Office Action 1: Non-Final Rejection (2024-12-11)
Rejection types: 103 - Obviousness, 112 - Written Description/Enablement

CLAIMS:
WHAT IS CLAIMED IS:

1\. A light assembly of a string light comprising:a first wire and a second wire, each of the first wire and the second wire comprising an end exposing copper strands;
a first light-emitting diode (LED) chip soldered to the exposed copper strands of the first wire and the second wire;
a colloid encapsulating the first LED chip soldered to the first wire and the second wire;
a light head securing the colloid and a part of the first wire and the second wire; and
a decorative shell secured onto the light head and enclosing the colloid encapsulating the first LED chip.
2\. The light assembly of claim 1, further comprising a rear plug placed in a space between the first wire and second wire where the first wire and second wire diverge.
3\. The light assembly of claim 1, further comprising a second LED chip soldered to the exposed copper strands of the first wire and the second wire.
4\. The light assembly of claim 1, wherein the string light comprises a plurality of light assemblies.
5\. The light assembly of claim 1, wherein the first LED chip comprises an anode and a cathode; and wherein the anode is soldered to the exposed copper strand of the first wire and the cathode is soldered to the exposed copper strand of the second wire.

6\. The light assembly of claim 1, wherein the decorative shell is in the shape of one of a mini light bulb, round globe, snowflake, and pentagram.
7\. A method of making a light assembly of a string light, the method comprising:
providing a first wire and a second wire;
stripped of insulation to expose a portion of the copper strands of each of the first wire and the second wire;
soldering a first LED chip to the first wire and the second wire;
encapsulating the first LED chip with a colloid;
attaching a light head to the first wire and second wire; and
securing a decorative shell on the light head,
wherein the decorative shell and light head enclosing the colloid encapsulating the first LED chip.
8\. The method of claim 7, further comprises placing a rear plug in a space between the first wire and the second wire where the first wire and the second wire diverge.
9\. The method of claim 7, wherein soldering the first LED chip to the first wire and the second wire comprises soldering an anode of the first LED chip to the exposed copper strands of the first wire and soldering a cathode of the first LED chip to the exposed copper strands of the second wire.

10\. The method of claim 7, wherein the light head is assembled or made by foam injection.

11\. The method of claim 7, wherein the colloid is formed over the first LED chip using one of injection molding, casting, and foam injection.

12\. The method of claim 7, further comprises soldering a second LED chip to the exposed copper strands of the first wire and the second wire.

OFFICE ACTION:
DETAILED ACTION
Notice of Pre-AIA  or AIA  Status
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
Priority
Receipt is acknowledged of certified copies of papers required by 37 CFR 1.55.
Claim Objections
Claim 7 is objected to because of the following informalities: The limitation “wherein the decorative shell and light head enclosing the colloid encapsulating the first LED chip” in lines 9-10 of the claim is grammatically incorrect. The Examiner respectfully suggests amending it to be --wherein the decorative shell and light head enclose .  Appropriate correction is required.
Claim Rejections - 35 USC § 112
The following is a quotation of 35 U.S.C. 112(b):
(b)  CONCLUSION.—The specification shall conclude with one or more claims particularly pointing out and distinctly claiming the subject matter which the inventor or a joint inventor regards as the invention.
The following is a quotation of 35 U.S.C. 112 (pre-AIA ), second paragraph:
The specification shall conclude with one or more claims particularly pointing out and distinctly claiming the subject matter which the applicant regards as his invention.
Claims 6-12 are rejected under 35 U.S.C. 112(b) or 35 U.S.C. 112 (pre-AIA ), second paragraph, as being indefinite for failing to particularly point out and distinctly claim the subject matter which the inventor or a joint inventor (or for applications subject to pre-AIA  35 U.S.C. 112, the applicant), regards as the invention.
Claim 6 is rejected as being indefinite as it is not clear if the recitation “wherein the decorative shell is in the shape of one of a mini light bulb, round globe, snowflake, and pentagram” requires the claimed decorative shell to include a shape of at least one of a mini light bulb, round globe, snowflake, and pentagram, or simply at least one of either the shape of a mini light bulb, round globe, snowflake, or pentagram.  The Applicant is respectfully advised that the use of the phrase “at least one of… and…” (or the similar phrase “one or more of… and…”) is a conjunctive list requiring at least one of each of the listed elements; “at least one of… or…” (or the similar phrase “one or more of… or…”) must be used when the intended requirement is to define a structure having at least just one of the cited elements. See Superguide Corp. v DirecTV Enters., Inc., 358 F.3d 870 (69 UPQ2d 1865) (fed. Cir. 2004).  The Applicant is further advised that, in comparing the claimed invention with the Prior Art, the Examiner assumed, based on the originally filed description and drawings, Claim 6 as defining the decorative shell including a shape of at least one of either a mini light bulb, round globe, snowflake, or pentagram.
