Abstract:
The present invention discloses a LED light bulb, comprising: a LED printed circuit board, a sealed body and a base. The sealed body made of two thermoplastic parts form vapor transport channel inside the body that extends between two heat transfer locations spaced apart on an exterior surface of the body, a wick or a plurality of grooves in the vapor transport channel wall that extends between the two heat transfer locations, and a working fluid that partially fills the vapor transport channel. In a method of making this LED light bulb, the two thermoplastic parts are desirably formed together as a seamless monolithic structure, the LED printed circuit board is bent, mounted and fixed on the sealed body. With the apparatus and manufacturing method introduced by present invention, the LED light bulb would be ease for manufacturing, heat dissipation effective and cost effective. The sealed body transfers heat as a conventional heat pipe.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present disclosure is related to a LED light bulb and manufacturing method of the same. 
         [0003]    2. Description of Related Art 
         [0004]    Light emitting diode (LED) has advantages of small size, long lifespan, low power consumption, luminescence and mercury free so that has become the main research project in illuminating field. However the LED chip creates significant heat during working. If heat could not dissipate properly, many problems will occur such as low light efficacy and short lifespan. Therefore, an efficient heat dissipating structure for a LED light bulb is necessary for removing the heat away from the illuminating module to avoid the aforementioned problems. 
         [0005]    Various apparatus and techniques have been used and are presently being used for removing heat from LED chips in the LED light bulb design. One such heat dissipation technique involves the attachment of a high surface area metal heat sink to LED chips. Due to the manufacturing methods limitation and physical geometry of the heat sink, thus increase the cost, size and weight of the light bulb. 
         [0006]    Another method is using thermal conductive plastic material heat sink instead of metal heat sink. Due to the thermal conductive plastic material has less perfect heat conductivity and higher cost than metal, its usage especially in high power light bulb is limited. 
         [0007]    Therefore, it would be advantageous to develop a LED light bulb apparatus to effectively remove heat from LED chips, with higher heat dissipation ability, lower material cost and less manufacturing constraints. 
       SUMMARY OF THE INVENTION 
       [0008]    An object of the present invention is to provide a novel LED light bulb apparatus includes a body that on which LED printed circuit board can be mounted directly. 
         [0009]    A further object of the present invention is to provide a novel LED light bulb apparatus with said body made of two thermoplastic parts, said body being sealed and having cavity suction apparatus inside said body that extends between two heat transfer locations spaced apart on an exterior surface of said body, a vapor transport channel inside said body that extends between said two heat transfer locations, and a working fluid that partially fills said vapor transport channel. 
         [0010]    A further object of the present invention is to provide a novel LED light bulb apparatus with a LED printed circuit board, said LED printed circuit board is desirably designed to be bent, mounted on and fixed on said body. 
         [0011]    Another object of the present invention is to provide a novel method of making this novel LED light bulb apparatus that includes providing a body of two thermoplastic parts, providing cavity suction apparatus and a vapor transport channel inside said body, said cavity suction apparatus and said vapor transport channel that extends between two heat transfer locations spaced apart on an exterior surface of said body, evacuating said body, providing a working fluid inside said body that partially fills said vapor transport channel, and sealing said body closed. 
         [0012]    A further object of the present invention is to provide a novel method of making this novel LED light bulb apparatus that bend, mount and fix the LED printed circuit board on said body. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a pictorial cutaway view of an embodiment of the present invention. 
           [0014]      FIG. 2  is a pictorial representation of an embodiment of the present invention. 
           [0015]      FIG. 3  is a pictorial exploded view of an embodiment of the present invention. 
           [0016]      FIG. 4  is a pictorial exploded cutaway view of an embodiment of the present invention. 
           [0017]      FIG. 5  is a pictorial cutaway view of a sub-assembly of an embodiment of the present invention. 
           [0018]      FIG. 6  is a pictorial representation of a outer part of an embodiment of the present invention. 
           [0019]      FIG. 7  is a pictorial representation of a outer part of an embodiment of the present invention, with showing section planes position from perspective view. 
           [0020]      FIG. 8  is a pictorial representation of a outer part of an embodiment of the present invention, with showing section planes position from top view. 
           [0021]      FIG. 9  is a pictorial cutaway view of a outer part of an embodiment of the present invention taken along the section plane  40  in  FIG. 7  and  FIG. 8 . 
