Title of Invention

REPLACEABLE LED LAMP

Abstract

A replaceable LED lamp comprising atleast one LED with or without its operating circuitry moulded/housed with respect to atleast a polymeric base of desired shape and configuration to fit to a desired holder having power supply and operatively connect said LED to said power supply. The replaceable LED lamp is cost effective to manufacture and simple to use. The replaceable LED lamp is especially suitable for use as indicator lamp, signaling, domestic application such as decorative lamp, night lamp etc. It is also suitable in installation of various electrical and electronics devices for industrial as well as domestic use.

Full Text

The present invention relates to a replaceable LED lamp. In particular, the present invention relates to replaceable LED lamps suitable for use as indicator/lamps, signaling, automotive indicators/lamps and domestic applications of LED such as for decoratve lamps, night lamps etc. Also, the replaceable LED lamps of the invention have applications as indicators and signals in various electrical and electronics devices, industries, power generation plants, steel plants, fertilizer plants, defense, railways and domestic uses. LED as is well known is a light emitting diode(LED) which requires to forward operating voltage and current. It is usually wired in series with current limiting resistor and/or capacitor to control the supply current. It is presently known to have LED lamps as indicators which comprise of polymeric or bakelite based holders which house the LED lamps and their operating circuitry of various specifications including, those involving capacitor/resistor and rectifier based circuitry. In particular, in such conventional LED units, the LED lamp and its operating circuitry is loosely inserted within said housing and at the front a filter means is releasably secured to the said holder. It is also known to use incandescent lamps as indicators instead of LEDs. However, such application of incandescent lamps requires use of expensive holders with the incandescent lamp replaceably connected to said holder. It is found that such conventional indicator/signalling means presently available as discussed above suffer from some inherent disadvantages/drawbacks in as far as its manufacture, application and use in various fields are concerned. In particular, some of the basic disadvantages/drawbacks associated with such known LED lamp include the following: 1) In such known LED units when the holders house the LED lamps and operative circuitry, in the instance the LED lamp and/or any component of the circuit get damaged, the whole unit inclusive of the holder requires replacement which add to recurring cost and maintenance expenditure. 2) Conventional replaceable incandescent lamp indicators suffer from inherent drawbacks including short life, higher power consumption, production of heat and 1) 2 are also fragile requiring very careful handling to avoid breakage. Such lamps frequently require replacement due to damage and/or breakage which again add to the cost of use and maintenance of such known replaceable incandescent lamps and its operating units. Also, such conventional LED and incandescent lamps require special holder which require sophisticated machinery and technical expertise to manufacture and is also cost extensive to obtain. 3) The conventional LED lamp units usually have a separate colour filter attached to the holder at the front thereof which apart from requiring additional expenses on provision of such separate filters are also not shock and vibration resistant and thus subject to breakage adding to additional cost on replacement and maintenance. Also such front colour filters which are not integral result in loss of effective luminance from the lamp units thereby further reducing effective luminance power of such LED lamps. 4) The conventional filament incandescent lamp also require separate colour filter to provide for desired indicator colour unit and the problems of breakage and resultant cost burdened is also common problem for such conventional filament/incandescent lamp also. 5) The conventional LED holders further have space constraint which pose problems in assembling of the unit with plurality of LED lamps which in turn affect the lumen output desired out of such units. It is thus the basic objective of the present invention to provide for replaceable indicator/signaling LED lamps which would avoid the above discussed problems of existing LED lamp units and incandescent lamps. Another objective of the present invention is to provide for replaceable LED lamps which would be simple to manufacture and would be cost effective. Another object of the present invention is to provide for replaceable LED lamps which would avoid the problems of loss of luminance for indicator purposes and would thereby provide for more efficient use of LED lamps. Yet further object of the present invention is directed to provide for replaceable LED lamp which can be easily used, applied and replaced as and when desired using conventional lamp holders. 3 Yet further object of the present invention is to provide for replaceable LED lamps which would have effective longer life and would also consume less power as compared to conventional incandescent lamps used for signaling thereby serving for an effective replacement even for conventional incandescent lamps. Yet further object of the present invention is to provide for replaceable LED lamp which would be sturdy, durable and non-breakable and thus be cost-effective to use. Yet further object of the present invention is directed to provide a replaceable LED lamp which would have protection against shock and vibration. Yet another object of the present invention is to provide for replaceable LED lamp which would be simple to manufacture and would not require expensive and/or heavy machinery and can be obtained by simple manufacturing gadgets and without requiring extensive technical skill and expertise. Yet further object of the present invention is to provide for replaceable LED lamp of desired shapes, size and configuration through simple and cost effective means and for varied applications and use. Thus according to the present invention there is provided replaceable LED lamp comprising: atleast one LED with or without its operating circuitry moulded/housed with respect to atleast a polymeric base of desired shape and configuration to fit to a desired holder having power supply and operatively connect said LED to said power supply. In accordance with one aspect of the present invention the replaceable LED lamp comprise: said atleast one LED with or without its operating circuitry moulded/housed with respect to said polymeric base member with or without releasably connected front cover/filter means. 