Regarding claim 7, the limitation “stripped of insulation to expose a portion of the copper strands of each of the first and second wire” in lines 3-4 of the claim renders the claim indefinite because it is unclear what specific structure is being stripped of insulation in this method step, rendering the exact scope of the claim unascertainable. Further, the recitation “the copper strands” lacks antecedent basis. Based on a review of the Specification and Drawings as filed, for the purpose of examination, the Examiner has assumed that this method step requires ends of each of the first and second wire to be stripped of insulation to expose a portion of copper strands inside the first and second wires, and so the Examiner respectfully suggests amending it to be --stripping an end of each of the first wire and the second wire
Claims 8-10 and 12 are rejected due to their dependence on indefinite Claim 7.
Claim 11 is rejected as being indefinite as it is not clear if the recitation “wherein the colloid is formed over the first LED chip using one of injection molding, casting, and foam injection” in lines 1-2 of the claim requires the claimed colloid to be formed by at least one of injecting molding, casting, and foam molding, or simply at least one of either injection molding, casting, or foam molding.  The Applicant is respectfully advised that the use of the phrase “at least one of… and…” (or the similar phrase “one or more of… and…”) is a conjunctive list requiring at least one of each of the listed elements; “at least one of… or…” (or the similar phrase “one or more of… or…”) must be used when the intended requirement is to define a structure having at least just one of the cited elements. See Superguide Corp. v DirecTV Enters., Inc., 358 F.3d 870 (69 UPQ2d 1865) (fed. Cir. 2004).  The Applicant is further advised that, in comparing the claimed invention with the Prior Art, the Examiner assumed, based on the originally filed description and drawings, Claim 11 as defining a method including the colloid being formed using at least one of either foam molding, casting, or foam injection.
Appropriate correction is required.
Claim Rejections - 35 USC § 103
The following is a quotation of 35 U.S.C. 103 which forms the basis for all obviousness rejections set forth in this Office action:
A patent for a claimed invention may not be obtained, notwithstanding that the claimed invention is not identically disclosed as set forth in section 102, if the differences between the claimed invention and the prior art are such that the claimed invention as a whole would have been obvious before the effective filing date of the claimed invention to a person having ordinary skill in the art to which the claimed invention pertains. Patentability shall not be negated by the manner in which the invention was made.
Claims 1-12 are rejected under 35 U.S.C. 103 as being unpatentable over Tsai (US 12,085,244) in view of Chen (US 2018/0187840).
Regarding claim 1, Tsai teaches a light assembly of a string light (light assembly 100 of a light string 120 of connected light assemblies; see Figs. 1A-9; Abstract; col. 4, lines 23-60; col. 6, lines 50-56; col. 7, lines 8-20, 45-57; col. 15, lines 58-67; col. 16, lines 1-35) comprising a first wire and a second wire, each of the first wire and the second wire comprising an end exposing strands (first conductive lead wire 112 and second conductive lead wire 114 each have exposed conductors at their ends; see Figs. 1A-1F, 2, 8-9; col. 6, lines 50-67; col. 7, lines 1-65); a first light-emitting diode (LED) chip soldered to the exposed strands of the first wire and the second wire (a light emitting source 110 which comprises a light emitter 110C in the form of an LED is soldered to the exposed conductive strands of the first wire 112 and the second wire 114; see Figs. 1A-1F, 2, 8-9; col. 6, lines 50-67; col. 7, lines 1-65; col. 10, lines 20-50); an epoxy resin encapsulating the first LED chip soldered to the first wire and the second wire (a filler 116 such as epoxy resin or similar material is deposited in a light cap 104 and positioned over the first LED 110 to encapsulate the LED and its solder connections to the first and second wires 112, 114; see Figs. 1A-1F, 2; 8-9; col. 7, lines 66-67; col. 8, lines 1-47; col. 10, lines 12-58); a light head securing the epoxy resin and a part of the first wire and the second wire (housing 106; see Figs. 1A-6C, 8-9; col. 4, lines 47-52; col. 5, lines 36-67; col. 6, lines 13-56; col. 7, lines 8-31, 66-67; col. 8, lines 1-40, 63-67; col. 10, lines 12-67); and a decorative shell secured onto the light head and enclosing the epoxy resin encapsulating the first LED chip (light cap 104 is secured onto the light head 106 and encloses the epoxy resin 116 encapsulating the first LED chip 110 therein; see Figs. 1A-1F, 2, 8-9; col. 4, lines 47-67; col. 5, lines 1-35, 59-67; col. 6, lines 1-56; col. 7, lines 66-67; col. 8, lines 1-40; col. 9, lines 8-61; col. 10, lines 12-58).
However, the teachings of Tsai fail to specifically disclose the strands are copper strands, and the epoxy resin is a colloid.
Chen teaches a light assembly of a string light (string light 100; see Figs. 1-1A; Abstract; par. [0028]) comprising a first wire and a second wire, each of the first wire and the second wire comprising exposed copper strands (a parallel pair of positive wire 1 and negative wire 2, which comprise bulb welding positions 10 in the form of positive wire bulb welding positions 101 and negative wire bulb welding positions 102 evenly distributed along the two wires to expose the copper wire strands inside the two wires; see Figs .1-1A; para. [0005], [0028]-[0030], [0033], [0041]-[0042], [0045]); a first light emitting diode (LED) chip soldered to the exposed copper strands of the first wire and the second wire (LED chips 3 are soldered to the exposed copper strands of the first wire 1 and second wire 2 at their respective positive wire bulb welding positions 1 and negative wire bulb welding positions 2; see Figs. 1-1A; para. [0028], [0035]-[0036], [0038], [0046]-[0047]); and a colloid encapsulating the first LED chip soldered to the first wire and the second wire (the entire first LED chip 3, including the points where its electrodes are soldered to the first and second wires 1 and 2, is encapsulated by a high-transmission epoxy resin colloid 4; see Figs. 1-1A; para. [0028], [0047]).
