LED for interfacing and connecting to conductive substrates

An illumination device for enhancing the structural and aesthetic appearance of associated articles or substrates and to provide operative coaction with conductive current paths made from conductive paints, inks and the like compositions on such articles and substrates is disclosed. The illumination device comprises an LED having leads, the LED and at least one portion of the leads are encapsulated within a substantially nonconductive relatively transparent or translucent housing. At least a second portion of the leads of the LED extend outside of the housing and are arranged substantially flush along an exterior surface of the housing so that when the housing is connected by suitable connectors to the associated article or substrate, electrical communication with an external power source can be established for operating and actuating the LED.

FIELD OF THE INVENTION 
The present invention relates to light emitting diodes (LEDs). More 
particularly, the present invention relates to LED modules disposed for 
providing illuminated decorations, designs or assemblies on apparel such 
as wearing apparel, decorative apparel, toys, clothing for dolls or 
accessories and operatively associated with conductive paints, inks and 
the like type of compositions on such articles for transmitting electrical 
current for the operation and actuation of such LED modules. 
BACKGROUND OF THE INVENTION 
The use of LED modules for decorating various articles, such as wearing 
apparel or accessories, is well known in the apparel industry. Such LED 
modules are also connected to many types of articles, the structure of the 
LED modules and the means for connecting the LED modules to an associated 
article varies depending upon the structure of the article to which the 
LED modules are affixed and the means for conducting the current for 
operating and actuating such LED modules. 
Although the prior art discloses LED modules that are connected to various 
types of articles such as clothing, footwear, sunglasses, etc. and to 
electrical circuitry thereon generally utilizing hard wire conductors for 
operating and actuating the LED modules, there is no teaching or 
suggestion as to how to affix LED modules to electrically conductive 
paths, such as conductive paint, arranged on the associated apparel, 
footwear, toys, etc. 
U.S. Pat. No. 5,278,734 discloses a creative structure which utilizes 
cooperating threads to attach LED modules to various articles including 
wearing apparel such as sweatshirts and the like. 
The prior art also discloses encapsulated LEDs for various purposes. For 
example, U.S. Pat. No. 5,018,053 discloses a partially encapsulated LED 
within a non-conductive enamel-like material for use as jewelry. U.S. Pat. 
No. 3,812,406 discloses a crystal on which a large number of 
electroluminescent diodes are manufactured to display an alphanumeric 
letter. The crystal is made of a semi-conductor material and is protected 
by a transparent resin. 
None of the aforementioned patents disclose an LED encapsulated within a 
housing made of non-conductive material wherein the leads of the LED 
extend outside of the housing and are bent or formed for placement 
substantially flush against the housing wall through which they extend. 
This arrangement is a significant improvement over known LED modules as it 
provides a structure suitable for electrical connection to conductive 
paint paths, and other electrically conductive paths, arranged on an 
associated article or substrate. 
Further, there is a need in the prior art for providing an efficient 
arrangement for connecting an LED module to an associated article, such as 
clothing for humans or dolls or other accessories wherein the LED module 
can be affixed to the apparel in an aesthetically pleasing manner. 
The term apparel as used in the present application is intended to 
encompass various types of articles including wearing apparel, decorative 
articles, footwear, clothing for dolls, accessories for dolls or other 
accessories on which an LED module may be affixed for decorative purposes. 
The present invention solves all of these shortcomings in the prior art and 
particularly provides an improved LED module encapsulated within a housing 
and which is intended to be secured, affixed or adhered to various types 
of apparel to create a design on or enhance the appearance of apparel, or 
to toys, dolls and other devices. 