           [0022]      FIG. 10  is a pictorial cutaway view of a outer part of an embodiment of the present invention taken along the section plane  41  in  FIG. 7  and  FIG. 8 . 
           [0023]      FIG. 11  is a pictorial cutaway view of a outer part of an embodiment of the present invention taken along the section plane  42  in  FIG. 7  and  FIG. 8 . 
           [0024]      FIG. 12  is a pictorial representation of a inner part of an embodiment of the present invention. 
           [0025]      FIG. 13  is a pictorial representation of a inner part of an embodiment of the present invention, with showing section planes position from perspective view. 
           [0026]      FIG. 14  is a pictorial representation of a inner part of an embodiment of the present invention, with showing section planes position from top view. 
           [0027]      FIG. 15  is a pictorial cutaway view of a inner part of an embodiment of the present invention taken along the section plane  46  in  FIG. 13  and  FIG. 14 . 
           [0028]      FIG. 16  is a pictorial cutaway view of a inner part of an embodiment of the present invention taken along the section plane  47  in  FIG. 13  and  FIG. 14 . 
           [0029]      FIG. 17  is a pictorial cutaway view of a inner part of an embodiment of the present invention taken along the section plane  48  in  FIG. 13  and  FIG. 14 . 
           [0030]      FIG. 18  is a pictorial cutaway view of a inner part of an embodiment of the present invention taken along the section plane  49  in  FIG. 13  and  FIG. 14 . 
           [0031]      FIG. 19  is a pictorial representation of a wick of an embodiment of the present invention. 
           [0032]      FIG. 20  is a pictorial representation of a wick of an embodiment of the present invention, with showing section planes position from perspective view. 
           [0033]      FIG. 21  is a pictorial representation of a wick of an embodiment of the present invention, with showing section planes position from top view. 
           [0034]      FIG. 22  is a pictorial cutaway view of a wick of an embodiment of the present invention taken along the section plane  43  in  FIG. 20  and  FIG. 21 . 
           [0035]      FIG. 23  is a pictorial cutaway view of a wick of an embodiment of the present invention taken along the section plane  44  in  FIG. 20  and  FIG. 21 . 
           [0036]      FIG. 24  is a pictorial cutaway view of a wick of an embodiment of the present invention taken along the section plane  45  in  FIG. 20  and  FIG. 21 . 
           [0037]      FIG. 25  is a pictorial representation of a LED printed circuit board of an embodiment of the present invention. 
           [0038]      FIG. 26  is a pictorial front view of a LED printed circuit board of an embodiment of the present invention. 
           [0039]      FIG. 27  is a pictorial back view of a LED printed circuit board of an embodiment of the present invention. 
           [0040]      FIG. 28  is a pictorial left side view of a LED printed circuit board of an embodiment of the present invention. 
           [0041]      FIG. 29  is a pictorial top view of a LED printed circuit board of an embodiment of the present invention. 
           [0042]      FIG. 30  is a pictorial representation of a bent LED printed circuit board of an embodiment of the present invention. 
           [0043]      FIG. 31  is a pictorial representation of a bent LED printed circuit board of an embodiment of the present invention, with showing section planes position from perspective view. 
           [0044]      FIG. 32  is a pictorial representation of a bent LED printed circuit board of an embodiment of the present invention, with showing section planes position from top view. 
           [0045]      FIG. 33  is a pictorial cutaway view of a bent LED printed circuit board of an embodiment of the present invention taken along the section plane  50  in  FIG. 31  and  FIG. 32 . 
           [0046]      FIG. 34  is a pictorial cutaway view of a bent LED printed circuit board of an embodiment of the present invention taken along the section plane  51  in  FIG. 31  and  FIG. 32 . 
           [0047]      FIG. 35  is a pictorial cutaway view of a bent LED printed circuit board of an embodiment of the present invention taken along the section plane  52  in  FIG. 31  and  FIG. 32 . 
           [0048]      FIG. 36  is a pictorial representation of a sub-assembly of an embodiment of the present invention. 
           [0049]      FIG. 37  is a pictorial representation of a sub-assembly of an embodiment of the present invention, with showing section planes position from perspective view. 
           [0050]      FIG. 38  is a pictorial representation of a sub-assembly of an embodiment of the present invention, with showing section planes position from top view. 
           [0051]      FIG. 39  is a pictorial cutaway view of a sub-assembly of an embodiment of the present invention taken along the section plane  55  in  FIG. 37  and  FIG. 38 . 
