Patent Abstract:
A light emitting diode (LED) assembly designed to be used in a light bulb mounting assembly in a vehicle, such as taillight or turn indicator assembly. The LED assembly having a plurality of LEDs mounted upon a single circuit board that may be arranged in numerous colors, patterns and shapes to give a distinctive look to the light generating assembly. The LED assembly is contained within a durable water and shock resistant structure with a compatible plug member to be used in conjunction with existing light bulb mounts present in the vehicle. The LED assembly can be used to easily replace existing incandescent light bulbs present in the vehicle and provide additional color and lighting patterns eliminating the need for tinted glass bulbs or light transmissive covers to generate variations in colored light.

Full Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally relates to light bulb assemblies for vehicles, and in particular, concerns taillight assembly for an automobile wherein a light emitting diode assembly is mounted within a durable water-resistant structure that is used in conjunction with existing light bulb mounts present in the automobile. 
     2. Description of the Related Art 
     Light generating sources for automobiles typically comprise an assembly wherein an incandescent light bulb is mounted within a mounting apparatus further comprising a base, which may be reflective, and a light-transmissive cover, which may be tinted to produce a particular illuminated color. Prior art light assemblies are often large and bulky in nature, especially in the case where a reflector is used to direct and intensify the light source. 
     Another limitation of existing incandescent light sources employing evacuated glass bulbs with tungsten filaments or higher intensity halogen-based light sources is that they typically only produce one hue of white light. As a result, in order to obtain variations in color of the light, the glass of the bulb must be tinted or a light-transmissive cover having a tint must be used. However, the appearance of the tinted covers of tail light assemblies may not be a desired appearance by all vehicle owners, particularly if the tail light assembly requires significant amounts of red material. 
     Further, most rear tail light assemblies on vehicles require both red warning lights and white back up lights. As the incandescent light sources provide only a single hue of white light, the tail light assembly must have both red and white tinted light transmissive covers over the light sources. This increases the overall size and cost of the tail light assembly as it requires multiple shades of light transmissive covers. 
     A further difficulty that occurs with existing tail light assemblies is that the assemblies can become dirty which inhibits the light transmissive properties of the cover. With the particular example of a brake light, if the light transmissive cover becomes too dirty, the cover transmit less light which makes the brake lights harder to see by oncoming vehicles. This problem is particularly exacerbated with red brake light assemblies as the red plastic comprising the cover is already dark in color and is more easily occluded. 
     To address this problem, most incandescent light used in brake light assemblies are high intensity lights such that the brake lights will adequately illuminate the cover even when the cover is dirty. These high intensity lights, however, have comparatively low lifespans as they are operating at such a high intensity. When the light sources burn out, the risk to the driver of the vehicle is increased as the brake light is no longer visible to oncoming traffic. 
     One possible solution to this problem is to use LED light sources, which illuminate in a red color and have longer lifespans. One example of an LED light source is illustrated in U.S. Pat. No. 5,947,588 to Huang. In this patent, an LED light source is positioned within a cover and is connected to an existing incandescent-style mounting location. While the LED light source in the &#39;588 patent can illuminate the cover with red light, it is not readily adapted for use as an aftermarket replacement to existing incandescent lights in vehicle applications. 
     Specifically, the &#39;588 patent discloses the LED light source being positioned within a cover such that the printed circuit board is positioned exposed within the cover space. This results in the circuitry that operates the LEDs being exposed to water and dirt that enters the space beneath the cover. One problem that occurs in the covered space in which the light bulbs are positioned is that water vapor can condense within the covered space. In the device disclosed in the &#39;588 patent, water can thus condense on the electronic circuitry of the LED light source thereby damaging the circuitry and potentially causing the failure of the light. 
     Hence, there is a need for an improved light source that has longer life and produces light in a desired hue that is less affected by occlusion of the colored covers covering the light. To this end, there is a need for an LED light source that is better protected from the elements and thus able to provide light in a red hue for a longer period of time. 
     SUMMARY OF THE INVENTION 
     The aforementioned needs are satisfied by the LED assembly of the present invention which, in one aspect, comprises a replacement light assembly for a vehicle that has a circuit board having a first and a second side with a plurality of LEDs mounted on a first side of the circuit board and at least one electrical components coupled to the plurality of LEDs wherein the at least one electrical components are connected to the second side of the circuit board. The assembly further includes a housing that defines a recess wherein the circuit board is mounted within the housing such that the circuit board and the housing define an enclosed space so that the second side of the circuit board is positioned within the enclosed space separate from the LEDs themselves and is thereby more protected from the elements. In this aspect, the light assembly includes a plug member that is connected to the housing which is adapted to fit in a receptacle in the vehicle, wherein the at least one wire extends through the plug member so as to be coupled with electrical connectors positioned within the receptacle of the vehicle. 
