Patent Publication Number: US-11391421-B2

Title: String lighting and methods of assembly

Description:
This application is a continuation-in-part of and claims the benefit of priority of from U.S. patent application Ser. No. 16/909,487, filed on Jun. 23, 2020, and U.S. patent application Ser. No. 16/691,298, filed on Nov. 21, 2019, which are incorporated herein by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The field of the invention is lights, more specifically, string lighting and light components with removable light elements and lampshades, and methods of assembling light components. 
     BACKGROUND 
     The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art. 
     String lighting is a popular choice for both indoor and outdoor lighting and is also commonly used for seasonal decorating. Conventional string lighting assemblies typically comprise a main wired connection line that provides electrical current to a plurality of sockets and light components extending or hanging from the main line. One end of the string has an electrical plug that mates with, and receives electricity from, a power outlet. Optionally, the other end of the string can have another plug for providing power to another string. 
     Examples of different string light assemblies and light components can be found in U.S. Pat. Nos. 8,070,347, 9,752,763, U.S. Ser. Nos. 10/100,986, 10/309,591, 10/422,486, U.S. Pat. Publ. Nos. US20160215942 and US20180340676, and China Patent Nos. CN105805618B, CN106122821A, CN107370003A, CN108224135A, CN205678443U, CN206723917U, CN206846401U, CN207716102U, CN207893476U, CN208222138U, and CN304484212S. These and all other extrinsic materials discussed herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply. 
     While various string light assemblies are known, there remains a need for a string light assembly that has fewer parts, is easier to assemble, and is more reliable than conventional string light designs. It would also be advantageous to provide a string light that has removable and interchangeable components such as lampshades to change and customize the appearance of the string light assembly. 
     SUMMARY OF THE INVENTION 
     The inventive subject matter provides apparatus, systems, and methods in which a string light assembly comprises a wired connection that has two ends. The first end has an electrical connector configured to electrically couple with an electrical power supply and the second end can optionally have an electrical connector configured to electrically couple with, and provide electricity to, another string light assembly. The wired connection comprises a plurality of light components extending therefrom at intervals located along a length of the wired connection. It is contemplated that the intervals can be regular (e.g., evenly spaced, repeat pattern spacing) or irregular (e.g., randomly spaced). 
     Each light component comprises two covers that join together and form a housing that has an interior space. A pair of electrical wires are sized and dimensioned to fit inside the interior space of the housing. The housing can comprise two arms extending from a body wherein each arm has an opening for receiving one of the wires. In this manner, the pair of electrical wires can pass through the interior space of the housing to provide electricity to the light element. In some embodiments, the housing can comprise a t-shaped body with two arms extending from the body in different directions and in alignment with one another (e.g., along the same line). However, it is also contemplated that the arms could extend from the body at different angles (e.g., not along the same line). 
     In some embodiments, the pair of electrical wires can connect with an electrical socket for receiving and removably coupling the light element. The electrical socket can have a cavity with an electrical connection for connecting a light element such as an LED bulb. When the electrical socket is placed inside the interior space of the housing, the cavity of the socket is accessible via an opening in the housing. 
     Each light component further comprises a collar sized and dimensioned to fit over a portion of the housing. In addition, a light element is configured to electrically and removably couple with the pair of electrical wires. The light element (also referred to as light source) is covered and/or protected by a first lampshade that either removably couples with the collar or is integrally formed with the light element. 
     Each light component can also include a second lampshade that has an opening sized and dimensioned to receive and fit over an external surface of the distal end of the housing, while at the same time the opening is smaller than an outer width of the collar. In this manner, the collar can be used to removably secure the second lampshade to the housing by first inserting the distal end of the housing through the opening of the second lampshade, and then securing the collar to the external surface of the distal end of housing. In some embodiments, the collar has internal threads that are configured to mate with external threads on the housing. However, it is also contemplated that non-threaded fasteners, such as press-fit (e.g., tapered surfaces), snap-fit (e.g., latching elements), male/female engagements, and magnetic fasteners can be used in a manner that is consistent with the inventive principles disclosed herein. 
     In yet other embodiments, the first lampshade can have external threads that mate with the internal threads on the collar. In this embodiment, the internal threads are long enough such that one end of the collar can be used to engage the housing while the other end of the collar can be used to engage the first lampshade. 