4 The front cover can preferably comprise of filter means to favour the purpose as an indicator means. In the above disclosed LED of the invention, the filter means can comprise of coloured filters and said releasably connection of the said filter means with respect to said base can be by way of releasable threaded and/or press fit connection. Advantageously, such replaceable LED lamps of the invention provide for simple installation of such LED lamp in any conventional holder and can be attended by any person without any specialized skill/knowledge. Also, in case of requirement of replacement of LED lamp of the invention the same can be simply removed from the holder and a fresh one installed in its place. It is simple and cost-effective to obtain and use. According to another aspect of the present invention the replaceable LED lamp comprise: said at least one Led with or without/its operating circuitry moulded/housed with respect to said polymeric base and a polymeric mass/cover as front cover/filter means at the front with said LED with or without the operating circuitry housed therein. The replaceable LED lamp according to this embodiment apart from the advantages of the other embodiment discussed above provides for better illumination (lumen output) and more shock and vibrationresistance having the front protection cover of the polymeric filter. In the above disclosed replaceable LED lamps of the invention the basic component used are selected from the conventional LED, the resistor, diode, capacitor which are moulded/housed with respect to the said polymeric base with or without the polymeric filter at the front. The replaceable LED lamps of this invention are convenient for use in any conventional lamp holder and should serve as an effective replacement for conventional LED unto with suitable holders. Importantly, the replaceable LED lamps being moulded/housed 5 with respect to the polymeric base and easy to operatively connect to any conventional holder can be used and installed by one and all without requiring any technical expertise in its installation and use. This favours use, replacement and maintenance of the LED lamps of the present invention. In accordance with yet further aspect of the present invention there is provided a process for manufacture of replaceable LED lamp comprising : providing moulding/housing of desired shape and configuration depending upon the desired shape and configuration for the polymeric base of the LED lamp ; ii) moulding/housing with respect to a polymeric material said atleast one LED lamp with or without operating circuitry operatively connected thereto to atleast partially expose said LED lamps at the front with said polymeric base at the rear having the desired shape and configuration for fitting to a holder, providing a metallic apron on said polymeric base adapted to constitute an operating link therebetween the LED and the power supply at the said holder. Preferably in accordance with a further aspect of the process of the present invention the process of manufacture of the replaceable LED comprise : i) providing a first mould ; ii) introducing said at least one LED lamp with or without operating circuitry within said mould ; iii) providing a first moulding of a polymeric material on said LED lamp with or without circuitry to provide for a polymeric cover over said LED lamps at the front; iv) placing the thus moulded LED lamp with or without circuitry in a second mould ; v) providing a second moulding at the base to provide a polymeric base of desired shape and configuration adapted to fit to a holder; vi) providing a metallic cap thereon said polymeric base to provide for operating connector of said LED to said power supply at the holder. Preferably in the above process of the invention the polymeric moulding/housing of the base is attended using coloured polymeric material to protect against loss of luminance from the rear. Also, the moulded base/housing base is preferably extended upto the 6 sides to favour further arrest of lumen and its conventional emission through the front polymeric mass/cover only thereby achieving better lumen output at the front. The polymeric mould/housing in the above process can be achieved by way of thermosetting polymers and/or thermplastic polymers. In the instance thermosetting polymers are used suitable catalyst/accelerator are also used to cure and inside the mould. Such thermosetting polymers can be selected from polysterin, epoxy resins etc. Suitable catalyst comprises MEK (Methyl Ethyl Ketone), MEKP (Methyl Ethyl Ketone peroxide), TBP (Tertiary Butyl Peroxide) and Benzoyl peroxide. Suitable accelerators include cobalt salts such as cobalt octate. Suitably thermoplastic polymers which can be used comprise phenolics, polyethylene, Napthalate (PEN), Polyacetal Resins and Polycarbonates. The moulds/housing can be obtained of any desired shape, size and configuration to suit different end uses and holder configurations. The mould release material can be selected from petroleum jelly, silicone gel etc. The operating circuitry integrally moulded to the LED lamp can be any desired operating circuitry known in the art. The period for setting of the polymeric material in the process of obtaining the replaceable moulded LED will depend upon the selected polymeric material and also the process of moulding of the same whether following thermosetting or thermoplastic polymeric. The details of the invention its objects and advantages are explained in greater detail with reference to the non-limiting exemplary embodiment of the replaceable LED lamp and its process of manufacture described hereunder with reference to the accompanying figures as submitted with the provesonal specification wherein : Fig. 1 illustrates a first embodiment of the replaceable LED lamp in accordance with the present invention. 