           [0052]      FIG. 40  is a pictorial cutaway view of a sub-assembly of an embodiment of the present invention taken along the section plane  56  in  FIG. 37  and  FIG. 38 . 
           [0053]      FIG. 41  is a pictorial cutaway view of a sub-assembly of an embodiment of the present invention taken along the section plane  57  in  FIG. 37  and  FIG. 38 . 
           [0054]      FIG. 42  is a pictorial cutaway view of a sub-assembly of an embodiment of the present invention taken along the section plane  58  in  FIG. 37  and  FIG. 38 . 
           [0055]      FIG. 43  is a pictorial representation of a body  20  of an embodiment of the present invention. 
           [0056]      FIG. 44  is a pictorial cutaway view of a body  20  of an embodiment of the present invention. 
           [0057]      FIG. 45  is a pictorial representation of a sub-assembly of the present invention showing magnified view section plane  53 . 
           [0058]      FIG. 46  is a pictorial magnified view of a sub-assembly of the present invention, taken along the section plane  53  in  FIG. 45 . 
           [0059]      FIG. 47  is a pictorial representation of  FIG. 46 , showing section plane position from perspective view. 
           [0060]      FIG. 48  is a pictorial representation of  FIG. 46 , showing section plane position from top view. 
           [0061]      FIG. 49  is a pictorial cutaway view of  FIG. 46 , taken along the section plane  54  in  FIG. 47  and  FIG. 48 . 
           [0062]      FIG. 50  is a pictorial representation of an embodiment of the present invention, showing pin, mushroom head and iron head. 
           [0063]      FIG. 51  is a pictorial representation of the second embodiment of the present invention, showing a different heat transfer surface  6 . 
           [0064]      FIG. 52  is a pictorial representation of the third embodiment of the present invention, showing different thermoplastic materials used on outer part and inner part. 
           [0065]      FIG. 53  is a pictorial representation of the fourth embodiment of the present invention, showing grooves on vapor transport channel walls of outer part and inner part. 
           [0066]      FIG. 54  is a pictorial cutaway view of the sixth embodiment of the present invention, which has drum shape outer part. 
           [0067]      FIG. 55  is a pictorial cutaway view of the seventh embodiment of the present invention, which has umbrella shape outer part. 
           [0068]      FIG. 56  is a pictorial cutaway view of the eighth embodiment of the present invention, which has additional heat transfer surface at top of the LED light bulb. 
           [0069]      FIGS. 57 to 59  are a pictorial representation of the ninth embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0070]    Please refer to  FIGS. 1 to 50  for the first embodiment of the present invention. 
         [0071]    Please refer to  FIGS. 1 to 5 , a LED light bulb  21  of the present invention includes a cover  22 , a LED printed circuit board  11 , a body  20  and a base  31 . Said body  20  consists of a outer part  1 , a wick  10  and a inner part  2 . Said cover  22  may be design to be transparent, translucent or a lens directing light direction, and sometime may be eliminated. Although the cover  22  and base  31  shown in  FIGS. 1 to 5  are representing of a LED light bulb for retrofitting type A incandescent light bulb, the present invention may also be used with other types of base and cover, for example but not limited to halogen light bulb and HID light bulb.  FIG. 5  shows a cutaway view of sub-assembly  26  of the present invention. 
         [0072]    Please refer to  FIGS. 6 to 11  regarding outer part  1 .  FIG. 6  shows the perspective view of outer part  1 .  FIGS. 7 and 8  show section planes position of outer part  1  from perspective view and top view respectively.  FIGS. 9 to 11  show sectional view of outer part  1  along section plane  40  to  42  respectively. 
         [0073]    Please refer to  FIGS. 12 to 18  regarding inner part  2 .  FIG. 12  shows the perspective view of inner part  2 .  FIGS. 13 and 14  show section planes position of inner part  2  from perspective view and top view respectively.  FIGS. 15 to 18  show sectional view of inner part  2  along section planes  46  to  49  respectively. 
         [0074]    The outer part  1  and inner part  2  may be made with same thermal conductive plastic material. One example of such thermal conductive plastic material is D1202, thermally conductive and dielectric PP, 5 W/mK, made by Cool Polymers, Inc. Other thermal conductive plastic materials with thermal conductivity over 0.5 W/mK are also viable. The thermal conductive plastic material is made by adding thermal conductive fillers into the regular thermoplastic resin to change its thermal conductivity. The common fillers used include ceramic, carbon and metal powders. The thermal conductive plastic material usually costs much higher than regular thermoplastic material. 