     In other aspects, the first and second covers that form the housing can each comprise a half-shell of the housing. It is also contemplated that the first cover and second cover can comprise either symmetrical or non-symmetrical portions of the housing. 
     Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a string light assembly. 
         FIG. 2  is a perspective view of the string light assembly of  FIG. 1  with the lights turned on. 
         FIG. 3  is an exploded view of a light component of  FIG. 1 . 
         FIG. 4  is a perspective view of the string light assembly of  FIG. 1  with a second lampshade. 
         FIG. 5  is a perspective view of the string light assembly of  FIG. 4  with the lights turned on. 
         FIG. 6  is an exploded view of the light component of  FIG. 4  with a second lampshade. 
         FIG. 7  is an exploded view of another embodiment of a light component. 
         FIG. 8  is an exploded view of the light component of  FIG. 7  with a second lampshade. 
         FIG. 9  are several perspective views of different ornaments hanging from the light component of  FIG. 1 . 
         FIG. 10  is a side view of another embodiment of a light component with a latching collar. 
         FIG. 11  is a side view of another embodiment of a light component with a screw hole in the housing. 
         FIG. 12  is a side view of the first cover and second cover of the socket housing of  FIG. 11 . 
         FIG. 13  is a side view of the inside of the first cover and second cover of  FIG. 12 . 
         FIG. 14  is a side view of another embodiment of a light component with an ultrasonic weld. 
         FIG. 15  is a perspective view of another embodiment of a string light assembly. 
         FIG. 16  is an exploded view of a light component of  FIG. 15 . 
         FIG. 17  is an exploded view of the light component of  FIG. 15  with interchangeable light elements. 
         FIG. 18  is a perspective view of another embodiment of a string light assembly with a second lampshade. 
         FIG. 19  is an exploded view of the light component of  FIG. 18  with a second lampshade. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus, if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed. 
       FIG. 1  shows a string light assembly  100  that has a plurality of light components  110  electrically coupled via wired connection  105 . A first end of wired connection  105  can comprise an electrical plug (not shown) configured to couple with a power source to provide electricity to the lights  110  for illumination.  FIG. 2  shows string light assembly  100  with the light components  110  turned on. A second end of wired connection  105  can include an electrical plug (not shown) configured to couple with, and provide electricity to, an end of another string light assembly. 
       FIG. 3  shows an exploded view of a light component  110 . Light component  110  comprises a first socket cover  112  and a second socket cover  116  that couple together to form a socket housing with an interior space. The interior space is sized and dimensioned to enclose an electrical socket  114 . First socket cover  112  and second socket cover  116  can be coupled together by screwing the threaded collar  118  onto the external threads of first socket cover  112  and second socket cover  116 . It is also contemplated that collar  118  could employ non-threaded fasteners to secure first socket cover  112  and second socket cover  116  together, including male-female engaging connectors, press-fit connections (e.g., tapered surfaces), snap-in connections (e.g., latching elements), and magnetic fasteners. 
     First socket cover  112  and second socket cover  116  can be made of plastic, metal, a composite, or any other material suitable for housing an electrical socket and light element. When coupled, first socket cover  112  and second socket cover  116  form a t-shaped housing with two arms extending in different directions. The arms also have openings on their respective ends that allow the two wired connections of socket  114  to pass therethrough. 
     Socket  114  can be any suitable electrical socket such as parallel XTW or SPT for #20 AWG light string with E12 socket or E17 socket, or parallel XTW or SPT for #18 AWG light string with E17 socket. Socket  114  has a threaded cavity with electrical connections for supplying power to a light element  120 . Light element  120  can be any suitable light source, such as E12/E17 incandescent bulbs or LED bulbs. Light element  120  has external threads that mate with the threads of the cavity of socket  114 . However, it is also contemplated that light element  120  can removably couple with socket  114  using other known fasteners, including male-female engaging connectors, press-fit or snap-in connections, and magnetic fasteners. 
     Light component  110  also comprises a lamp shade  122  that removably couples with collar  118  via external threads that mate with the internal threads of collar  118 . However, it is contemplated that light component  110  could also be removably coupled with collar  118  using other fasteners. Lampshade  122  has an interior space that is sized and dimensioned to house light element  120  for protection. Lampshade  122  can be made of plastic, metal, or any suitable material for protecting light element  120 . Lampshade  122  can also be made of different colors and/or levels of translucency to produce different lighting. 