     Since the electrical components of the circuit board are positioned within an enclosed space, the electrical components arc thereby more protected from exposure to the elements and, thus, the life of the light assembly is enhanced. Moreover, since the light source is an LED, a high intensity red light source is thereby provided which can provide red illumination suitable for, among other things, brake lights, without requiring the same power as ordinary incandescent lights which results in a longer lasting, brighter light. Moreover, the use of red LED lights can also permit the use of clear tinted replacement taillight assemblies instead of red tinted assemblies. 
     In another aspect of the present invention, the LED assembly includes a two piece housing that is coupled together via clips to retain the circuit board within an enclosed space defined by the two piece housing. The housing also advantageously connects to the plug member such that when the housing members are interconnected, the plug member is securely attached to the housing. The use of such a two-piece housing results in an inexpensive, easy to assembly housing that still affords protection to the circuitry of the LED from dust, dirt and water, but allows for quick and easy manufacturing of the assembly. These and other objects and advantages of the present invention will become more fully apparent from the following description taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded perspective view of the components of the light assembly comprising an LED assembly to be joined with a plug member using two side housing members; 
     FIG. 2 is an exploded perspective view of the partially assembled light assembly of FIG. 1 wherein the LED assembly and plug member have been joined to one side housing member; 
     FIG. 3 is an exploded perspective view of the fully assembled light assembly of FIG. 1 wherein the LED assembly and plug member have been secured used two housing members; 
     FIG. 4 is perspective view of the light assembly of FIG. 3 housed within a mounting assembly present in a vehicle comprising a light reflective member and a light transmissive lens. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Reference will now be made to the drawings wherein like numerals refer to like parts throughout. FIG. 1 illustrates an exploded view of the LED assembly  100  with left  104  and right  102  housing members and a male plug member  106 . The assembled light fixture  90  (shown in FIG. 3) is adapted to be mounted by removable attachment to a female plug member (not shown) such as might be found in taillight or turn indicator assembly in a vehicle. The male plug member  106  may be adapted to join with any of a number of female plug member configurations so as to be compatible with various makes and models of vehicles. The light assembly of the present invention as such, can therefore be used to replace stock incandescent light bulbs in these vehicles by quickly and easily removing the light assembly without modifying the existing components of the female plug member or light assembly housing of the vehicle. 
     While a particular plug and LED configuration is shown in the illustrated embodiment it should be appreciated by those of skill in the art that many possible plug and LED combinations are possible which represent other embodiments and applications of the present invention. Thus other configurations, color combinations, or quantities of LEDs can be utilized without detracting from the spirit of the present invention. Similarly, the shape and configuration of the circuit board and housing members can be configured to other shapes and LED arrangements, for example; a rectangle, a triangle, an ellipse, a star, or other similar rounded or polygonal shape. 
     Referring again to FIG. 1, the LED assembly  100  in the illustrated embodiment comprises a plurality of LEDs I  10  arranged in a circular pattern. Each LED  110  is attached to a first (top) side  120  of a circuit board  122 . The circuit board  122  is further configured to be circular in shape and is sized to contain the base of each LED  110  in the desired pattern. The power contacts or wires  132  for each LED  110  are attached to the circuit board  122  by crimping, soldering or suitable means, mounting the LED  110  in an upright manner substantially perpendicular to the first side  120  of the circuit board  122  with the base of each LED  110  resting flushly against the first side  120  of the circuit board  122 . 
     The power contacts or wires  132  for each LED  110  are further passed through the circuit board  122  where they are joined to one or more electronic components  140  necessary to power and illuminate the LEDs  110  in the sequence and patterns desired. The electronics  140  which may include for example; resistors, capacitors, and wiring are located in the area directly below the bottom side  154  of the circuit board  122  and are further disposed in the recesses of the housing members  102 ,  104  of the completed light assembly  100  as will be discussed in greater detail hereinbelow. 
