, and pleasing to look at.
[0033] There has thus been outlined, rather broadly, the more
important features of the invention in order that the detailed
description thereof may be better understood, and in order that the
present contribution to the art may be better appreciated. There
are additional features of the invention that will be described
hereinafter and which will form the subject matter of the claims
appended hereto. The features listed herein and other features,
aspects and advantages of the present invention will become better
understood with reference to the following description and appended
claims.
BRIEF DESCRIPTION OF THE FIGURES
[0034] The accompanying drawings, which are incorporated in and
form a part of this specification, illustrate embodiments of the
invention and together with the description, serve to explain the
principles of this invention.
[0035] FIG. 1 is a front cutaway view of a mold.
[0036] FIG. 2 is a front cutaway view of a mold with a ridge.
[0037] FIG. 3 is a side cutaway view of two separate halves of a
mold.
[0038] FIG. 4 is a side cutaway view of two halves of a mold that
are placed together.
[0039] FIG. 5 is a side view of two halves of a mold with a shaped
LED light bulb in the mold.
[0040] FIG. 6 is a front view of a shaped LED light bulb.
[0041] FIG. 7 is a front view of a shaped LED light bulb with a
groove.
[0042] FIG. 8 is a side view of a shaped LED light bulb.
[0043] FIG. 9 is a side view of a strand of shaped LED light
bulbs.
[0044] FIG. 10 is a side cutaway view of a mold with 3 shaped LED
light bulbs in the mold.
[0045] FIG. 11 is a top cutaway view of multiple molds put
together.
[0046] FIG. 12 is a top view of multiple molds put together.
[0047] FIG. 13 is a side cutaway view of a cavity mold to create a
shaped LED light bulb with three raw diodes.
[0048] FIG. 14 is a perspective view of multiple cavity molds in a
structure that secures the cavity molds together.
[0049] FIG. 15 is a front view of a shaped LED light bulb with
layers of epoxy resin.
[0050] FIG. 16 is a side view of a shaped LED light bulb with a
battery.
[0051] FIG. 17 is a side view of a strand of four shaped LED light
bulbs.
DETAILED DESCRIPTION OF THE INVENTION
[0052] Many aspects of the invention can be better understood with
the references made to the drawings below. The components in the
drawings are not necessarily drawn to scale. Instead, emphasis is
placed upon clearly illustrating the components of the present
invention. Moreover, like reference numerals designate
corresponding parts through the several views in the drawings.
[0053] FIG. 1 is a front cutaway view of a cavity mold. The cavity
mold 10 defines the shape of an LED light bulb (not shown in this
figure).
[0054] FIG. 2 is a front cutaway view of a cavity mold with a
ridge. The cavity mold 20 defines the shape of an LED light bulb
(not shown in this figure). Further, there is a ridge 21 that will
create a groove in the LED light bulb when it is molded.
[0055] FIG. 3 is a side cutaway view of two separate halves of a
cavity mold. The left half of the cavity mold 30 fits and mates
with the right half of the cavity mold 31. Each cavity mold may be,
but is not necessarily, the mirror image of the other half.
[0056] FIG. 4 is a side cutaway view of two halves of a cavity mold
that are placed together. The left half of the cavity mold 40 fits
and mates with the right half of the cavity mold 41.
[0057] FIG. 5 is a side view of two halves of a cavity mold with a
shaped LED light bulb in the cavity mold. The left half of the
cavity mold 50 fits and mates with the right half of the cavity
mold 51. The raw diode 53 is placed in between the left half of the
cavity mold 50 and the right half of the cavity mold 51. The raw
diode 53 is connected to a lower guide wire 55 and an upper guide
wire 56. The resin for the plastic lens is poured into the cavity
52 left between the two halves of the cavity mold.
[0058] FIG. 6 is a front view of a shaped LED light bulb. The raw
diode 60 is surrounded by the plastic lens 61 that has been shaped
by the mold (not shown in this figure).
[0059] FIG. 7 is a front view of an LED light bulb with a groove.