7 Fig. 2 illustrates a second embodiment of the replaceable LED lamp in accordance with the present invention. Fig. 3 illustrates a third embodiment of the replaceable LED lamp in accordance with the present invention. Fig. 4 is a fourth embodiment of the replaceable LED lamp in accordance with the invention. Fig. 5 shows a top plan view of the front cover of polymeric mass of the replaceable LED lamp of the invention. Fig, 6 shows a top plan view of a further embodiment of the front cover of polymeric mass of the replaceable LED lamp of the invention. As illustrated in figure 1 the replaceable LED unit according to one embodiment can have only its base portion (BP) moulded with the LED or housing the LED with or without the operating circuitry such that the LED at the top is exposed. In such an embodiment, the LEDs are allowed to remain exposed or in the alternatively the same can be provided with releasably secured polymeric caps/filter means (not shown) to favour luminance output. The replaceable connection of the filter to said base of the LED unit can be obtained by means of connecting threads and/or press fit connection of the LED base with that of the filter or any other convenient mode of securing the releasable connection of the filter with respect to the base of the unit. Reference is now invited to the accompanying figures 2 to 4 which shows further improved embodiments of the replaceable LED unit of the invention. As illustrated in said figures such a replaceable LED unit provides for moulding/housing of the LED with or without its operating circuitry with respect to a polymeric base material. In particular, according to such preferred embodiment the polymeric mass covers the LED with or without the operating circuitry both at the rear constituting of the base (BP) of the unit and also at the front constituting a protective front cover (FC) of polymeric means for the LED lamps. Importantly, the base is obtained of high density polymeric material and of coloured material to avoid any loss of luminance from the rear 8 of the unit. Also the base of the polymeric unit can be extended at the sides to avoid any leakage of luminance from sides of the unit. The front cover/filter means can be obtained of translucent polymeric material to provide for effective emission there through from said light emitting diodes for indicator and/or other like purposes. All the embodiments illustrated in figures 1 to 4 have the unique advantage of replaceable LED lamp and can be obtained by simple manufacturing process. In particular the process of manufacture involves conventional mould designing and moulding technique following the simple process steps as detailed and discussed hereinbefore. Fig. 5 and 6 shows two varieties of designs of the front cover of moulded polymeric means which can be provided on the top of the moulded polymeric cover constituting the front cover of the replaceable LED lamp of the invention, importantly, such integral moulded LED lamp provides for easy installation of such LEDs in any conventional holder means by any ordinary person not necessarily having technical skill and expertised. It is important to mention that the consideration of presently/available LED units are so complicated that replacement and reinstallation of such LED unit require skill and expertise to attend to the same and it was not possible for ordinary workman to attend to such replacement of conventional LEDs. Moreover, in the instance of any lamp failure the entire unit alongwith the holder required replacement since the holder, operating circuitry and the LED together constituted a single unit. This added to the cost of replacement and maintenance of such known LED lamps. Thus the replaceable LED lamp of the invention provide for the following advantages : 1) the LED unit with or without operating circuitry of the invention is replaceable and can be easily replaced after the specified life and/or for maintenance purposes without need for the technical expertise and the replacement and maintenance cost are reduced to the minimum ; 2) additional colour filter is not required as the mould material is made of specified colour LED lamps and accordingly the brightness is more and the cost of the colour filter is reduced substantially ; 3) the LED lamps of the invention can be used without the conventional lamp holders which require expensive and complicated manufacturing procedure and can be used with any known simple lamp holder; 1) 9 4) the lamp constitutes a solid mass of polymer and hence well protected against the shock and vibration ; 5) the manufacturing process is simple and can be carried out without any expensive machinery and/or technical expertised by any ordinary workman and thus the manufacturing as compared to conventional LEDs ; 6) any desired shape and size can be provided for such integrally moulded LED lamps; 7) the replaceable LED lamp can be obtained of easily available components and thus rendered its manufacture much simpler and cost effective. 4) 10 WE CLAIM : A replaceable LED lamp comprising atleast one LED (LED) with or without its operating circuitry moulded/housed with respect to atleast a polymeric base (BP) of desired shape and configuration to fit to a desired holder having power supply and operatively connect said LED to said power supply. 2. A replaceable LED lamp as claimed in claim 1 comprising : said atleast one LED with or without its operating circuitry moulded/housed with respect to said polymeric base member with or without a releasably connected front cover/filter means. 3. A replaceable LED lamp as claimed in anyone of claims 1 or 2 wherein the front cover carrpreferably comprise of filter means constituting indicator means. 4. A replaceable LED lamp as claimed in anyone of claims 1 to 3 wherein said filter means comprise of coloured filters and said releasable connection of the said filter means with respect to said base can be by way of releasable threaded and/or press fit connection. 