Therefore, in view of Chen, it would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify the light assembly of Tsai by forming the wire strands of each of the first and second wires as copper strands, since it has been held by the courts that selection of a prior art material on the basis of its suitability for its intended purpose is within the level of ordinary skill. See In re Leshing, 125 USPQ 416 (CCPA 1960) and Sinclair & Carroll Co. v. Interchemical Corp., 65 USPQ 297 (1945). One would have been motivated to modify the known light assembly of Tsai by forming the wire strands of each of the first and second wires as copper strands, as taught by Chen, in order to improve the overall flexibility of the wires and electrical conductivity of the wires.
Further, in view of Chen, it would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify the light assembly of Tsai by forming the epoxy resin encapsulating the first LED chips as a colloid, See In re Leshing, 125 USPQ 416 (CCPA 1960) and Sinclair & Carroll Co. v. Interchemical Corp., 65 USPQ 297 (1945). One would have been motivated to modify the known light assembly of Tsai by forming the epoxy resin encapsulating the first LED chips as a colloid, as taught by Chen, in order to ensure a full 360 degrees of transmission from each LED chip and maximize the light transmission through the encapsulant (see Chen, par. [0047] for the motivation).
Regarding claim 2, Tsai teaches the light assembly further comprising a rear plug placed in a space between the first wire and the second wire where the first wire and second wire diverge (spacer plug 108; see Figs. 1A-1F, 7A-8; col. 6, lines 30-49; col. 7, lines 8-44; , 58-65; col. 8, lines 15-40; col. 13, lines 15-67; col. 15, lines 20-67).
However, regarding claim 3, the teachings of Tsai as modified fail to disclose or fairly suggest the light assembly further comprising a second LED chip soldered to the exposed copper strands of the first wire and the second wire.
It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to further modify the light assembly of Tsai by soldering a second LED chip to the exposed copper strands of the first wire and the second wire, since it has been held that mere duplication of essential working parts of a device involves only routine skill in the art.  St. Regis Paper Co. v. Bemis Co., 193 USPQ 8. In this case, further modifying the known light assembly of Tsai by soldering a second LED chip to the exposed copper strands of the first wire and the second wire would have flown naturally to one of ordinary skill in the art as necessitated by the particular design requirements of a given application, in order to increase the amount of light emitted by each light assembly.
Regarding claim 4, Tsai teaches wherein the string light comprises a plurality of light assemblies (the light string 120 comprises a plurality of light assemblies 100; see Fig. 9; col. 16, lines 8-35).
Regarding claim 5, Tsai as modified teaches wherein the first LED chip comprises an anode and a cathode (the first LED chip 110 includes a first contact 110A functioning as an anode connector of the LED and a second contact 110B functioning as a cathode connector of the LED, which are each soldered to the exposed strands of the first and second wires 112, 114; see Figs. 1A-1F, 2; col. 6, lines 57-67; col. 7, lines 1-44; col. 10, lines 31-50; col. 14, lines 19-51); and wherein the anode is soldered to the exposed copper strand of the first wire and the cathode is soldered to the exposed copper strand of the second wire (see Figs. 1A-1F, 2; col. 6, lines 57-67; col. 7, lines 1-44; col. 10, lines 31-50; col. 14, lines 19-51).
Regarding claim 6, Tsai teaches wherein the decorative shell is in the shape of one of a mini light bulb, round globe, snowflake, and pentagram (the decorative shell 104 can have a generally frusto-conical shape as a miniature light bulb and other suitable shapes such as for decorative, functional, or other purposes; see Figs. 1A-1F, 2, 8-9; col. 4, lines 61-67; col. 5, lines 1-9).