         [0075]    Please refer to  FIGS. 19 to 24  regarding wick  10 .  FIG. 19  shows the perspective view of wick  10 .  FIGS. 20 and 21  show section planes position of wick  10  from perspective view and top view respectively.  FIGS. 22 to 24  show sectional view of wick  10  along section plane  43  to  45  respectively. The wick  10  may be formed outside the body and inserted into vapor transport channel  8  before the body sealed closed. The shape of wick  10  is not limited to which shown in  FIGS. 19 to 24 . It is viable to any shapes as long as the wick extended between the two heat transfer locations  6 ,  7  and only fills partial of the vapor transport channel  8 , leaves passing through space for vaporized gas flow from vapor end  5  to condense end  4 . The wick can be made from conventional copper heat pipe wick materials, include powder metal, mesh or fiber. One example of the wick material is Scott Naturals paper towels, made by Kimberly-Clark Corporation. 
         [0076]    Please refer to  FIGS. 25 to 29  regarding a LED printed circuit board  11 .  FIG. 25  shows the perspective view of a LED printed circuit board  11 .  FIGS. 26 to 29  show front, back, left and top view of a LED printed circuit board  11  respectively. The LED printed circuit board  11  includes open slots  17  along the LEDs  23  as shown in  FIGS. 26 and 27 . When bend and mount said LED printed circuit board  11  on body  20 , the deformed area of said LED printed circuit board  11  will be limited to locations  18 , the top layer copper traces above said locations  18  will be slightly stretched but will not break. The areas of said LED printed circuit board  11  where underneath LEDs  23  won&#39;t become curved shape, thus LEDs  23  soldering points won&#39;t experience deform stress. The material used for LED printed circuit board  11  is preferable but not limited to FR4, the glass-reinforced epoxy laminate sheets, a common printed circuit board material. Aluminum based printed circuit board material can also be used. The thickness of the LED printed circuit board is preferable but not limited to 20 mil with 1 layer or 2 layers copper. The thickness of copper layer is preferable to be more than 0.5 oz to avoid circuitry damaging may caused by bending process. The backside of the LED printed circuit board may be V scored along locations  18  to ease bending process. The PCB layout of LED printed circuit board  11  is not limited to which shown in  FIGS. 25 to 29 . The number of LED strings or number of LEDs on each string may be flexible to choose, it is viable as long as the LEDs  23  located on the portion of said LED printed circuit board  11  which mounted on top of heat transfer surface  7  of said body  20 . 
         [0077]    Please refer to  FIGS. 30 to 35  regarding a bent LED printed circuit board  11 .  FIG. 30  shows the perspective view of a bent LED printed circuit board  11 .  FIGS. 31 and 32  show section planes position of a bent LED printed circuit board  11  from perspective view and top view respectively.  FIGS. 33 to 35  show sectional view of a bent LED printed circuit board  11  along section planes  50  to  52  respectively. 
         [0078]    Please refer to  FIGS. 36 to 44  regarding sub-assembly  26  consists of a LED printed circuit board  11  mounted on a body  20 .  FIG. 36  shows the perspective view of sub-assembly  26 .  FIGS. 37 and 38  show section planes position of sub-assembly  26  from perspective view and top view respectively.  FIGS. 39 to 42  show sectional view of sub-assembly  26  along section planes  55  to  58  respectively.  FIG. 43  shows the perspective view of body  20 .  FIG. 44  shows the perspective cutaway view of body  20 . The body  20  includes outer part  1  and inner part  2  made of thermoplastic material, formed a vapor transport channel  8  that extends between two heat transfer locations  6 ,  7  spaced apart on an exterior surface of said outer part  1 , a wick  10  locates inside said vapor transport channel  8  and extends between said two heat transfer locations  6 ,  7 , and a working fluid  9  partially fills said vapor transport channel  8 . A LED printed circuit board  11  may be mounted directly on said body  20 . The portion of said LED printed circuit board  11  where LEDs  23  located, mounted on the heat transfer location  7 . The other heat transfer location  6  may be exposed to a cooler temperature. So the heat transfer operation of the body  20  is like a conventional heat pipe. 