5. A replaceable LED lamp as claimed in anyone of claims 1 to 4 wherein the replaceable LED lamp comprise : said at least one Led with or without its operating circuitry moulded/housed such as to provide said polymeric base and a polymeric mass/cover as front cover/filter means at the front with said LED with or without the operating circuitry housed therein. 6. A replaceable LED lamp as claimed in anyone of claims 1 to 5 wherein said LED comprise the conventional LED and said operating circuitry comprise of conventional resistor, diode, capacitor means which are moulded/housed with respect to the atleast said polymeric base with or without the polymeric filter at the front. 7. A replaceable LED lamp as claimed in anyone of claims 1 to 6 wherein said polymeric base is adapted for operative connection with respect to any conventional holder means having the power source. 11 8. A replaceable LED lamp as claimed in anyone of claims 1 to 7 wherein said polymeric base is obtained of coloured polymeric material. 9. A replaceable LED lamp as claimed in anyone of claims 1 to 8 wherein said polymeric base extends to the sides of the LED lamps. 10. A replaceable LED lamp as claimed in anyone of claims 1 to 9 wherein said polymeric mass constituting the front cover/filter means is obtained of trnaslucent polymeric material. 11. A replaceable LED lamp as claimed in anyone of claims 1 to 10 wherein said operating circuitry comprise any conventional LED operating circuitry. 12. A process for manufacture of replaceable LED lamp as claimed in claim 1comprising : a) providing moulds/housing of desired shape and configuration depending upon the desired shape and configuration for the polymeric base of the LED lamp ; b) moulding/housing with respect to said polymeric base material said atleast one LED lamp with or without operating circuitry operatively connected thereto to atleast partially expose said LED lamps at the front with said polymeric base at the rear as a moulding/housing having the desired shape and configuration for fitting to a holder, providing a metallic apron on said polymeric base adapted to constitute an operating link therebetween the LED and the power supply at the said holder. 13. A process for manufacture of replaceable LED lamp as claimed in claim 12 comprising; i) providing a first mould; ii) introducing said at least one LED lamp vvith or without operating circuitry within said mould ; iii) providing a first moulding of a polymeric material on said LED lamp with or without circuitry to provide for a polymeric cover over said LED lamps at the front; iv) placing the thus moulded LED lamp with or without circuitry in a second mould ; 12 v) providing a second moulding at the base to provide a polymeric base of desired shape and configuration adapted to fit to a holder; vi) providing a metallic cap thereon said polymeric base to provide for operating connector of said LED to said power supply at the holder. 14. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 or 13 wherein said polymeric moulding/housing of the base is attended using coloured polymeric material. 15. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 to 14 wherein said moulded base/polymeric housing is preferably extended upto the sides. 16. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 to 15 wherein said polymeric moulding/housing of said polymeric base with or without said front cover/filter polymeric mass/cover is obtained by use of thermosetting polymers and/or thermplastic polymers. 17. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 to 16 wherein said thermosetting polymers are used alontwith suitable catalyst/accelerator. 18. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 to 17 wherein said thermosetting polymers are selected from polysterin, epoxy resins and said catalyst is selected from MEK (Methyl Ethyl Ketone), MEKP (Methyl Ethyl Ketone peroxide), TBP (Tertiary Butyl Peroxide) and Benzoyl peroxide. 19. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 to 18 wherein said accelerators include cobalt salts preferably cobalt octate. 20. A process for manufacture of replaceable LED lamp as claimd in anyone of claims 12 to 19 wherein said thermoplastic polymers comprise phenolics, polyethylene, Napthalate (PEN), Polyacetal Resins and Polycarbonates. 20. 13 21. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 to 20 wherein said moulds/housing are selected of any desired shape, size and configuration to suit different end uses and holder configurations. 22. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 to 21 wherein mould release material used is preferably selected from petroleum jelly, silicone gel. 23. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 to 22 wherein said operating circuitry integrally moulded to the LED lamp is of any desired operating circuitry known in the art. 24. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 to 23 wherein the period for setting of the polymeric material in the process of obtaining the integrally moulded LED depends upon the selected polymeric material and also the process of moulding. 25. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 to 24 wherein said polymeric base is obtained of high density polymeric material and of coloured material. 26. A process for manufacture of replaceable LED lamp as claimed in anyone of claims 12 to 25 wherein said moulding/housing constituting the polymeric front cover means is applied with ornamental designs. 27. A replaceable LED lamp and a process of manufacturing the same substantially as hereindescribed and illustrated with reference to the accompanying figures. A replaceable LED lamp comprising atleast one LED with or without its operating circuitry moulded/housed with respect to atleast a polymeric base of desired shape and configuration to fit to a desired holder having power supply and operatively connect said LED to said power supply. The replaceable LED lamp is cost effective to manufacture and simple to use. The replaceable LED lamp is especially suitable for use as indicator lamp, signaling, domestic application such as decorative lamp, night lamp etc. It is also suitable in installation of various electrical and electronics devices for industrial as well as domestic use.