Regarding claim 7, Tsai teaches a method of making a light assembly of a string light (light assembly 100 of a light string 120 of connected light assemblies; see Figs. 1A-9; Abstract; col. 4, lines 23-60; col. 6, lines 50-56; col. 7, lines 8-20, 45-57; col. 15, lines 58-67; col. 16, lines 1-35), the method comprising providing a first wire and a second wire (first conductive lead wire 112 and second conductive lead wire 114 each have exposed conductors at their ends; see Figs. 1A-1F, 2, 8-9; col. 6, lines 50-67; col. 7, lines 1-65); stripping an end of each of the first wire and the second wire of insulation to expose a portion of strands of each of the first wire and the second wire (first conductive lead wire 112 and second conductive lead wire 114 each have exposed conductors at their ends; see Figs. 1A-1F, 2, 8-9; col. 6, lines 50-67; col. 7, lines 1-65); soldering a first LED chip to the first wire and the second wire (a light emitting source 110 which comprises a light emitter 110C in the form of an LED is soldered to the exposed conductive strands of the first wire 112 and the second wire 114; see Figs. 1A-1F, 2, 8-9; col. 6, lines 50-67; col. 7, lines 1-65; col. 10, lines 20-50); encapsulating the first LED chip with an epoxy resin (a filler 116 such as epoxy resin or similar material is deposited in a light cap 104 and positioned over the first LED 110 to encapsulate the LED and its solder connections to the first and second wires 112, 114; see Figs. 1A-1F, 2; 8-9; col. 7, lines 66-67; col. 8, lines 1-47; col. 10, lines 12-58); attaching a light head to the first wire and the second wire (a housing 106 is connected to the first wire 112 and the second wire 114; see Figs. 1A-6C, 8-9; col. 4, lines 47-52; col. 5, lines 36-67; col. 6, lines 13-56; col. 7, lines 8-31, 66-67; col. 8, lines 1-40, 63-67; col. 10, lines 12-67); and securing a decorative shell on the light head, wherein the decorative shell and light head enclose the epoxy resin encapsulating the first LED chip (light cap 104 is secured onto the light head 106 and encloses the epoxy resin 116 encapsulating the first LED chip 110 therein; see Figs. 1A-1F, 2, 8-9; col. 4, lines 47-67; col. 5, lines 1-35, 59-67; col. 6, lines 1-56; col. 7, lines 66-67; col. 8, lines 1-40; col. 9, lines 8-61; col. 10, lines 12-58).
However, the teachings of Tsai fail to specifically disclose the strands are copper strands, and the epoxy resin is a colloid.
Chen teaches a method of making a light assembly of a string light (string light 100; see Figs. 1-1A; Abstract; par. [0028]), the method comprising providing a first wire and a second wire, and stripping portions of each of the first wire and second wire of insulation to expose a portion of copper strands of each of the first wire and the second wire (a parallel pair of positive wire 1 and negative wire 2, which comprise bulb welding positions 10 in the form of positive wire bulb welding positions 101 and negative wire bulb welding positions 102 evenly distributed along the two wires to expose the copper wire strands inside the two wires; see Figs .1-1A; para. [0005], [0028]-[0030], [0033], [0041]-[0042], [0045]); soldering a first LED chip to the first wire and the second wire (LED chips 3 are soldered to the exposed copper strands of the first wire 1 and second wire 2 at their respective positive wire bulb welding positions 1 and negative wire bulb welding positions 2; see Figs. 1-1A; para. [0028], [0035]-[0036], [0038], [0046]-[0047]); and encapsulating the first LED chip with a colloid (the entire first LED chip 3, including the points where its electrodes are soldered to the first and second wires 1 and 2, is encapsulated by a high-transmission epoxy resin colloid 4; see Figs. 1-1A; para. [0028], [0047]).
Therefore, in view of Chen, it would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify the method of making a light assembly of Tsai by forming the wire strands of each of the first and second wires as copper strands, since it has been held by the courts that selection of a prior art material on the basis of its suitability for its intended purpose is within the level of ordinary skill. See In re Leshing, 125 USPQ 416 (CCPA 1960) and Sinclair & Carroll Co. v. Interchemical Corp., 65 USPQ 297 (1945). One would have been motivated to modify the known method of Tsai by forming the wire strands of each of the first and second wires as copper strands, as taught by Chen, in order to improve the overall flexibility of the wires and electrical conductivity of the wires.
Further, in view of Chen, it would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to modify the method of making a light assembly of Tsai by forming the epoxy resin encapsulating the first LED chips as a colloid, See In re Leshing, 125 USPQ 416 (CCPA 1960) and Sinclair & Carroll Co. v. Interchemical Corp., 65 USPQ 297 (1945). One would have been motivated to modify the known method of Tsai by forming the epoxy resin encapsulating the first LED chips as a colloid, as taught by Chen, in order to ensure a full 360 degrees of transmission from each LED chip and maximize the light transmission through the encapsulant (see Chen, par. [0047] for the motivation).
Regarding claim 8, Tsai teaches the method further comprising placing a rear plug in a space between the first wire and the second wire where the first wire and the second wire diverge (spacer plug 108; see Figs. 1A-1F, 7A-8; col. 6, lines 30-49; col. 7, lines 8-44; , 58-65; col. 8, lines 15-40; col. 13, lines 15-67; col. 15, lines 20-67).
Regarding claim 9, Tsai as modified teaches the method wherein soldering the first wire and the second wire comprises soldering an anode of the first LED chip to the exposed copper strands of the first wire and soldering a cathode of the first LED chip to the exposed copper strands of the second wire (the first LED chip 110 includes a first contact 110A functioning as an anode connector of the LED and a second contact 110B functioning as a cathode connector of the LED, which are each soldered to the exposed strands of the first and second wires 112, 114; see Figs. 1A-1F, 2; col. 6, lines 57-67; col. 7, lines 1-44; col. 10, lines 31-50; col. 14, lines 19-51).
Regarding claim 10, Tsai teaches the method wherein the light head is assembled or made by foam injection (the entire light head (housing 106) can be injection molded or otherwise machined (i.e., assembled); see Figs. 1A-1G, 3-6C, 8-11D,  col. 12, lines 30-34).
