Abstract:
A repair device for fixing a malfunctioning shunt across a failed filament in a light bulb in a group of series-connected miniature decorative bulbs includes a piezoelectric pulse generator producing one or more pulses of a magnitude greater than the standard AC power line voltage. A connector receives the pulses from the pulse generator and supplies them to the group of series-connected miniature decorative bulbs.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application claims priority to U.S. Provisional Application Serial No. 60/277,481 filed Mar. 20, 2001; to U.S. Provisional Application Serial No. 60/289,865 filed May 9, 2001; and to U.S. application Ser. No. 10/041,032 filed Dec. 28, 2001. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to devices for repairing and testing decorative lights, including lights for Christmas trees, including pre-strung or “pre-lit” artificial trees.  
         BACKGROUND OF THE INVENTION  
         [0003]    One of the most common uses of series-connected light strings, particularly of the commonly called “miniature” type, is for decoration and display purposes, particularly during Christmas time and other holidays. Such light strings are especially popular for the decoration of Christmas trees, both inside and outside commercial, industrial and residential buildings, trees and shrubbery, and the like.  
           [0004]    Probably the most popular light set currently available on the U.S. market comprises one or more strings of 50 miniature light bulbs each. In Europe and other countries that have 240-volt power rather than 120 volts, strings of 100 lights are more common. Each bulb typically has an operating voltage of 2.5 volts, and the filaments of each 50-bulb string are connected in an electrical series circuit arrangement. If overall light sets of more than 50 bulbs are desired, the common practice is to provide a plurality of 50-bulb strings, with the bulbs in each string connected in electrical series, and with the plurality of strings being connected in a parallel circuit arrangement with respect to each other to form the light set.  
           [0005]    As the bulbs in each string are connected in series, when a single bulb fails to illuminate for any reason, the whole string fails to light, and it is very frustrating and time consuming to locate and replace a defective bulb or bulbs. Usually many bulbs have to be checked in order to find the failed bulb. In fact, in many instances, the frustration and time-consuming efforts are so great as to cause one to completely discard and replace the string with a new string. Replacement, however, does not offer a practical solution if the lights are on an already decorated Christmas tree where removal could cause damage to the ornaments, or on wire frame yard decorations where the lights have many clips and wire ties holding them to the frame.  
           [0006]    Light bulb manufacturers have also attempted to solve the problem of light section or string failures caused by single bulb failure by designing each light bulb in the string in a manner whereby the filament in each light bulb is shorted by a shunting device whenever it burns out for any reason, thereby preventing an open circuit condition from occurring in the socket of the burned-out bulb. However, in actual practice, it has been found that such short circuiting feature within the bulb does not always operate in the manner intended, resulting in the entire series section or string going out whenever a single bulb burns out.  
           [0007]    The above-cited attempts to prevent string failure in series-circuit light strings have included the use of one or more shunt devices in association with each bulb and socket combination. The shunt is typically positioned directly within the glass envelope of each bulb in the string, making the effectiveness of the shunt depend on the presence at all times of a bulb within each of the bulb sockets in the string. In operation, the shunt provides an alternate path through which electric current will flow in the event of filament failure. After bulb failure and as long as the bulb remains in the string, the shunt allows current to continue to flow through the bulb, thereby preventing the failure of the entire series section of the light string.  
           [0008]    The shunt is typically made at least in part of a material that is non-conductive as long as the bulb filament is operative, but becomes conductive whenever the filament fails. In normal operation, current will flow through the filament to produce incandescent light within the bulb envelope. When the filament breaks, however, the increased voltage differential across the bulb lead wires causes the non-conductive material to break down so that current continues to flow through the shunt in the failed bulb to the other bulbs in series therewith. That is, each shunt is inoperative unless and until it is subjected to substantially the full output voltage of the power source. When the bulb filament associated with a shunt fails, that shunt is subjected to the full voltage of the power supply, which renders that shunt operative to bypass the failed filament. A variety of different shunt structures and materials are well known in the industry, such as those described in U.S. Pat. Nos. 4,340,841 and 4,808,885.  
           [0009]    In actual practice, the shunts described above do not function with a high degree of reliability, and thus the failure of a single bulb still often extinguishes the entire string.  
         SUMMARY OF THE INVENTION  
         [0010]    In accordance with the present invention, there is provided a repair device for fixing a malfunctioning shunt in a decorative light string comprising series-connected miniature decorative bulbs, each bulb having a filament and a shunting device connected across the filament of the bulb for actuation by an increase in the voltage across the bulb when the filament fails. The repair device comprises a piezoelectric high-voltage pulse generator connected to the light string for supplying the string with electrical pulses of a magnitude greater than the standard AC power line voltage and containing sufficient energy to cause a malfunctioning shunting device to conduct. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    The invention may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in which the single figure is a schematic diagram of a string of decorative lights being plugged into a repair device embodying the present invention, with the repair device shown in side elevation with a portion of the housing broken away to show the internal structure, portions of which are also shown in section. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0012]    Although the invention will be described in connection with certain preferred embodiments, it will be understood that the invention is not limited to those particular embodiments. On the contrary, the invention is intended to include all alternatives, modifications and equivalent arrangements as may be included within the spirit and scope of the invention as defined by the appended claims.  