       FIG. 4  shows string light assembly  100  with a secondary lampshade  124  removably attached to each light component  110 .  FIG. 5  shows the string light assembly  100  and secondary lampshade  124  with the lights turned on by a power supply (not shown). 
       FIG. 6  shows an exploded view of string light  100  with the secondary lampshade  124 . The parts shown in  FIG. 6  are the same as  FIG. 3  except for the addition of the secondary lampshade  124 . Lampshade  124  removably couples with the first socket cover  112  and the second socket cover  116  by placing the distal end of the t-shaped body through the opening of lampshade  124  and then screwing collar  118  onto the external threads of first socket cover  112  and the second socket cover  116 . The size of the opening of lampshade  124  is less than an outer width or diameter of the collar and a rim or annular flange on the housing. In this manner, fastening the collar  118  onto the housing will press and secure lampshade  124  to the housing. 
     It is contemplated that lampshade  124  can be made of plastic, metal, a composite, or any material suitable for providing shading to a light element. It is also contemplated that lampshade  124  can be made in many different shapes to provide different styles (e.g., outdoor, indoor, modern, rustic, etc.) and can be interchangeable with different shapes and colors of lampshades to create a different style for the string light assembly. It is also contemplated that lampshade  122  and light element  120  can be interchangeable with other lampshades and light elements, respectively, to provide different shapes, colors, and light types (e.g., LED vs incandescent, 60 watts vs 100 watts, etc.). 
     The light component design described herein advantageously allows for different lampshades and light elements to be interchangeable to customize the look and feel of the string light assembly. Additionally, the light component design is easy to assemble due to a reduced number of parts. The design can also be used to imitate the effect of an E26 string light, but with the lower cost due to use of an LED bulb. 
       FIG. 7  shows an exploded view of a light component  210 . Light component  210  comprises a first cover  212  and a second cover  216  that couple together to form a housing with an interior space. The interior space is sized and dimensioned to enclose a pair of electrical wires  214 . First cover  212  and second cover  216  can be coupled together by screwing the threaded collar  218  onto the external threads of first cover  212  and second cover  216 . It is also contemplated that collar  218  could employ non-threaded fasteners to secure first cover  212  and second cover  216  together, including male-female engaging connectors, press-fit or snap-in connections, and magnetic fasteners. 
     First cover  212  and second cover  216  can be made of plastic, metal, a composite, or any other material suitable for housing a pair of electrical wires. When coupled, first cover  212  and second cover  216  form a t-shaped housing with two arms extending in different directions. The arms also have openings on their respective ends that allow the pair of electrical wires  214  to pass therethrough. 
     Pair of electrical wires  214  can be any suitable electrical wiring, including #22 AWG, #20 AWG, and #24 AWG light string. Pair of electrical wires  214  can be suitable light string for an incandescent light bulb or a light emitting diode (LED) bulb. Pair of electrical wires  214  supply power to a light element  220 . Light element  220  can be any suitable light source, such as E12/E17 incandescent bulbs or LED bulbs. Light element  220  can be either permanently or removably coupled with pair of electrical wires  214 . In some embodiments, light element  220  can be removably coupled with the pair of electrical wires  214  via a threaded coupling, male-female engaging connectors, press-fit or snap-in connections, magnetic fasteners, or any other suitable fastening means. 
     Light component  210  also comprises a lamp shade  222  that removably couples with collar  218  via external threads that mate with the internal threads of collar  218 . However, it is contemplated that light component  210  could also be removably coupled with collar  218  using other fasteners. Lampshade  222  has an interior space that is sized and dimensioned to house light element  220  for protection. Lampshade  222  can be made of plastic, metal, or any suitable material for protecting light element  220 . Lampshade  222  can also be made of different colors and/or levels of translucency to produce different lighting. 
       FIG. 8  shows an exploded view of string light  210  with the secondary lampshade  224 . The parts shown in  FIG. 7  are the same as  FIG. 8  except for the addition of the secondary lampshade  224 . Lampshade  224  removably couples with the first cover  212  and the second cover  216  by placing the distal end of the t-shaped body through the opening of lampshade  224  and then screwing collar  218  onto the external threads of first cover  212  and the second cover  216 . The size of the opening of lampshade  224  is less than an outer width or diameter of the housing (e.g., rim or flange) and the collar. In this manner, collar  218  can be used to secure lampshade  224  to the housing formed by first cover  212  and second cover  216 . 