Regarding claim 11, Tsai as modified teaches the method wherein the colloid is formed over the first LED chip using one of injection molding, casting, and foam injection (the epoxy resin 116 is injected into the decorative shell (light cap 104) to secure the decorative shell to the light head 106 and encapsulate the first LED chip 110 and its solder connections to the first and second wires 112, 114; see Figs. 1A-1F, 2; col. 7, lines 66-67; col. 8, lines 1-40).
However, regarding claim 12, the teachings of Tsai as modified fail to disclose or fairly suggest the method further comprises soldering a second LED chip to the exposed copper strands of the first wire and the second wire.
It would have been obvious to one of ordinary skill in the art before the effective filing date of the claimed invention to further modify the method of making a light assembly of Tsai by soldering a second LED chip to the exposed copper strands of the first wire and the second wire, since it has been held that mere duplication of essential working parts of a device involves only routine skill in the art.  St. Regis Paper Co. v. Bemis Co., 193 USPQ 8. In this case, further modifying the known method of Tsai by soldering a second LED chip to the exposed copper strands of the first wire and the second wire would have flown naturally to one of ordinary skill in the art as necessitated by the particular design requirements of a given application, in order to increase the amount of light emitted by each light assembly.
Conclusion
The prior art made of record and not relied upon is considered pertinent to applicant's disclosure. Tsai (US 11,499,700), Chen (US 10,393,351), Yu (US 8,083,393), and Tsai (US 7,740,503) all disclose light assemblies of light strings comprising first and second wires having an LED electrically connected to the wires by solder or other conventional methods and enclosed by at least a light head and a decorative shell.


NEXT OFFICE ACTION: ALLOWABILITY NOTICE
Notice of Pre-AIA  or AIA  Status
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
Response to Amendment
Applicant's amendment filed on 4/11/2025 has been entered.  Claims 7 and 11 have been amended.  Claims 1-6 have been cancelled.  No claims have been added.  Claims 7-12 are still pending in this application, with claim 7 being independent.
The objection to Claim 7 has been withdrawn in view of the amendment.
The rejections of Claims 6-12 under 35 U.S.C. 112(b) have been withdrawn in view of the amendment.
EXAMINER'S AMENDMENT
An examiner’s amendment to the record appears below. Should the changes and/or additions be unacceptable to applicant, an amendment may be filed as provided by 37 CFR 1.312. To ensure consideration of such an amendment, it MUST be submitted no later than the payment of the issue fee.
Authorization for this examiner’s amendment was given in an interview with Kenneth Xie, Reg. #60,350 on 6/4/2025.
The application has been amended as follows:
Claim 7 (currently amended): A method of making a light assembly of a string light, the method comprising:
providing a first wire and a second wire;
stripping an end of each of the first wire and the second wire of insulation to expose a portion of copper strands of each of the first wire and the second wire;
encapsulating the first LED chip with a colloid;
attaching a light head to the first wire and the second wire after the first LED chip is encapsulated with the
securing a decorative shell on the light head after the light head is attached to the first wire and second wire,
wherein the decorative shell and the light head enclose the colloid encapsulating the first LED chip.
Allowable Subject Matter
Claims 7-12 are allowed.
The following is an examiner’s statement of reasons for allowance:
Regarding claim 7, the Prior Art taken as a whole fails to specifically disclose or suggest, in combination, “A method of making a light assembly of a string light, the method comprising providing a first wire and a second wire; stripping an end of each of the first wire and the second wire of insulation to expose a portion of copper strands of each of the first wire and the second wire; soldering a first LED chip to the first wire and the second wire; encapsulating the first LED chip with a colloid; attaching a light head to the first wire and second wire after the first LED chip is encapsulated with the colloid; and securing a decorative shell on the light head after the light head is attached to the first wire and second wire, wherein the decorative shell and light head enclose the colloid encapsulating the first LED chip” (emphasis added).
The closest Prior Art, Tsai (US 12,085,244), lacks the teaching of the light head being attached to the first and second wires after the first LED chip has been encapsulated with the colloid, and subsequently securing the decorative shell onto the light head after attaching the light head to the first and second wires, as required by amended Claim 7. Additionally, although Wang (US 10,823,376) teaches an LED light bar comprising a colloidal shell enclosing the LEDs, which is directly plugged into a light head/lamp holder after assembly of the encapsulated LED light bar to connect the LEDs to a wire in the light head, Wang also teaches the wire is already installed in the light head prior to the connection of the LED bar to the wires, rather than the first LED chip being soldered to the first and second wires prior to the LED chip being encapsulated by the colloid and then attaching the first and second wires attached to the light head, as required by amended Claim 7.
Accordingly, although methods of making a light assembly of a string light are known, as evidenced by the Prior Art already of record, no Prior Art was found teaching individually, or suggesting in combination, all the features of Applicant’s invention, in particular the above limitations in combination with the remaining features of the claim, and there would be no motivation, absent the Applicant’s own disclosure, to modify the references in the manner distinctly and specifically called for in the combination as claimed in amended Claim 7.
Claims 8-12 are allowable due to their dependence on allowable Claim 7.
Any comments considered necessary by applicant must be submitted no later than the payment of the issue fee and, to avoid processing delays, should preferably accompany the issue fee.  Such submissions should be clearly labeled “Comments on Statement of Reasons for Allowance.”