SUMMARY AND OBJECTS OF THE INVENTION 
According to one aspect of the present invention, an illumination device 
comprises an LED having a diode body and a pair of leads connected to the 
diode body. Each of the leads includes a first portion extending along a 
first plane away from the diode body. Encapsulating material is provided 
which forms a housing which completely surrounds the diode body and 
defines external walls having predetermined boundaries such that the first 
portion of the leads extends along the first plane and through at least 
one of the external walls formed by the encapsulating material. Each of 
the leads also includes a second portion which extends outside of the 
housing along a second plane generally transverse to the respective first 
portion of the leads so as to lie substantially flush against the external 
wall of the housing through which the first portion extends. The second 
portion of the leads preferably terminates at a location within the 
boundary defined by the external wall along which the respective second 
portion of the leads extends. 
Preferably, the respective second portion of the leads begins at a location 
after the associated first portion of the leads exits the housing. In one 
preferred embodiment, the second portion of the leads extends 
substantially to the boundary of the external wall. 
The encapsulating housing of the illumination device may comprise various 
shapes and sizes. In a preferred embodiment, the housing includes facets 
thereon which act to enclose the diode body of the LED within a jewel-like 
casing. 
The illumination device may also comprise a connector means for affixing 
the housing to a given piece of apparel or other substrate. The connector 
means may comprise a coacting socket for removably engaging the housing 
with the apparel or other substrate to which the housing is being affixed. 
Alternatively, a suitable connector on the housing can extend through the 
apparel, toy, doll or other substrate or device. Any of the connector 
means for such illuminating device act to enable the leads on the 
illumination device to be brought into operative association with the 
conductive paints, inks or the like compositions on the apparel, toys, 
dolls and other devices for delivering the current for operating and 
actuating the encapsulated LED. 
The apparel used in connection with the illumination device in accordance 
with the present invention may comprise wearing apparel, decorative 
articles, clothing for dolls, accessories for dolls and humans, etc. The 
apparel may include a first surface and a second surface and may have 
current conducting means arranged on the first surface for transmitting 
current from a power source to the associated LED module or modules as the 
case may be. In this embodiment, the second portion of the leads is 
arranged adjacent to the first surface of the apparel for electrical 
communication with the current conducting means. The socket may be 
arranged adjacent the second surface of the apparel in alignment with the 
housing so that it can be brought into engagement therewith. 
The engagement between the socket and the housing may be enhanced by 
adhering or gluing the housing to the first surface of the apparel and 
alternately or selectively adhering or gluing the socket to the second 
surface of the apparel. 
Where the connector means extends through the apparel, toy, doll or other 
substrate or device, a suitable removable and independent locking means 
can be provided for engaging and holding each respective LED module or 
modules in assembled position, as the case may be. 
The present invention is also directed toward a decorative article of 
apparel in combination with the illumination device discussed above. 
Preferably, the decorative article of apparel includes current conducting 
path thereon for permitting current to flow from a power source to an 
associated LED module. The current conducting path may comprise conductive 
paint, ink or other conductive compositions. 
It may be desirable for the decorative article to include a switch which 
controls the flow of current from the power source to the illumination 
device of the present invention. Various switches or the like devices may 
be used. Alternatively, a human finger, or other body part, may act as a 
switch when placed across a conductive path so that current is momentarily 
permitted to flow from the associated power source to the LED module or 
modules, thus permitting the associated or desired LED module or modules 
to be momentarily and selectively activated. 
Other objects, features and advantages of the present invention will be 
more fully understood with reference to the following detailed description 
of the preferred embodiments when taken in conjunction with the 
accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
In accordance with one embodiment of the invention, FIGS. 1, 2 and 3 show 
an illumination device generally designated 10. The illumination device 10 
includes an internally arranged diode forming an LED 12 having a pair of 
conductive leads 14A and 14B. 
Each of the leads 14A and 14B include a first vertically or longitudinally 
extending portion 16A and 16B. The leads 14A and 14B also include a second 
portion 18A and 18B which extend generally transverse or even 
substantially perpendicular to the vertically extending portions 16A and 
16B, all of which is shown in FIG. 1 of the drawings. 