     A plurality of wires  170  comprising power lines to the LED assembly  100  extend from the electronic components  140  and enter a plug member  106  through an opening  174  defining a slit which extends through the body  169 , top side  171  and bottom side  173  of the plug member  106 . The number and arrangement of power lines  170  is based, in part, on the desired control patterns to be used with the LEDs  110  as well as any existing power contacts in the female plug member present in the automobile. In the illustrated embodiment, a series of four power lines  170  arc shown. Each power line  170  extends through the male plug member  106  and is coupled to a slit opening  176  on the bottom edge of the plug member  106 . The power line  170  is positioned within the slit opening  176  and secured in position by bending, gluing, soldering or other suitable methods to provide discrete and accessible contacts points that are mated with power contacts in the female connector of the vehicle. 
     As previously described, the male plug member  106  is further configured to fit within a female plug member in the vehicle. In the illustrated embodiment, the plug member  106  comprises a piece of plastic, metal or other durable material, generally rectangular in shape and having front and back side  200 ,  202 , two side walls  204 ,  206 , and a top  171  and bottom  173  side. The width of the male plug member  106  allows it to be inserted securely into a complimentary female plug member and secured, in part, by friction generated when the male plug member sides  200 ,  202 ,  204 ,  206  and wiring  170  extending from the slits  176  when inserted into a compatible female plug member. 
     Areas along each side wall  204 ,  206  of the plug member  106  further define two recesses  210 ,  212  of similar size and depth. The recessed areas  210 ,  212  are configured accept latching flanges  300 ,  302  present on the left  102  and right  104  housing members that are passed through the recessed areas  210 ,  212  creating a substantially uniform edge along each side wall  204 ,  206  of the plug member  106  when the components comprising the right and left housing members  102 ,  104  and the plug member  106  are joined together as will be discussed in greater detail in subsequent figures. 
     The plug member  106  also has a throughgoing opening  230  that transverses the front and back sides  200 ,  202 , adjacent to the top side  171 , and equidistant from the two side walls  204 ,  206  of the male plug member  106 . The diameter of the opening  230  is further configured to be substantially the same as the diameters of the two cylindrical pin members  310  present on the inner surfaces of each housing member  102 ,  104 . As will be described in greater detail below, the cylindrical pin members  310  are sized so as to extend through the opening  230  so as to retain the plug member  106  within the housing defined by the two housing members  102 ,  104  when the housing members  102 ,  104  are secured together. 
     As is also illustrated in FIG. 1, a thin, substantially rectangular plate  240  is flushly mounted along the top side  171  of the plug member  106  wherein the plate  240  is configured to extend parallel to the top  171  and bottom  173  sides and perpendicular to the front/back sides  200 ,  202  and side wall  204 ,  206  members. The plate  240  extends slightly beyond the area defining the top side  171  of the male plug member  106  so as to create an overhang  242  along the top edge of the plug member  106 . The slits  246  are positioned along the overhang  242  and aligned in parallel with the slit openings  176  in the bottom side  178  of the plug member  106  relative to the side walls  204 ,  206 . The slits  246  each receive one power line  170  that has been passed through the male plug member  106  and bent about a slit  176  in the bottom side  178  in a manner that will be described in greater detail below. 
     The left  104  and right  102  housing members are comprised of plastic, metal or other durable material and joined to each other using couplers which in the illustrated embodiment comprise top  320 ,  322  and bottom  300 ,  302  latching flanges. The couplers comprising latching flanges  320 ,  322 ,  300 ,  302  extend from the housing member  102 ,  104  in a perpendicular direction to the plane created between the interface  301  between the joined housing members  102 ,  104  (see FIG.  3 ). The latching flanges  320 ,  322 ,  300 ,  302  are mated with flange receiving openings  321 ,  323 ,  325 ,  327  formed on the opposing housing member  102 ,  104  in the region where the latching flange  320 ,  322 ,  300 ,  302  of one housing member joins with the opposing housing member. An outwardly extending catch  299  formed on the ends of the latching flanges  320 ,  322 ,  300 ,  302  is positioned within the openings  321 ,  323 ,  325  and  327  and thereby secures the housing member sides  102 ,  104  together through snapwise assembly. Preferably, the flanges  320 ,  322 ,  300  and  302  are biased outward such that the extending catch  299  is biased into the openings  321 ,  323 ,  235  and  327  to thereby retain the interconnection between the flanges  320 ,  322 ,  300  and  302  and the respective openings. As will be described below, the flanges and the openings are positioned so as to engage with each other at either ends of the housing member  102 ,  104  so as to retain interconnection therebetween. 