Conclusion
The prior art made of record and not relied upon is considered pertinent to applicant's disclosure. Lu (US 2023/0128538) discloses an LED lamp string and method of making the LED lamp string comprising soldering a first LED chip to exposed contacts of first and second wires and encapsulating the first LED chip with an encapsulating material to form a lamp bead using injection molding, and Loomis et al. (US 2015/0211727) discloses an LED light string and method of making the LED light string comprising a first LED chip electrically connected without solder to a first wire and a second wire, encapsulating the first LED chip with a lens, attaching a light head to the first wire and the second wire, and securing a decorative shell on the light head after the light head is attached to the first and second wires, the decorative shell and the light head both enclosing the lens encapsulating the first LED chip.

CITED REFERENCE SUMMARIES: Ref US12085244B1: Claims:
A light string, comprising: a housing with a passageway therethrough defining a light aperture and a wire aperture; a light cap, the light cap having: a cap body that is non-opaque, the cap body having a hollow therein; an upper tip at an upper end of the cap body forming an enclosed end of the light cap; and a peripheral visibility ring extending outwardly from the cap body opposite the upper tip, the peripheral visibility ring being non-opaque; wherein, the light cap is coupled to and extends from the housing such that the hollow of the cap body aligns axially with the light aperture and the peripheral visibility ring seats adjacent to an end of the housing proximate the light aperture; and a light assembly having: a light emitting source, a first conductive lead wire electrically coupled to the light emitting source that extends out from the wire aperture of the housing, and a second conductive lead wire electrically coupled to the light emitting source that extends out from the wire aperture of the housing; a filler deposited in the light cap that is transparent when solidified, the filler coupling the light cap and light assembly to the housing; wherein: the light emitting source, when energized, emits light that is visible from outside the light cap; the filler defines a light guide that directs light within the light cap to the peripheral visibility ring; and the peripheral visibility ring reflects light in a direction different from the light emitted by the light emitting source such that the light emitted by the light emitting source is visible when an observer is looking at a side view of the cap body.
a housing with a passageway therethrough defining a light aperture and a wire aperture;
a light cap, the light cap having: a cap body that is non-opaque, the cap body having a hollow therein; an upper tip at an upper end of the cap body forming an enclosed end of the light cap; and a peripheral visibility ring extending outwardly from the cap body opposite the upper tip, the peripheral visibility ring being non-opaque; wherein, the light cap is coupled to and extends from the housing such that the hollow of the cap body aligns axially with the light aperture and the peripheral visibility ring seats adjacent to an end of the housing proximate the light aperture; and
a cap body that is non-opaque, the cap body having a hollow therein;
an upper tip at an upper end of the cap body forming an enclosed end of the light cap; and
a peripheral visibility ring extending outwardly from the cap body opposite the upper tip, the peripheral visibility ring being non-opaque;
wherein, the light cap is coupled to and extends from the housing such that the hollow of the cap body aligns axially with the light aperture and the peripheral visibility ring seats adjacent to an end of the housing proximate the light aperture; and
a light assembly having: a light emitting source, a first conductive lead wire electrically coupled to the light emitting source that extends out from the wire aperture of the housing, and a second conductive lead wire electrically coupled to the light emitting source that extends out from the wire aperture of the housing; a filler deposited in the light cap that is transparent when solidified, the filler coupling the light cap and light assembly to the housing;
a light emitting source, a first conductive lead wire electrically coupled to the light emitting source that extends out from the wire aperture of the housing, and a second conductive lead wire electrically coupled to the light emitting source that extends out from the wire aperture of the housing;
a filler deposited in the light cap that is transparent when solidified, the filler coupling the light cap and light assembly to the housing;
wherein: the light emitting source, when energized, emits light that is visible from outside the light cap; the filler defines a light guide that directs light within the light cap to the peripheral visibility ring; and the peripheral visibility ring reflects light in a direction different from the light emitted by the light emitting source such that the light emitted by the light emitting source is visible when an observer is looking at a side view of the cap body.
the light emitting source, when energized, emits light that is visible from outside the light cap;
the filler defines a light guide that directs light within the light cap to the peripheral visibility ring; and
the peripheral visibility ring reflects light in a direction different from the light emitted by the light emitting source such that the light emitted by the light emitting source is visible when an observer is looking at a side view of the cap body.
The light string of claim 1 , wherein the peripheral visibility ring comprises a reflector such that light passes through the filler functioning as a light guide to the reflector such that a brightness of light viewed from a side of the cap body is similar to a brightness of light observed when viewing the upper tip.
The light string of claim 1 , wherein the upper tip of the light cap comprises a tip reflector that reflects some light towards the peripheral visibility ring through the light guide of the filler.
The light string of claim 1 further comprising a spacer plug having an insulative projection that extends between the first conductive lead wire and the second conductive lead wire.
The light string of claim 4 , wherein: the light assembly is coupled to the housing such that the light emitting source extends into and bonds with the filler, and at least a portion of the insulative projection extends into and bond with the filler such that the light string is impervious to water reaching the light emitting source in water up to 1 meter deep for up to 30 minutes.
the light assembly is coupled to the housing such that the light emitting source extends into and bonds with the filler, and at least a portion of the insulative projection extends into and bond with the filler such that the light string is impervious to water reaching the light emitting source in water up to 1 meter deep for up to 30 minutes.