         [0079]    The vapor transport channel  8  extends between the two heat transfer locations  6 ,  7 . In operation the vaporized working fluid (vaporized by the heat from the LEDs  23  in vapor end  5  at heat transfer location  7 ) moves through the vapor transport channel  8  to condense end  4  at heat transfer location  6  where the vapor condenses. The shape of the vapor transport channel is not limited to any particular geometry. The shape of said vapor transport channel  8  is not limited to which shown in  FIGS. 36 to 44 . It is viable to any shape as long as the vapor transport channel  8  extended between two heat transfer locations  6 ,  7  and a continuous vapor transport channel to be maintained through the body  20  between the vapor end  5  and the condense end  4  in order to allow vapor to move freely between the two regions. The pressure gradient inside the vapor transport channel impels the vapor from the ‘hot spot’ toward other locations where condensation can occur at a slightly lower temperature. 
         [0080]    The working fluid  9  only partially fills the vapor transport channel  8  inside the body  20  so there is open space for vapor transport between the heat transfer locations. The wick  10  conveys the condensate back to the heat transfer location  7  by capillary action and the cycle is repeated. The interior of said vapor transport channel  8  preferably is evacuated before the working fluid is introduced in order to maximize the efficiency of the heat transfer as residual gas inside the vapor transport channel will interfere with the vapor transport within the device. Evacuate the vapor transport channel  8  may also lower said working fluid  9  phase change temperature point. It is preferable but not limited to use distilled water as working fluid. It is also viable to use alcohol or other liquids as working fluid based on the thermoplastic materials and application temperature range requirement. 
         [0081]    Please refer to  FIGS. 45 to 50  regarding mounting holes and pins.  FIG. 45  shows the magnified view section plane  53  position of a sub-assembly  26 .  FIG. 46  shows magnified view along section plane  53  shown in  FIG. 45 .  FIGS. 47 and 48  show section plane position of magnified view in  FIG. 46  from perspective view and top view respectively.  FIG. 49  shows sectional view of magnified view in  FIG. 46  along section plane  54 .  FIG. 50  shows the pin  24 , mushroom head  25  and iron head  27 . 
         [0082]    When a LED printed circuit board  11  being bent and mounted on body  20 , the mounting holes  19  of said LED printed circuit board  11  are positioned on respective pins  24  of said body  20 . All said pins  24  being heated by iron head  27  to form mushroom heads  25 , said mushroom heads  25  fix the LED printed circuit board  11  in place permanently. For demonstration purpose, only one mushroom head  25  is shown. The shape of said mushroom head  25  is defined by said iron head  27 . Said iron head  27  and mushroom head  25  are not limited to the shape shown in  FIGS. 45 to 50 , it is viable to be any shape as long as the mushroom head  25  partially fills and extends outside the mounting hole  19 . 
         [0083]    Please refer to  FIG. 51  for the second embodiment of the present invention. The heat transfer surface  6  on outer part  1  of the first embodiment of the present invention may be processed to be shown in  FIG. 51 . Due to increased surface area of said heat transfer surface  6 , the heat dissipation ability from said heat transfer surface  6  to surrounding environment will be greatly improved. Said process may be done by machining after out part  1  fabricated, but it is preferable to have it integrated into the out part  1  design. 
         [0084]    Please refer to  FIG. 52  for the third embodiment of the present invention. The outer part  1  and inner part  2  of the first embodiment of the present invention may use different thermoplastic materials to further reduce material cost. The inner part  2  may be made with regular thermoplastic material  15 , the heat transfer surface  7  portion of outer part  1  may be made with thermal conductive plastic material  16 , the heat transfer surface  6  portion of outer part  1  may be made with thermal conductive plastic material  14 , the rest portion of the outer part  1  may be made with regular thermoplastic material  15 . One example of these materials are: regular thermoplastic material  15 , polypropylene (PP), CAS number 9003-07-0, from PolyOne Corporation; thermal conductive plastic material  16 , D1202, thermally conductive and dielectric PP, 5 W/mK, from Cool Polymers, Inc; thermal conductive plastic material  14 , MT-210-14, thermally conductive PP, 1.1 W/mK, from SABIC Innovative Plastics Holding BV. 
         [0085]    Please refer to  FIG. 53  for the fourth embodiment of the present invention. Without use wick as working fluid transfer material in the first embodiment of the present invention, a plurality of grooves  13  may be integrated into the vapor transport channel walls  12 . The grooves  13  extends between the two heat transfer locations  6 ,  7  and will function same as wick to conveys the condensate back to the heat transfer location  7  by capillary action. 