     In the illustrated embodiment shown in the FIG. 1, the housing members  102 ,  104  possess a top semicircular region  340  with the sides  342  of the housing members  102 ,  104  further shaped to enclose a semicylindrical recess  341  of sufficient size so as to contain all of the electronic components  140  present below the bottom side  154  of the circuit board  122  when the two housing members  102 ,  104  are joined. The bottom  360  of the semicylindrical sides  342  further taper to join with a rectangular region  362  of the housing members  102 ,  104 . The rectangular region  362  additionally comprises a recessed area  367  with a coupler that joins the plug member  106  to the housing member  102 ,  104 . In the illustrated embodiment the coupler comprises a centrally disposed cylindrical protrusion comprising a plug positioning pin  310  extending into the space of the recessed area  361 . 
     When the two housing members  102 ,  104  are joined the cylindrical cuplike recess  341  is formed which is contains the electronic components  140  attached to the lower side  154  of the circuit board  122 . The circuit board  122  is further secured in a first position between a plurality of board positioning tabs  372 ,  374 ,  376  present along the inside perimeter of the semicylindrical sides  342  of both housing members  102 ,  104 , As shown in the illustrated embodiment, three board positioning tabs  372 ,  374 ,  376  comprising two outer board positioning tabs  374 ,  376  and one central board positioning tab  372  are spaced substantially equidistant from each other along the inside wall  380  of the housing member  102 ,  104 . The central board positioning tab  372  is situated along the top edge  378  of the housing member  102 ,  104  and equidistant from both ends  382 ,  384  of the housing member  102 ,  104 . The two additional outer board positioning tabs  374 ,  376  are each positioned equidistant from the ends  383 ,  384  of the housing member  102 ,  104  and disposed below the central board positioning tab  372  at a distance substantially equivalent to the thickness of the material comprising the circuit board  122 . 
     The plug positioning pin  310  is further disposed in the center of the rectangular region  362  of the housing member  102 ,  104  at a position substantially equidistant from the lower edge of the rectangular region  362  and the tapered region  360  of the housing member  102 ,  104 . The plug positioning pin  310  is configured with similar diameter as the opening  230  in the plug member  106  with a height measuring approximately half of the width of the plug member  106 . 
     FIG. 2 illustrates a partially assembled light fixture  89  wherein the LED assembly  100  and circuit board have been positioned within the semicylindrical recess  341  of the housing member  104  between the board positioning tabs  372 ,  374 ,  376  (not visible). The housing member  104  is slidably attached to the circuit board  122  by positioning the housing member  104  with the central board positioning tab  372  above the top side  120  of the circuit board  122  and the outer board positioning tabs  374 ,  376  below the lower side  154  of the circuit board  122 . When so positioned, the circuit board  122  may be slidably inserted into the semicylindrical recess  160  whereby the sides  342  of the housing members  102 ,  104  flushly fit against the contour of the edge of the circuit board  122 . The board positioning tabs  372 ,  374 ,  376  further secure the circuit board  122  along a plane substantially parallel with and defined by the outer semicircular perimeter of the housing member  104 . When so positioned, the LED assembly  100  extends from the housing member  104  with the circuit board  122  forming a top side enclosing the upper semicircular plane of the housing member  104 . 
     Prior to mounting of the plug member  106  to the housing member  104 , power lines  170  extending below the circuit board  122  are passed through the central slit opening  174  of the plug member  106  with each power line  170  exiting from the bottom side  173 . Each power line  170  is further bent about a second slit opening  176  directing the power lines  170  towards the LED assembly  100  along the outer face of the front or back side  200 ,  202  of the plug member  106 . The free end of each power line  170  is subsequently captured by a third slit openings  246  present on the plate  240  on the top side of the plug member  106  to secure the power line  170  in position and provide a conductive surface along the power line  170  extending from the second  176  to third slit  246  areas that will be met by contacts within the female plug member (not shown). 
