Abstract:
An LED night-light includes a housing and a toggle switch mounted on the housing. First and second prongs are supported by the housing. An LED driver circuit is electrically connected to a light-emitting diode. Movement of the toggle switch to a first position presses a second conductor against the second prong and thereby switchably connects the second conductor to the second prong. Movement of the toggle switch to a second position allows the second conductor to move out of contact with the second prong and thereby switchably provides an open circuit between the second conductor and the second prong. Electricity is supplied to the light-emitting diode and to the LED driver circuit when the toggle switch is in the first position. No electricity is supplied to the light-emitting diode and LED driver circuit when the toggle switch is in the second position.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation application of U.S. Ser. No. 13/544,365, filed Jul. 9, 2012 which is a continuation of U.S. Ser. No. 12/466,209, filed May 14, 2009, issued as U.S. Pat. No. 8,215,820, the entire contents of which are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention generally relates to an LED (light-emitting diode) night-light, and more specifically to an LED night-light assembly configured from a typical night-light assembly for an incandescent bulb. 
         [0003]    A typical night-light incandescent bulb includes of a glass envelope enclosing a filament. A plurality of support wires and connecting wires extend from the filament to an electrical contact. A screw cap is usually placed over the end of the glass envelope to facilitate connecting the bulb to a treaded socket of a housing for a standard night-light assembly. As shown in  FIG. 1 , a typical housing  1  of the prior art contains a body  3  having a threaded opening  5  for engaging the screw cap and a contact  7  electrically connecting to an electrical contact on the screw cap. 
         [0004]    The housing used for LED&#39;s of the prior art are typically a different construction than those for standard light bulbs. The present invention allows for an LED to be used with a standard night-light assembly for an incandescent bulb, such as those having a threaded opening. 
       SUMMARY OF THE INVENTION 
       [0005]    In one aspect, an LED night-light generally comprises a housing and a toggle switch mounted on the housing and moveable between a first position and a second position. First and second prongs are supported in parallel by the housing. The prongs have interior ends extending into an interior of the housing and have exterior ends extending out of the housing such that the exterior ends are configured for insertion into an electrical outlet. A light-emitting diode. An LED driver circuit is electrically connected to the light-emitting diode. A first conductor electrically connects the first prong to the light-emitting diode and the LED driver circuit. A second conductor switchably connects the second prong to the light-emitting diode and the LED driver circuit. Movement of the toggle switch to the first position presses the second conductor against the second prong and thereby switchably connects the second conductor to the second prong. Movement of the toggle switch to the second position allows the second conductor to move out of contact with the second prong and thereby switchably provides an open circuit between the second conductor and the second prong. The toggle switch is adapted to supply electricity to the light-emitting diode and to the LED driver circuit when the toggle switch is in the first position and the first and second prongs are connected to an electrical outlet. The toggle switch is adapted such that no electricity is supplied to the light-emitting diode and LED driver circuit when the toggle switch is in the second position and the first and second prongs are connected to an electrical outlet. 
         [0006]    In another aspect, an LED night-light generally comprises a housing comprising a front panel and a back panel. First and second prongs extend out of the housing and are configured for insertion into an electrical outlet. The prongs are slideably received through the back panel. A light-emitting diode is mounted on the housing. At least one circuit component is electrically connected to the light-emitting diode and configured for energizing the light-emitting diode when the first and second prongs are inserted into an electrical outlet connected to a power source. A solder connection electrically connects the first prong to the at least one circuit component such that the light-emitting diode, the at least one circuit component, and the first prong comprise a self-contained unit free of the second prong. 
         [0007]    In still another aspect, an LED assembly for use in an LED night-light generally comprises a light-emitting diode and an electrical conductor connected to the light-emitting diode. At least one circuit component is electrically connected to the electrical conductor and configured for energizing the light-emitting diode. A prong is electrically connected to the electrical conductor. The light-emitting diode, the electrical conductor, the at least one circuit component, and the prong comprise a self-contained unit free of a second prong. 
         [0008]    Other features will be in part apparent and in part pointed out hereinafter. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a light assembly of the prior art; 
           [0010]      FIG. 2  is a perspective view of an embodiment of an LED night-light of the present invention; 
           [0011]      FIG. 3  is a perspective of the LED night-light with a cover removed; 
           [0012]      FIG. 4  is an exploded view of the LED night-light; 
           [0013]      FIG. 5  is a front view of the perspective of  FIG. 3 ; 
           [0014]      FIG. 6  is a front view of a back panel of a housing of the present invention; 
           [0015]      FIG. 7  is a back view of a front panel of the housing of the present invention; 
           [0016]      FIG. 8  is a perspective of an LED, circuit board and prong of the present invention; and 
           [0017]      FIG. 9  is a schematic of a circuit of the LED night-light; 
       
    
    
       [0018]    Corresponding reference characters indicate corresponding parts throughout the drawings. 
       DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0019]    Referring to  FIGS. 2 ,  4  and  6 , an LED night-light assembly of the present invention is generally indicated at  10 . The assembly includes a housing  12  having a front panel  14  and a back panel  16  connected to the front panel by a screw  18 . An optional transparent cover  19  is secured to the housing  12 . First and second parallel prongs  20 ,  22  are supported by the housing  12  and are received through slots  24  in the back panel  16 . A printed circuit board (PCB)  26  is mounted on the first prong  20 . A light-emitting diode (LED)  28  has a first lead wire  30  connected to the PCB  26  and a second lead wire  32  extending from the LED  28  and attached to a spring  34 . A disk  36  seats the LED  28 . Holes (not shown) in the disk  36  receive the first and second connection wires  30 ,  32  allowing the wires to pass through the disk to connect to the PCB  26  and spring  34 , respectively. A toggle switch  38  having a resilient extension  40  is mounted on the front panel  14 . The toggle switch  38  is moveable for powering the assembly on and off when the prongs engage an electrical outlet connected to a power source. 
         [0020]    Referring to  FIGS. 2 and 3  each panel  14 ,  16  of the housing  12  has an upper portion  42 F,  42 B and a lower portion  44 F,  44 B. An annular channel  41  extends around the housing  12  between the upper and lower portions  42 ,  44 . The optional cover  19  has a U-shaped cutout  43  which slides into the channel  41  for attaching the cover to the housing  12 . It will be understood that the cover  19  can be attached to the housing  12  in any suitable manner and other covers or no cover may be used, within the scope of the present invention. 
         [0021]    Referring to  FIGS. 4-7 , the upper portions  42 F,  42 B form a cylindrical housing for the LED  28 . An opening  45  in the upper portion  42  of the housing  12  forms a rim  47  surrounding the opening and defining a plane P which is substantially horizontal when the night-light assembly  10  is vertical and engages a wall outlet. Threads  46  on an interior surface of the upper portion  42  are adapted to mate with a threaded end of a light bulb (not shown). The housing  11  has a modular configuration such that the housing is adapted to separately receive a light bulb and an LED. 
         [0022]    The lower portion  44  of the housing  12  is more rectangular and houses, at least partially, the PCB  26 , prongs  20 ,  22 , spring  34 , toggle switch  38  and extension  40  within an interior  53  of the housing. A bore  54 F,  54 B in the front and back panels  14 ,  16  receives the screw  18  by a threaded engagement for connecting the panels  14 ,  16 . The back panel  16  has locating holes  50  configured to mate with locating pins  52  on the front panel  14  when the panels are connected. The back panel has a post  56  and a pair of sleeves  58  extending from an inner surface. The post  56  holds the extension  40  in place on the back panel  16 . The sleeves  58  are sized and shaped to slideably receive interior ends  59  of the prongs  20 ,  22 . When received in the sleeves  58 , the prongs are supported in parallel by the housing  12 . A catch  60  on the prongs  20 ,  22  prevents the prongs from sliding out the back of the back panel  16  once the prongs are inserted in the back panel  16 . Exterior ends  61  of the prongs  20 ,  22  extend out of the housing  12  and are configured for insertion into an electrical outlet (not shown) connected to a power source. The front panel  14  has a pair of stops  62  formed in the front panel which prevent the prongs  20 ,  22  from being pushed and pulled with respect to the housing  12  when the panels are connected. The front panel  14  also has a window  64  and U-shaped supports  66  which receive the toggle switch  38 . It is understood that the housing can have other configurations and still be within the scope of the present invention. For instance the housing could have other shapes or be formed from a single piece. 
         [0023]    Referring to  FIGS. 8 and 9 , the PCB  26  comprises a rigid substrate having an electrically conductive surface layer L. The PCB  26  along with the conductive surface layer is mounted onto the first prong  20  by solder S which electrically interconnects the prong  20  and the layer L. Electrically connected to the PCB  26  is an LED driver circuit  70  comprising a rectifier (diode)  72  and a resistor  74  configured for energizing the LED  28  when the prongs  20 ,  22  engage an outlet connected to a power source. The diode  72  and resister  74  are connected in series between the first prong  20  and the LED  28 . The LED  28  is also electrically connected to the PCB  26 , in series with the resistor  74 , via the first connection wire  30 . The diode  72 , resistor  74  and LED  28  are standard electrical components well known to those of skill in the art. The disk  36  supports the LED and is received in a groove  48  in the interior surface of the housing  12  for positioning the LED  28  in the housing (see  FIG. 5 ). In the illustrated embodiment, the groove  48  is located above the threads  46 . One advantage of embodiments having the threads  46  and groove  48  is that molds used to make a typical night-light assembly for an incandescent bulb may be easily modified by adding the groove  48  for the disk  36  supporting the LED  28 . Thus, a typical night-light assembly for an incandescent bulb may be easily converted to an LED night light. It is also contemplated that the disk may be configured to engage one of the grooves defined by the threads  46 . 