         [0013]    In the illustrative embodiment shown in the drawing, a portable, hand-held housing  10  contains a conventional piezoelectric device  11  capable of generating high-voltage pulses containing sufficient energy to cause a malfunctioning shunting device to conduct. The piezoelectric device  11  is actuated by a rod  12  that extends out of the housing  10  into a finger hole  13  where the rod  12  is attached to a trigger  14 . When the trigger  14  is pulled, the rod  12  is retracted and retracts with it the left-hand end of a compression spring  15  and a cam element  16 . The compression spring  15  is supported by a stationary rod  17  which telescopes inside the retracting rod  12  while the spring  15  is being compressed against a latch plate  18  at the right-hand end of the spring.  
         [0014]    When the spring  15  is fully compressed, an angled camming surface  16   a  on the cam element  16  engages a pin  18   a  extending laterally from the latch plate  18 , which is free to turn around the axis of the rod  17 . The camming surface  16   a  turns the pin  18   a  until the pin reaches a longitudinal slot  19 , at which point the compression spring  15  is released to rapidly advance a metal striker  20  against a striker cap  21  on one end of a piezoelectric crystal  22 . The opposite end of the crystal  22  carries a second metal cap  23 , and the force applied to the crystal  22  by the striker  20  produces a rapidly rising output voltage across the two metal caps  21  and  23 . When the trigger  14  is released, a light return spring  24  returns the striker  20  and the latch plate  18  to their original positions, which in turn returns the cam element  16 , the rod  12  and the trigger  14  to their original positions.  
         [0015]    Although the piezoelectric device is illustrated in the drawing as containing a single crystal  22 , it is preferred to use those commercially available devices that contain two stacked crystals. The striking mechanism in such devices strikes both crystals simultaneously, producing an output pulse that is the sum of the pulses produced by both crystals.  
         [0016]    The metal caps  21 ,  23  are connected to a pair of conductors  25  and  26  leading to a socket  30  for receiving a plug  31  on the end of a light string  32 . The conductor  26  may be interrupted by a pulse-triggering air gap  29  formed between a pair of electrodes  27  and  28 , forming an air gap having a width from about 0.20 to about 0.25 inch. The voltage output from the piezoelectric crystal  22  builds up across the electrodes  27 ,  28  until the voltage causes an arc across the gap  29 . The arcing produces a sharp voltage pulse at the socket  30  connected to the conductor  26 , and in the light string  32  plugged into the socket  30 . The trigger  14  is typically pulled several times (e.g., up to five times) to supply repetitive pulses to the light string.  
         [0017]    Substantially the entire voltage of each pulse is applied to any inoperative shunt in a failed bulb in the light string, because the shunt in a failed bulb appears as an open circuit (or at least a very high impedance) in the light string. The light string is then unplugged from the socket  30  and plugged into a standard AC electrical outlet to render conductive a malfunctioning shunt not repaired by the pulses. It has been found that the combination of the high-voltage pulses and the subsequent application of sustained lower-voltage power (e.g., 110 volts) repairs a high percentage of failed bulbs with malfunctioning shunts. When a malfunctioning shunt is fixed, electrical current then flows through the failed bulb containing that shunt, causing all the bulbs in the light string except the failed bulb to become illuminated. The failed bulb can then be easily identified and replaced.  
         [0018]    In cases where a hundred-light set comprises two fifty-light sections connected in parallel with each other, each applied pulse is divided between these two sections and may not have enough potential to activate a malfunctioning shunt in either section. In these cases, an additional and rather simple step is added. First, any bulb from the working section of lights is removed from its base. This extinguishes the lights in the working section and isolates this working section from the one with the bad bulb. Next, the string of series-connected bulbs is plugged into the socket of the repair device, and the trigger-pulling procedure is repeated. The lights are then unplugged from the repair device, the removed bulb is re-installed, and the light set is re-plugged into its usual power source. Since the shunt in the bad bulb is now operative, all the lights except the burned out one(s) will come on.  
         [0019]    When a bulb does not illuminate because of a bad connection in the base of the bulb, the pulse from the piezoelectric element will not fix/clear this type of problem. Bad connections in the base and other miscellaneous problems usually account for less than 20% of the overall failures of light strings.