The LED body 12 and a portion of the leads 14A and 14B are encapsulated 
within a housing 24, preferably made of a non-conductive relatively 
transparent or translucent material. Suitable materials for this purpose 
are well known in the art. Those skilled in the art will recognize that 
the particular material used to form the housing 24 which encapsulates the 
LED body 12 and the portion of the leads 14A and 14B is not critical. 
Thus, in addition to the materials above illustrated, housing 24 may be 
made of many different types of materials that can provide a supporting 
structure and may be formed, molded, cast and fabricated to provide a 
desired aesthetically pleasing appearance. 
Preferably, the encapsulating housing material is sufficiently transparent 
or translucent to allow light on operation of the LED 12 to be transmitted 
therethrough. The housing 24 includes a bottom surface 26, which may be 
substantially flat. This arrangement will permit sufficient contact to 
result between the second portion 18A and 18B of the leads 14A and 14B and 
the associated conductive paint paths or other materials used to form 
electrically conductive paths. 
As further illustrated in FIGS. 1 and 2, the housing 24 also includes a top 
section 28 which may have a pleasing ornamental design including facets 
thereon. The facets may appear similar to facets which are often cut into 
gem stones or cosmetic jewelry. This aspect of the present invention will 
provide the illumination device 10 with a creative aesthetic appearance 
when it is used to decorate an associated article. 
Referring further to FIGS. 1 and 3, the respective second portions 18A and 
18B of the leads 14A and 14B extend substantially flush along the external 
side of the bottom surface 26 of housing 24. Although the bottom surface 
26 is illustrated in FIGS. 1 and 3 as being substantially flat, it may 
have alternate shapes without departing from the scope of the present 
invention. However, regardless of the shape of the bottom surface 26, it 
is important that the respective second portion 18A and 18B of the leads 
14A and 14B extend along the external side of the bottom surface 26 to 
establish the necessary electrical communication between the leads 14A and 
14B to achieve the desired operation and activation of the LED 12 in the 
illumination device in accordance with the present invention. 
A transitional connecting portion 20A and 20B of the leads 14A and 14B as 
shown in FIGS. 1, 3 and 4 exists between the first portion 16A and 16B and 
the second portion 18A and 18B at the point where leads 14A and 14B emerge 
from the encapsulating material which forms housing 24. 
In a preferred embodiment, the second portion of the leads 18A and 18B 
terminates at a location designated 22A and 22B substantially adjacent to 
the outermost or peripheral boundary of the bottom surface 26. This aspect 
of the present invention is best shown in FIG. 3. In alternate 
embodiments, the second portion 18A and 18B of the leads 14A and 14B may 
not extend to the peripheral boundary defined by the bottom surface 26. 
However, it is important that a sufficient length of the respective second 
portion 18A and 18B of the leads 14A and 14B extend along the bottom 
surface 26 so that electrical contact can be made with electrically 
conductive paths arranged on an article or substrate such as an article of 
apparel, as shown in FIG. 6. 
FIG. 4 illustrates a second embodiment of the present invention wherein the 
illumination device 10' includes a sockets-type connector generally 
designated 30 that may be used to facilitate connecting the illumination 
device 10' to the surface of an article, such as clothing for people or 
dolls or accessories therefor. 
Socket 30 is preferably made of a nonconductive material which will 
minimize the risk of shorting the illumination device 10 when it is in 
electrical communication with the desired current conducting paints, inks 
and the like compositions defining the current conducting paths for 
operating the LED 12 encapsulated in the housing 24. In this regard, the 
socket 30 is preferably made of a plastic material or other material that 
is compatible with the housing 4. However, if desired, the socket 30 may 
also be made of a conductive material provided that the article to be 
arranged between the socket 30 and the second portion 18A and 18B of the 
leads 14A and 14B does not permit current to flow therebetween. 