Documents:

00152-cal-1999-abstract.pdf

00152-cal-1999-claims-1.1.pdf

00152-cal-1999-claims.pdf

00152-cal-1999-correspondence-1.1.pdf

00152-cal-1999-correspondence.pdf

00152-cal-1999-description(complete).pdf

00152-cal-1999-description(provisional).pdf

00152-cal-1999-drawings.pdf

00152-cal-1999-form-1.pdf

00152-cal-1999-form-19.pdf

00152-cal-1999-form-2-1.1.pdf

00152-cal-1999-form-2.pdf

00152-cal-1999-form-3.pdf

00152-cal-1999-form-5.pdf

00152-cal-1999-pa.pdf

152-CAL-1999-CORRESPONDENCE-1.2.pdf

152-CAL-1999-FORM 27.pdf

152-cal-1999-granted-abstract.pdf

152-cal-1999-granted-claims.pdf

152-cal-1999-granted-correspondence.pdf

152-cal-1999-granted-description (complete).pdf

152-cal-1999-granted-drawings.pdf

152-cal-1999-granted-form 1.pdf

152-cal-1999-granted-form 18.pdf

152-cal-1999-granted-form 2.pdf

152-cal-1999-granted-form 3.pdf

152-cal-1999-granted-form 5.pdf

152-cal-1999-granted-letter patent.pdf

152-cal-1999-granted-pa.pdf

152-cal-1999-granted-reply to examination report.pdf

152-cal-1999-granted-specification.pdf