The light string of claim 5 , wherein: the filler comprises an epoxy that is transparent when solidified at least partially fills an internal volume of the light cap such that the light cap is epoxied to, and forms a water-tight seal with the light emitting source.
the filler comprises an epoxy that is transparent when solidified at least partially fills an internal volume of the light cap such that the light cap is epoxied to, and forms a water-tight seal with the light emitting source.
The light string of claim 5 , wherein: the first contact of the light emitting source is implemented as an anode lead that is electrically coupled to a conductor of the first conductive lead wire; the second contact of the light emitting source is implemented as a cathode lead that is electrically coupled to a conductor of the second conductive lead wire; and the filler coats at least a portion of the anode lead and the cathode lead that extend into the light cap.
the first contact of the light emitting source is implemented as an anode lead that is electrically coupled to a conductor of the first conductive lead wire;
the second contact of the light emitting source is implemented as a cathode lead that is electrically coupled to a conductor of the second conductive lead wire; and
the filler coats at least a portion of the anode lead and the cathode lead that extend into the light cap.
The light string of claim 7 , wherein: the anode lead is electrically coupled to the conductor of the first conductive lead wire via at least one of splicing, contact crimping, welding or soldering; the cathode lead is electrically coupled to the conductor of the second conductive lead wire via at least one of splicing, contact crimping, welding or soldering; and the filler bonds the first conductive lead wire and the second conductive lead wire that extend into the light cap to the spacer plug.
the anode lead is electrically coupled to the conductor of the first conductive lead wire via at least one of splicing, contact crimping, welding or soldering;
the cathode lead is electrically coupled to the conductor of the second conductive lead wire via at least one of splicing, contact crimping, welding or soldering; and
the filler bonds the first conductive lead wire and the second conductive lead wire that extend into the light cap to the spacer plug.
The light string of claim 5 , wherein: the filler fills the light cap and does not fill the housing.
the filler fills the light cap and does not fill the housing.
The light string of claim 4 , wherein: the first conductive wire is sheathed in an insulator; the second conductive wire is sheathed in an insulator; the spacer plug includes a first channel and a second channel therealong; the first channel receives the insulator of the first conductive wire; and the second channel receives the insulator of the second conductive wire.
the first conductive wire is sheathed in an insulator;
the second conductive wire is sheathed in an insulator;
the spacer plug includes a first channel and a second channel therealong; the first channel receives the insulator of the first conductive wire; and the second channel receives the insulator of the second conductive wire.
the first channel receives the insulator of the first conductive wire; and
the second channel receives the insulator of the second conductive wire.
The light string of claim 4 , wherein: the filler fills the light cap such that any exposed conductor within the light cap is covered by the epoxy sufficient to form a waterproof seal.
the filler fills the light cap such that any exposed conductor within the light cap is covered by the epoxy sufficient to form a waterproof seal.
The light string of claim 1 further comprising: a bulb holder having a passageway therethrough, the passageway defining a first end and a second end; wherein: the housing seats inside the passageway of the bulb holder by inserting into the first end of the bulb holder; and a faceted bulb couples to the bulb holder by inserting into the second end of the bulb holder.
a bulb holder having a passageway therethrough, the passageway defining a first end and a second end;
the housing seats inside the passageway of the bulb holder by inserting into the first end of the bulb holder; and
a faceted bulb couples to the bulb holder by inserting into the second end of the bulb holder.
A light string, comprising: an electrical plug that plugs into a source of electrical power; a wire set coupled to the electrical plug; and a set of light string assemblies coupled to the wire set, each light string assembly comprising: a housing assembly having: a housing with a passageway therethrough defining a light aperture and a wire aperture; and a light cap, the light cap having: a cap body that is non-opaque, the cap body having a hollow therein; an upper tip at an upper end of the cap body forming an enclosed tip of the light cap; and a peripheral visibility ring extending outwardly from the cap body opposite the upper tip, the peripheral visibility ring being non-opaque; wherein, the light cap is coupled to and extends from the housing such that the hollow of the cap body aligns axially with the light aperture and the peripheral visibility ring seats adjacent to an end of the housing proximate the light aperture; and a light assembly having: a light emitting source having a first contact, a second contact, and a light emitter coupled to the first contact and the second contact; a first conductive lead wire electrically coupled to the first contact of the light emitting source; a second conductive lead wire electrically coupled to the second contact of the light emitting source; and a spacer plug having an insulative projection that extends between the first conductive lead wire and the second conductive lead wire; and a filler deposited in the light cap that is transparent when solidified, the filler coupling the light cap and light assembly to the housing; wherein: the light assembly is coupled to the housing such that the light emitting source extends into and bonds with the filler, and at least a portion of the insulative projection extends into and bond with the filler; the first conductive lead wire extends out the wire aperture of the housing, and the second conductive lead wire extends out the wire aperture of the housing; the light emitting source, when energized, emits light visible from outside the light cap; the filler defines a light guide that directs light within the light cap to the peripheral visibility ring; and the peripheral visibility ring reflects light in a direction different from the light emitted by the light emitting source such that the light emitted by the light emitting source is visible when an observer is looking at a side view of the cap body.