As best illustrated in FIGS. 4 and 5, the socket 30 includes a recessed 
area 32 designed to receive the housing 24. The recessed area 32 may be 
sized to accommodate a press fit engagement with the side walls of the 
housing 24. A shoulder 34 is arranged along the boundary of the socket 30 
to clearly define the recessed area 32. Optionally, the socket 30 may 
include a bottom surface 36. However, in alternate embodiments, the bottom 
surface 36 may be eliminated and the socket 30 may merely comprise an 
annular ring. In such embodiments, the annular ring is preferably sized 
and shaped to accommodate a frictional engagement to the housing 24 and 
the article on which the illumination device 10 is mounted. 
In the embodiment shown in FIGS. 4 and 5, the shoulder 34 protrudes further 
toward the center of the recessed area 32 than do the side walls of the 
socket 30. This is another optional feature of the present invention which 
is designed to accommodate a lip 24A arranged on the housing 24 adjacent 
the bottom surface 26. In assembled position, the lip 24A on the housing 
24 may extend beneath the protruding shoulder 34 to assure that the 
illumination device 10 is securely affixed in assembled position as shown 
in FIG. 5. 
FIG. 5 further shows that inwardly extending lugs 32A can be provided on 
the wall of the recess 32 for operative association with the lip 24A to 
prevent separation of the housing 24 from the socket 30 when in assembled 
position on the apparel or other article. 
In operation, the illumination device 10 is used to enhance the decorative 
appearance of an article such as wearing apparel or accessories for toy 
dolls. The encapsulating housing material 24 may be designed in the shape 
of a jewel, or it may have a less ornate appearance. In either case, it is 
preferable for the housing material 24 to be relatively transparent or 
translucent so that light from the LED 12 can be transmitted therethrough. 
The illumination device 10 or 10' is particularly suited to be secured to 
an article having conductive paths thereon. The conductive paths may 
include conductive paints, inks or the like compositions such as the first 
and second conductive paint paths 40A and 40B shown on a sweatshirt 38 in 
FIG. 6. As can be appreciated with reference to FIGS. 5 and 6, the 
substantially flush arrangement of the second portion 18A and 18B of the 
leads 14A and 14B with respect to the bottom surface 26 of the housing 24 
will facilitate electrical connection between conductive paint paths 40A 
and 40B and the second portion 18A and 18B of the leads. Further, the 
outermost ends 22A and 22B of the second portion 18A and 18B of the leads 
are shown in FIG. 6 as being in electrical contact with corresponding 
first and second conductive paint paths 40A and 40B. In order to enhance 
the ornamental appearance of the present invention, and to prevent 
structural defects, it is preferable that the outermost ends 22A and 22B 
of the second portion 18A and 18B of the leads 14A and 14B are terminated 
within the boundaries defined by the bottom surface 26 of the housing 24. 
The use of conductive paint paths 40A and 40B in combination with LEDs is a 
novel concept which has many different practical uses. For purposes of the 
present invention, it is not necessary to consider the current conducting 
capabilities of various types of conductive paints, inks and the like 
compositions. However, it should be appreciated that suitable examples of 
conductive paints include compositions or paints which permit sufficient 
current to flow therethrough so that the illumination device 10 can be 
selectively activated. The conductive paints may include different colors 
and may have a composition that can be washed along with an associated 
article without causing degradation of the current carrying capability 
thereof. 
A [If] further detailed description of conductive compositions that may be 
used in connection with the present invention [, there are] is describe 
[more fully] in U.S. Pat. No. 5,455,749 [co-pending application U.S. 
application Ser. No. 08/229, 359 filed Apr. 15, 1994], the disclosure of 
which is incorporated by reference herein. 
A power source designated by battery 42 is shown in FIG. 6 as being 
associated with the sweatshirt 38. It may be preferable to place the power 
source 42 in a pocket or on the inner surface of an article of apparel to 
make the outer appearance of the apparel or article as attractive as 
possible. In order to prevent light from being continuously transmitted 
from the LED 12, the present invention may utilize various types of LEDs 
or switches to control when current from the battery source 42 will be 
transmitted along the conductive paint, inks or other compositions 
defining the current conductive paths 40A and 40B and ultimately to 
associated LED or LEDs 12. 