The raw diode 70 is surround by the plastic lens 71 that has been
shaped by the mold (not shown in this figure). There is also a
groove 72 in the plastic lens created by a ridge in the mold.
[0060] FIG. 8 is a side view of a shaped LED light bulb. The raw
diode 80 is surrounded by the plastic lens 81 that has been shaped
by the mold (not shown in this figure).
[0061] FIG. 9 is a side view of a strand of shaped LED light bulbs.
The LED light bulbs 90 are connected to a power source 91 by means
of wires 92.
[0062] FIG. 10 is a side cutaway view of a cavity mold to create
three shaped LED light bulbs. The cavity mold 100 has three
cavities 101 that are used to create the shape of the plastic lens
(not shown in this figure). A raw diode 102 is placed into the
cavity 101 such that when the resin of the plastic lens is poured
into the cavity mold 100, the plastic lens will completely surround
the raw diode 102. The raw diode 102 is connected to a lower guide
wire 103 and an upper guide wire 104 which hold the raw diode 102
in the empty cavity 101. The cavity mold 100 also has guide rods
105 which align the cavity molds when they are placed together.
[0063] FIG. 11 is a top cutaway view of multiple cavity molds put
together. Each mold 110 is mated with its other half, and placed
together to form cavities 111. The cavity molds are aligned and
kept in a proper position by the use of guide rods 112, which run
through each cavity mold 110.
[0064] FIG. 12 is a top view of multiple cavity molds put together.
Each cavity mold 120 is mated with its other half, and placed
together to form cavities 121, and these cavities extend to the top
of the cavity mold 120. Upper and lower guide wires 122 hold the
raw diodes 123 in place in the cavities 121 created by the cavity
molds 120.
[0065] FIG. 13 is a side cutaway view of a cavity mold to create a
shaped LED light bulb with three raw diodes. The cavity mold 130
has one cavity 131 that is used to create the shape of the plastic
lens (not shown in this figure). Three raw diodes 132 are placed
into the cavity 131. The raw diodes 132 are connected to a lower
guide wires 133 and an upper guide wires 134 which hold the raw
diodes 132 in the cavity 131. The cavity mold 130 also has guide
rods 135 which align the cavity molds when they are placed
together.
[0066] FIG. 14 is a perspective view of multiple cavity molds in a
structure that secures the cavity molds together. Cavity molds 140
are contained within the structure 141. Guide rods 142 that run
through the cavity molds 140 also run through the structure 141,
thereby aligning the cavity molds 140 together in the structure
141. Raw diodes 143 are suspending in the cavities 144 in the
cavity molds 140. The raw diodes 143 are connected to lower guide
wires 145 and upper guide wires 146, which suspend the raw diodes
143 in the cavities 144. The lower guide wires 145 and the upper
guide wires 146 are secured to the structure 141 to hold and secure
all the various components in place.
[0067] FIG. 15 is a front view of a shaped LED light bulb with
layers of epoxy resin. A first layer 151, second layer 152, and
third layer 153 of epoxy resin are used to encapsulate a raw diode
150.
[0068] FIG. 16 is a side view of a shaped LED light bulb with a
battery. The raw led 160 of the bulb 161 is connected to a batter
162, where the batter is also encapsulated by the bulb 161.
[0069] FIG. 17 is a side view of a strand of four shaped LED light
bulbs. The LED light bulbs 170 are connected to a power source 171
by means of wires 172.
[0070] It should be understood that while the preferred embodiments
of the invention are described in some detail herein, the present
disclosure is made by way of example only and that variations and
changes thereto are possible without departing from the subject
matter coming within the scope of the following claims, and a
reasonable equivalency thereof, which claims I regard as my
invention.
[0071] All of the material in this patent document is subject to
copyright protection under the copyright laws of the United States
and other countries. The copyright owner has no objection to the
facsimile reproduction by anyone of the patent document or the
patent disclosure, as it appears in official governmental records
but, otherwise, all other copyright rights whatsoever are
reserved.
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