         [0086]    In the fifth embodiment of the present invention, the inner part  2  of the first embodiment of the present invention may be made of thermally conductive electrically conductive material, achieving the electromagnetic field shielding function. One example of such thermoplastic material is: E1202, thermally conductive and dielectric PP, 10 W/mK, from Cool Polymers, Inc 
         [0087]    Please refer to  FIG. 54  for the sixth embodiment of the present invention. The heat transfer surface  7  of outer part  1  of the first embodiment of the present invention may be designed to be a drum shape, where the LED printed circuit board may also be bent like a drum shape, thus the beam angle of the light bulb may be more omni. 
         [0088]    Please refer to  FIG. 55  for the seventh embodiment of the present invention. The heat transfer surface  7  of the outer part  1  of the first embodiment of the present invention may be designed to be umbrella shape, where the LED printed circuit board may also be bent like umbrella shape, thus prevents the light going upward direction. 
         [0089]    Please refer to  FIG. 56  for the eighth embodiment of the present invention. The outer part  1  of the first embodiment of the present invention may be designed to have a second heat transfer surface  6 , which two heat transfer surfaces  6  are located on both ends of said outer part  1 . Said second heat transfer surface  6  of the outer part  1  will increase heat dissipation area, thus increase maximum allowable output power of the LED light bulb. 
         [0090]    Please refer to  FIGS. 57 to 59  for the ninth embodiment of the present invention. The heat transfer surface  7  of outer part  1  of the first embodiment of the present invention may be designed to be a flat surface with bulge in the center, which allows the LED printed circuit board to be bent and mounted on, thus the beam angle of the LED light bulb may be designed to be close to, equal to or larger than 180 degree as needed. 
         [0091]    The manufacturing method of the LED light bulb apparatus of the present invention is described in details as below. 
         [0092]    The outer part  1  and inner part  2  may choose from appropriate thermoplastic materials. The outer part  1  and inner part  2  may be pre-formed using conventional thermoplastic processing techniques, such as injection molding, extrusion, blowing or casting. 
         [0093]    The outer part  1  and inner part  2  are aligned properly to form the vapor transport channel  8 . 
         [0094]    In one method the wick  10  is formed and inserted into the vapor transport channel  8 . The wick  10  may be made of powder metal, mesh or fiber with conventional copper heat pipe processing techniques. 
         [0095]    In another method the integrated grooves  13  on the vapor transport channel wall  12  are designed to be integrated into outer part  1  and inner part  2 , achieved during fabricating the outer part  1  and inner part  2 . 
         [0096]    The working fluid  10  is introduced inside the vapor transport channel  8 . Normally 30% of the internal space of vapor transport channel  8  is filled with working fluid  10 . The volume of the working fluid  10  may be adjusted based on the shape and geometry of the vapor transport channel  8 , with the essential requirement to keep working fluid  10  circulation during heat transfer operation. The working fluid  10  may be distilled water, but may also be other liquids like alcohol depends on the application and the thermoplastic material used for outer part  1  and inner part  2 . 
         [0097]    The vapor transport channel  8  then be evacuated conventionally. One example is by performing the body  20  assembly process inside an evacuated chamber. 
         [0098]    The outer part  1  and inner part  2  are sealed closed conventionally. The methods include but not limited to gluing, hot plate welding, vibration welding and ultrasonic welding. 
         [0099]    The LED printed circuit board  11  may be fabricated with conventional printed circuit board processing techniques. 
         [0100]    The LED printed circuit board  11  may be assembled with components with conventional processing techniques, which include but not limited to surface mount techniques. 
         [0101]    The LED printed circuit board  11  may be bent and hold in place on body  20 . This process may be done manually, but a machine driven fixture is preferable which faster and more precisely. 
         [0102]    The pins  24  may be heated and cooled down with an iron head  27 , formed mushroom heads  25 , this process may be done manually, but a machine driven fixture is preferable which faster and more precisely. 
         [0103]    The base  31  is attached to body  20  and electrically connected to LED printed circuit board  11  with conventional processing techniques. 
         [0104]    The cover  22  is optionally attached to body  20  with conventional processing techniques. 
         [0105]    While embodiments of the present invention have been described in the foregoing specification and drawings, it is to be understood that the present invention is defined by the following claims when read in light of the specification and drawings.