A human finger, or other body part, may be sufficient to activate the 
illumination device 10 of the present invention. As such, the placement of 
a human finger across both of the conductive paint paths 40A and 40B at 
the same time may act as a switch so that current is permitted to 
momentarily flow to the associated LED within the housing 24 so that light 
can be transmitted from the LED 12. When the present invention is used in 
this manner, an open circuit condition will exist between the battery 
source 42 and the conductive paint, inks or other composition paths 40A 
and 40B. The act of placing a human finger across the conductive paths 40A 
and 40B will thus serve as an additional conductive path so that current 
from the battery source 42 will be permitted to flow through a circuit 
formed by conductive path 40A, lead 14A, LED 12, lead 14B and conductive 
path 40B. 
In order to facilitate securing of the illumination device 10 on an article 
of apparel, such as the sweatshirt 38, it may desirable to use an external 
connecting means, such as the socket 30 illustrated in FIGS. 4 and 5. In 
this regard, the associated article of apparel, such as the sweatshirt 38, 
should be sufficiently flexible so that it can be press-fitted along with 
the housing 24 within the recessed area 32 of socket 30. The socket 30 may 
be designed to securely affix the housing 24 in assembled position on an 
article of apparel due to frictional forces. Alternatively, an adhesive 
composition can be used to secure the bottom surface 26 to an article of 
apparel in such a manner that the second portion of the leads 18A and 18B 
are arranged in proper position in conjunction with the first and second 
conductive paint, ink or other composition paths 40A and 40B so that 
electrical communication can be achieved. An adhesive composition can also 
be used in conjunction with the socket 30 to assure that the illumination 
device 10 is secured in a particularly stable manner on an associated 
article. In this regard, an adhesive composition may be placed between the 
bottom surface 26 and the surface of an article of apparel so that a bond 
is obtained therebetween. The socket 30 may then be press-fitted onto both 
the article of apparel and the housing 24 so that the bottom surface 26 
extends beneath the shoulders 34. Still further, the bottom surface 36 of 
the socket 30 may be glued to the opposing side of an article of apparel, 
such as sweatshirt 38. When the bottom surface 26 is adhesively bonded to 
the opposite surface of the sweatshirt 38 in such a manner, the second 
portion of the leads 18A and 18B should be arranged in electrical contact 
with the conductive paint paths 40A and 40B. 
FIGS. 7 to 12 of the drawings show a still further embodiment of an 
illumination device generally designated 110 in accordance with the 
present invention. Illumination device 110 differs from the embodiments of 
the present invention as above described because it illustrates another 
means for releasably connecting the illumination device into assembled 
position on an article of apparel, toys, dolls and other substrates and 
devices to provide operative connection with the conductive paint, ink or 
other composition current conducting paths on such apparel, toys, dolls 
and other substrates and devices. 
Thus, illumination device 110 includes an internally disposed LED 112 
having a pair of current conducting leads 114A and 114B. Leads 114A and 
114B respectively include a first portion as at 116A and 116B extending 
generally vertically or along the longitudinal line of the illumination 
device 110. Continuous with the respective first portions 114A and 114B is 
a second portion as at 118A and 118B, generally transverse or 
perpendicular to the longitudinal lines of the respective first portions 
and disposed relative to each other, to extend preferably in opposite 
directions. 
As in the above described embodiments, the LED 112 and the first portions 
116A and 116B of the leads 114A and 114B are encapsulated within a housing 
generally designated 124 made from non-conductive preferably translucent 
or transparent material capable of supporting the LED 112 and capable of 
being formed, molded, cast or fabricated to provide both the alternative 
connecting means for connecting the illumination device 110 in assembled 
position on apparel, toys, dolls and other devices and to achieve where 
desirable an aesthetic appearance for the illumination device 110. 