     It is contemplated that lampshade  224  can be made of plastic, metal, a composite, or any material suitable for providing shading to a light element. It is also contemplated that lampshade  224  can be made in many different shapes to provide different styles (e.g., outdoor, indoor, modern, rustic, etc.) and can be interchangeable with different shapes and colors of lampshades to create a different style for the string light assembly. 
       FIG. 9  shows different decorative ornaments  226  hanging from lampshade  224  for creating a special or unique atmosphere. The ornaments  226  can be a wind chime, an object that casts a shadow, or a decorative item. Lampshade  224  can have one or more holes near a circumferential edge to allow for attachment of a string or other fastener for hanging decorative ornaments  226 . Other fastener mechanisms are contemplated, including adhesives, clips, magnets, screws, or any other fastener suitable for attaching and hanging a decorative item. 
       FIG. 10  shows a side view of a light component  310 . Light component  310  has a socket housing comprising a first socket cover  312  and a second socket cover  316 . First socket cover  312  and second socket cover  316  are similar to socket cover  112  and socket cover  116  except for the non-threaded portion  330  and the annular groove  332 . Light component  310  also comprises a collar  318 , which has a threaded end  324  and a non-threaded end  322 . Threaded end  324  has internal threads that mate with a first lampshade  122 . Non-threaded end  322  has an internal annular flange  326  that is sized and dimensioned to press-fit with, and/or latch onto, annular groove  332 . Collar  318  can also be made of a material that has sufficient flexibility to allow annulate flange  326  to unlatch from annular groove  332 . Light component  310  also has a light element  120  that removably mates with an electrical socket  114  (not shown) disposed inside the socket housing (i.e., first socket cover  312  and second socket cover  316 ). 
       FIG. 11  shows a side view of a light component  410 . Light component  410  has a socket housing comprising a first socket cover  412  and a second socket cover  416 . First socket cover  412  and a second socket cover  416  are similar to socket cover  112  and socket cover  116  except for a non-threaded portion and a screw hole  420 . A screw passes through screw hole  420  in first socket cover  412  and second socket cover  416  to hold them together. Collar  418  has a non-threaded end that is sized and dimensioned to fit over the non-threaded portion of first socket cover  412  and second socket cover  416 . Collar  418  also has a threaded end that mates with lampshade  122 . Light element  120  removably couples with electric socket  114  (not shown) disposed inside the socket housing (i.e., first socket cover  412  and second socket cover  416 ). 
       FIG. 12  shows first socket cover  412  and second socket cover  416  decoupled and screw hole  420  passing through each part.  FIG. 13  shows the inside of first socket cover  412  and second socket cover  416  with screw hole  420  and screw hole  420  passing through each part. 
       FIG. 14  shows a side view of a light component  510 . Light component  510  has a socket housing comprising a first socket cover  512  and a second socket cover  516 . First socket cover  512  and second socket cover  516  are similar to socket cover  112  and socket cover  116  except for a non-threaded portion and an ultrasonic weld  550  that permanently joins them together. The weld is formed by applying high-frequency ultrasonic acoustic vibrations to the seam between the parts while holding the parts together under pressure. The vibrations create sufficient heat to form a solid-state weld between the parts. The parts can be made of either plastic or metal. In this manner, first socket cover  512  and second socket cover  516  are joined together permanently without the need for a screw and screw hole or external threads that mate with a threaded end of a collar. 
       FIG. 15  shows a perspective view of a string light assembly  600  that has a plurality of light components  610  electrically coupled via wired connection  605 . A first end of wired connection  605  (not shown) can comprise an electrical plug configured to couple with a power source to provide electricity to the lights  610  for illumination. 
       FIG. 16  shows an exploded view of light component  610 . Light component  610  comprises a first socket cover  112  and a second socket cover  116  that couple together to form a socket housing with an interior space. The interior space is sized and dimensioned to enclose an electrical socket  114 . First socket cover  112  and second socket cover  116  can be coupled together by screwing the threaded collar  118  onto the external threads of first socket cover  112  and second socket cover  116 . It is also contemplated that collar  118  could employ non-threaded fasteners to secure first socket cover  112  and second socket cover  116  together, including male-female engaging connectors, press-fit or snap-in connections, and magnetic fasteners. 