         [0024]    The disk  36  positions the LED  28  such that a majority (e.g. at least 50% of the height) of the LED is located below the rim  47 . In the illustrated embodiment, the LED is shown as extending out of the upper portion  42  of the housing  12  and through the plane P so that only the dome of the LED is above plane P. However, the LED can be located at other positions. One advantage of embodiments of the invention in which a substantial portion of the LED  28  is positioned below the rim  47  is that the cylindrical housing formed by the upper portions  42 F,  42 B create a shroud which blocks and reflects at least some of the light emitted by the LED  28 . As a result, when the night light is mounted in a wall outlet at eye level, at least some horizontal light is blocked and reflected so that the LED  28  does not appear as bright or as a hot spot to an observer. Additionally, in the illustrated embodiment the disk is circular, however, the disk can have other shapes such as square or triangular and still be within the scope of the present invention. 
         [0025]    Referring to  FIG. 8 , the spring  34  connected to the second connection wire  32  is formed from a bent piece of sheet metal. In the illustrated embodiment, the second connection wire  32  is electrically connected by solder S to the spring  34 . The metal piece is bent to conform to the space in the interior  53  of the housing  12 . A first spring portion  80  is positioned generally horizontally when the LED  28  is held in the housing  12 . A second spring portion  82  extends from the first spring portion  80  generally vertically. A third spring portion  84  extends from the second spring portion  82  at an angle toward the center of the housing  12 . The angle is sufficient to clear the second prong  22  such that a fourth spring portion  86  can extend from the third spring portion  84 , generally vertically, between the second prong  22  and the extension  40 . The spring  34  is moveable to electrically connect the LED  28  to the second prong  22 . As will be described in greater detail below, the fourth portion  86  of the spring  34  is positioned to be engaged by the extension  40  on the toggle switch  38  for powering on and off the assembly  10 . It should be understood, however, that other configurations and types of springs can be utilized within the scope of the present invention. 
         [0026]    Referring to  FIG. 4 , the toggle switch  38  includes a handle  90 , a bar  92  at the base of the handle and a retaining knob  94  extending from the bar having a pair of shoulders  96  (only one is shown). A projection  98  extends from the retaining knob  94  for attaching the switch  38  to the extension  40 . The extension comprises a coil spring having a pair of open ends. When the toggle switch  38  is received through the window  64  in the front panel  14  of the housing  12  the bar  92  abuts the U-shaped supports  66 , holding the toggle switch in the housing. The projection  98  inserts into one of the open ends of the extension  40  while the other open end of the extension fits around the post  56  on the back panel  16  of the housing  12 . The extension  40  has a resting length such that when the panels  14 ,  16  are attached, the extension exerts a spring force on the toggle switch  38  holding the bar  92  in contact with the supports  66  allowing the toggle switch to pivot back and forth (e.g. left or right when the prongs engage a wall outlet). The illustrated embodiment shows the toggle switch formed from one solid piece of electrically non-conductive material; however the toggle switch can comprise multiple components attached by any suitable manner. Moreover, other configurations of toggle switches and other types of switches are within the scope of the present invention. Thus, the toggle switch assembly comprises the toggle switch  38  and extension  40 . 
         [0027]    In operation, the toggle switch  38  can be moved to a first position by toggling the switch to the left as shown in  FIG. 5 , labeled “ON”. In this position, the extension  40  will engage the fourth portion  86  of the spring  34  causing the spring to contact the second prong  22 . If the assembly  10  is connected to a power source, the spring  34  contacting the prong  22  will close the circuit, as shown by the switch in  FIG. 9 , energizing the driver circuit  70  and LED  28 , powering on the LED. 
         [0028]    The toggle switch  38  can also be moved to a second position by toggling the switch to the right, in the position labeled “OFF”. In this position, the extension  40  will release engagement with the fourth portion  86  of the spring  34  allowing the spring to move back to its resting position away from the second prong  22 . This will open the circuit, de-energizing the driver circuit  70  and LED  28 , powering off the LED. 
         [0029]    Having described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. 
         [0030]    When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. 
         [0031]    As various changes could be made in the above constructions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.