an electrical plug that plugs into a source of electrical power;
a wire set coupled to the electrical plug; and
a set of light string assemblies coupled to the wire set, each light string assembly comprising: a housing assembly having: a housing with a passageway therethrough defining a light aperture and a wire aperture; and a light cap, the light cap having: a cap body that is non-opaque, the cap body having a hollow therein; an upper tip at an upper end of the cap body forming an enclosed tip of the light cap; and a peripheral visibility ring extending outwardly from the cap body opposite the upper tip, the peripheral visibility ring being non-opaque; wherein, the light cap is coupled to and extends from the housing such that the hollow of the cap body aligns axially with the light aperture and the peripheral visibility ring seats adjacent to an end of the housing proximate the light aperture; and a light assembly having: a light emitting source having a first contact, a second contact, and a light emitter coupled to the first contact and the second contact; a first conductive lead wire electrically coupled to the first contact of the light emitting source; a second conductive lead wire electrically coupled to the second contact of the light emitting source; and a spacer plug having an insulative projection that extends between the first conductive lead wire and the second conductive lead wire; and
a housing assembly having: a housing with a passageway therethrough defining a light aperture and a wire aperture; and a light cap, the light cap having: a cap body that is non-opaque, the cap body having a hollow therein; an upper tip at an upper end of the cap body forming an enclosed tip of the light cap; and a peripheral visibility ring extending outwardly from the cap body opposite the upper tip, the peripheral visibility ring being non-opaque; wherein, the light cap is coupled to and extends from the housing such that the hollow of the cap body aligns axially with the light aperture and the peripheral visibility ring seats adjacent to an end of the housing proximate the light aperture; and
a housing with a passageway therethrough defining a light aperture and a wire aperture; and
a light cap, the light cap having: a cap body that is non-opaque, the cap body having a hollow therein; an upper tip at an upper end of the cap body forming an enclosed tip of the light cap; and a peripheral visibility ring extending outwardly from the cap body opposite the upper tip, the peripheral visibility ring being non-opaque; wherein, the light cap is coupled to and extends from the housing such that the hollow of the cap body aligns axially with the light aperture and the peripheral visibility ring seats adjacent to an end of the housing proximate the light aperture; and
an upper tip at an upper end of the cap body forming an enclosed tip of the light cap; and
a light assembly having: a light emitting source having a first contact, a second contact, and a light emitter coupled to the first contact and the second contact; a first conductive lead wire electrically coupled to the first contact of the light emitting source; a second conductive lead wire electrically coupled to the second contact of the light emitting source; and a spacer plug having an insulative projection that extends between the first conductive lead wire and the second conductive lead wire; and
a light emitting source having a first contact, a second contact, and a light emitter coupled to the first contact and the second contact;
a first conductive lead wire electrically coupled to the first contact of the light emitting source;
a second conductive lead wire electrically coupled to the second contact of the light emitting source; and
a spacer plug having an insulative projection that extends between the first conductive lead wire and the second conductive lead wire; and
a filler deposited in the light cap that is transparent when solidified, the filler coupling the light cap and light assembly to the housing; wherein: the light assembly is coupled to the housing such that the light emitting source extends into and bonds with the filler, and at least a portion of the insulative projection extends into and bond with the filler; the first conductive lead wire extends out the wire aperture of the housing, and the second conductive lead wire extends out the wire aperture of the housing; the light emitting source, when energized, emits light visible from outside the light cap; the filler defines a light guide that directs light within the light cap to the peripheral visibility ring; and the peripheral visibility ring reflects light in a direction different from the light emitted by the light emitting source such that the light emitted by the light emitting source is visible when an observer is looking at a side view of the cap body.
wherein: the light assembly is coupled to the housing such that the light emitting source extends into and bonds with the filler, and at least a portion of the insulative projection extends into and bond with the filler; the first conductive lead wire extends out the wire aperture of the housing, and the second conductive lead wire extends out the wire aperture of the housing; the light emitting source, when energized, emits light visible from outside the light cap; the filler defines a light guide that directs light within the light cap to the peripheral visibility ring; and the peripheral visibility ring reflects light in a direction different from the light emitted by the light emitting source such that the light emitted by the light emitting source is visible when an observer is looking at a side view of the cap body.
the light assembly is coupled to the housing such that the light emitting source extends into and bonds with the filler, and at least a portion of the insulative projection extends into and bond with the filler;
the first conductive lead wire extends out the wire aperture of the housing, and the second conductive lead wire extends out the wire aperture of the housing;
the light emitting source, when energized, emits light visible from outside the light cap;
The light string of claim 13 , wherein the peripheral visibility ring comprises a reflector such that light passes through the filler functioning as a light guide to the reflector such that a brightness of light viewed from a side of the cap body is similar to a brightness of light observed when viewing the upper tip.
The light string of claim 13 , wherein the upper tip of the light cap comprises a tip reflector that reflects some light towards the peripheral visibility ring through the light guide of the filler.
The light string of claim 13 , wherein, for each light string assembly in the light string: the light emitting source is positioned within the housing assembly such that light emitted from the light emitting source shines out the light cap; and the filler comprises epoxy that fills an internal volume of the light cap such that the light
[Truncated to input limit]