Patent ID: 8257110
Filing Date: 2012-09-04
Classification: B29C,B29K,F21S,F21V,F21Y,H01R,Y10T

Abstract:
1. A method of forming an electrical connector of a light emitting diode (LED) light bar comprising: determining a coefficient of thermal expansion (CTE) of materials of a heat sink, wherein the heat sink has a channel with an opening; selecting injection molding materials having a CTE that is substantially the same as the CTE of materials of the heat sink; placing the opening of the channel of the heat sink into an injection mold; clamping a set of conductor pins into the injection mold at the opening of the channel of the heat sink; injecting the injection molding materials in molten state into the injection mold to fill cavities between the set of conductor pins and the heat sink; allowing the injection molding materials to solidify inside the injection mold to form the electrical connector, wherein the electrical connector includes the injection molding materials and the set of conductor pins surrounded radially by the injection molding materials; and removing the electrical connector and the heat sink from the injection mold.