Thus, as in the form of the housing above described for illumination device 
10 or 10' housing 124 includes a top section 126 and a bottom section 128 
with a defined outer periphery. 
The top section 126 may have an ornamental design including, for example, 
faceted surfaces to create a jewelry effect when the illumination device 
110 is used for decoration purposes. 
As in the earlier embodiments, the outer surface of bottom section 128 is 
shown as substantially flat with a defined outer border or periphery, it 
may have any desired shape so that when the housing 124 is connected or 
affixed in assembled position, the outer surface of the bottom section 128 
will be disposed for operative contact with the outer surfaces of apparel, 
toys, dolls, and other substrates or devices on which the conductive 
paints, ink, or other compositions are applied. The leads 114A and 114B as 
in the earlier embodiments above described have the first portions 116A 
and 116B extending through the bottom section 126 to the outer surface and 
the second portions 118A and 118B continuous with the first portions of 
the leads lie generally flush with the outer surface of the bottom section 
128 and extend from the point where the first portion of the leads exit 
onto the outer surface of the bottom section 128 preferably up to the 
outer periphery of the bottom section or at least a sufficient distance 
along the bottom section to enable the second portions to make electrical 
contact with the conductive paints, inks or other compositions providing 
the conductive paths for the current for operating and actuating the LED 
112. 
In this embodiment of the illumination device 110, housing 124 is further 
provided with a releasable connecting means as shown by a centrally 
disposed collarbutton shaped connecting member 130 projecting from the 
outer surface of the bottom section 128 along the longitudinal line of the 
housing in a direction generally opposite from the top section 126 of the 
housing 124. Collarbutton connecting member 130 includes a flange 132 and 
an elongated inner aspect 134 which is connected between the outer surface 
of the bottom section 128 and the flange 132 to hold the flange a 
predetermined distance from the bottom section 128. 
Collarbutton shaped connecting member 130 is adapted to fit through a 
suitable aperture 136 in the apparel, toy, doll or other substrate or 
device and, when so assembled, can receive a suitable resilient element 
such as an o-ring as at 138 about the elongated inner aspect 134 to hold 
the housing 124 and the illumination device 110 in assembled position on 
the apparel, toy, doll or other substrate or device to bring the second 
portions 118A and 118B into electrical communication with the conductive 
paint, inks or other compositions defining the conductive current paths as 
at 140 and 142, all of which is shown in FIG. 12 of the drawings. 
In operation, at any suitable aperture 136 in an apparel, toy, doll or 
other substrate or device about which the conductive communication paths 
140 and 142 have been established or applied, the collarbutton connecting 
member 130 for the housing 124 is inserted into aperture 136 until the 
second portions 118A and 118B of the leads 114A and 114B are in 
communication with the conductive current paths 140 and 142. The resilient 
element 138 is then affixed to the inner aspect 136 of the collarbutton 
connecting member 130 to releasably hold the housing in assembled 
position. 
The switch or other means provided in the current conducting system as 
above described can now be used to operate and actuate the LED 112 of the 
illumination device 110. 
Thus various embodiments of improved LED modules for use on and in 
connection with apparel, toys, dolls and other substrates or devices 
having conductive current paths made of conductive paints, inks or other 
compositions have been disclosed in accordance with the present invention. 
While the foregoing description of the illustrated figures of the drawings 
are directed toward the preferred embodiments in accordance with the 
present invention, those skilled in the art will appreciate that numerous 
modifications can be made to various aspects of the present illumination 
device. Indeed, such modifications are encouraged by the description to be 
made in the materials, structure and arrangement of the disclosed 
embodiments without departing from the spirit and scope of the same. Thus, 
the foregoing description of the preferred embodiment should be taken by 
way of illustration rather than by way of limitation with respect to the 
present invention which is defined by the claims set forth below.