     First socket cover  112  and second socket cover  116  can be made of plastic, metal, a composite, or any other material suitable for housing an electrical socket and light element. When coupled, first socket cover  112  and second socket cover  116  form a t-shaped housing with two arms extending in different directions. The arms also have openings on their respective ends that allow the two wired connections of socket  114  to pass therethrough. 
     Socket  114  can be any suitable electrical socket such as parallel XTW or SPT for #20 AWG light string with E12 socket or E17 socket, or parallel XTW or SPT for #18 AWG light string with E17 socket. Socket  114  has a threaded cavity with electrical connections for supplying power to a light element  620 . Light element  620  comprises a suitable light source, such as E12/E17 incandescent bulbs or LED bulbs, surrounded by an outer lampshade. Unlike the light component  110  and lampshade  122  in  FIG. 3 , light element  620  has a lampshade and light source that are unitary. The outer lampshade layer can be made of plastic, metal, or any suitable material for protecting the light source and/or diffusing light. The outer lampshade layer can also be made of different colors and/or levels of translucency to produce different lighting. 
     Light element  620  has external threads that mate with the threads of the cavity of socket  114 . However, it is also contemplated that light element  620  can removably couple with socket  114  using other known fasteners, including male-female engaging connectors, press-fit or snap-in connections, and magnetic fasteners. Since the lampshade layer of light element  620  is integral with the light source, collar  118  does not need internal threads on its distal end for coupling a lampshade. Thus, in alternative embodiments, collar  118  of light component  610  can be modified to have a threaded end and a non-threaded end. 
       FIG. 17  shows an exploded view of light component  610  with interchangeable light elements  620 ,  622 ,  624 , and  626 . Light elements  620 ,  622 ,  624 , and  626  have different shapes and types of outer lampshade layers. Light elements  620 ,  622 ,  624 , and  626  can also have different types of light sources (e.g., LED, incandescent, 60 watt, 100 watt, etc.). However, light elements  620 ,  622 ,  624 , and  626  have a similar threaded end for electrically and removably coupling with the threaded cavity of electrical socket  114 . 
       FIG. 18  shows string light assembly  600  with a secondary lampshade  624  removably attached to each light component  610 . 
       FIG. 19  shows an exploded view of light component  610  with the secondary lampshade  624 . The parts shown in  FIG. 19  are the same as  FIG. 16  except for the addition of the secondary lampshade  624 . Lampshade  624  removably couples with the first socket cover  112  and the second socket cover  116  by placing the distal end of the t-shaped body through the opening of lampshade  624  and then screwing collar  118  onto the external threads of first socket cover  112  and the second socket cover  116 . The size of the opening of lampshade  624  is less than an outer width or diameter of the housing (e.g., rim or flange) and the collar  118 . In this manner, collar  118  can be used to secure lampshade  624  to the housing formed by first socket cover  112  and second socket cover  116 . 
     It is contemplated that lampshade  624  can be made of plastic, metal, a composite, or any material suitable for providing shading to a light element. It is also contemplated that lampshade  624  can be made in many different shapes to provide different styles (e.g., outdoor, indoor, modern, rustic, etc.) and can be interchangeable with different shapes and colors of lampshades to create a different style for the string light assembly. 
     The light component design described herein advantageously allows for different lampshades to be interchangeable to customize the look and feel of the string light assembly. Additionally, the light component design is easy to assemble due to a reduced number of parts. The design can also be used to imitate the effect of an E26 string light, but with the lower cost due to use of an LED bulb. 
     From a methods perspective, the inventive subject matter includes a method of assembling a light component comprising the steps of: (i) placing an electrical socket between, and inside, the interior space of a first socket cover and a second socket cover; (ii) fastening the first socket cover and second socket cover together, such as by ultrasonic welding, threading a screw from the first socket cover to the second socket cover, or placing and fastening a collar over the distal end of the first and second socket cover; and (iii) removably coupling a light element or light source to the electrical socket, such as by threading external screws on the light element or light source to internal threads in the cavity of the electrical socket. The method can also include the step of placing a secondary lampshade over the distal end of the first and second socket cover prior to placing the collar over the distal end, and then placing the collar on the distal end to secure the secondary lampshade. 
     As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously. 
     It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the amended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.