     The plug member  106  is further attached to the housing member  102  in the rectangular recess  362  below the LED assembly  100 , circuit board  122 , and electronics and wiring  140  by positioning the opening  230  about the plug positioning pin  310  of the housing member  104 . The recessed areas  210  of the plug member  106  are additionally captured by the latching flange  302  resulting in alignment of the plug member  106  and securing it in a flush position against the rectangular portion  362  of the housing member  104 . The plug member  106  thereby partially extends from the bottom portion of the housing member  104  and is secured by the plug positioning pin  310  and latching flange  302  so as to prevent the plug member  106  from sliding in or out of the housing member  104 . Additionally, sufficient room is present in the recess between the plug member  106 , circuit board  122 , and housing member side  342  to contain the electronic components and wiring  140  protecting them and securing them in a confined area reducing their susceptibility to water and vibrational damage. 
     The second housing member  102  is joined to the LED assembly  100 , circuit board  122  and plug member  106  in a like manner as described above using the complimentary surfaces of these elements. When the two housing members  102 ,  104  have been positioned about the LED assembly I  00 , circuit board  122  and plug member  106 , the locking flanges  320 ,  322 ,  300 ,  302  of the housing members  102 ,  104  are positioned adjacent to the flange receiving areas  321 ,  323 ,  325 ,  327  and the resulting structure can be snapped into a completed light assembly  90  as shown in FIG.  3 . The construction of the light assembly  90  can be performed easily by hand and does not require any additional tools to complete. 
     FIG. 3 illustrates the assembled light fixture  90  comprising the LED assembly  100  disposed above the plug member  106  and disposed between the two housing members  102 ,  104 . Top latching flanges  320 ,  322  and lower latching flanges  300 ,  302  further join the two housing members  102 ,  104  together, capturing the LED assembly  100  and plug member  106  therebetween. A portion of the male plug member  106  extends below the housing members  102 ,  104  and conforms to the appropriate shape and size required to be mated with a female accepting plug member present in the vehicle (not shown). The power lines  170  individually positioned within the lower slit openings  176  and bent to extend into the top slit areas  246  (not visible in this illustration) of the male plug member  106 , provide suitable contacts that are conductively mated with components present in the female plug member to power the LED assembly  100 . 
     The LED assembly  100  shown in FIG. 3 extends from the housing members  102 ,  104  in an opposite direction from the plug member  106  with the electronic components and wiring  140  housed within the cuplike recess of the assembled light fixture  90 . This assembly  90  forms a rigid and water-resistant barrier that secures the LED assembly  100  and plug member  106  in a non-moveable manner and further protects the components and wiring  140  from corrosion or vibrational damage. 
     Additional elements such as protrusions  324 , recesses  326 , and contours  328  may optionally be present along the outer surface of the light assembly  90  to conform to the structure and design of the female plug member into which the light assembly  90  is inserted. Such structures may serve as additional mounting means whereby the male plug member  106  is secured in the female plug member of the light housing of the vehicle. 
     An illustrated embodiment of a mounting assembly  404  housing the assembled light fixture  90  is shown in FIG.  4 . The mounting assembly  404  comprises a substantially cylindrical component  406  with a proximal end enclosed by a substantially concave light reflective cover  410 . The reflective cover  410  contains an area  412  defining an opening through which the male plug member  106  of the assembled light fixture  90  is inserted. The mounting assembly  404  is further configured to rest over a female plug member (not shown) wherein the male plug member  106  is joined by insertion of the assembled light fixture  90  through the area  412  of the opening in the reflective cover  410 . When the plug members are joined the assembled light fixture  90  is positioned within the reflective cover  410  with the portion of the LED assembly  100  extending from the surface of the reflective cover  410 . A portion of the housing members  102 ,  104  further extend from the reflective cover  410  so as to allow grasping of the assembled light fixture  90  about the housing members  102 ,  104  facilitating insertion and removal of the assembled light fixture  90 . A light transmissive lens cover  402  may be additionally affixed to the mounting assembly  404  by attachment to the cylindrical component  406  in such a manner as to contain the LED assembly  100  under the lens cover  402  to provide additional protection of the components contained therein. 
     The mounting assembly and lens cover illustrated in FIG. 4 represents one of many possible configurations and, as such, other shapes and configurations of mounting assemblies may exist with or without a lens covers which perform similar functions and thus represent other applications of the present invention. Although the foregoing, description of the invention has shown, described and pointed out novel features of the invention, it will be understood that various omissions, substitutions, and changes in the form of the detail of the apparatus as illustrated as well as the uses thereof, may be made by those skilled in the art without departing from the spirit of the present invention. Consequently the scope of the invention should not be limited to the foregoing, discussion but should be defined by the appended claims.

Technology Classification (CPC): 5