Method of replacing a conventional vehicle light bulb with a...

Illumination – Supported by vehicle structure – Plural light sources

Reexamination Certificate

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Details

C362S800000, C362S229000

Reexamination Certificate

active

06276822

ABSTRACT:

BACKGROUND OF THE INVENTION
The present invention relates to vehicle warning light assemblies such as taillights, head lights, brake lights, turn signal lights, dash lights, side marker lights, interior dome and courtesy lights and reverse lights. More particularly, the present invention relates to a conversion kit which allows one to easily replace the standard incandescent bulbs currently used in such vehicle warning light assemblies with a light-emitting diode array.
Presently, vehicle warning light assemblies are equipped with conventional filament light bulbs which have a number of well-known problems. For example, the light bulbs draw excessive current and in certain conditions are not bright enough to see from a trailing vehicle. Moreover, traditional light bulbs have a relatively short life span, requiring frequent replacement. However, light bulbs are oftentimes not replaced promptly, creating an unsafe vehicle condition and possible injury not only to those within the vehicle but also to persons in other vehicles as well.
Light emitting diodes (LEDs) have recently been developed for use as a light source in motor vehicle lamps. An advantage to using LEDs is that they typically have an operating life of as much as 100,000 hours before they begin to degrade. LEDs also draw less current from the vehicle's electrical system and emit more light than similarly configured or styled filament light bulbs.
Current systems utilizing LEDs suffer many disadvantages. In some, there are not enough LEDs to emit sufficient light to act as a taillight under government regulations. In others, a special housing and lens cover must be used to operate the system. Thus, the entire lamp assembly for a filament light bulb must be replaced to utilize an LED system. Replacing the entire assembly with a new system can be a difficult task for the average consumer. Additionally, replacement is oftentimes prohibitively expensive considering that nearly all vehicles in use today already have incandescent bulb systems in place.
Thus, what is needed is an LED system which utilizes a sufficient number of LEDs to emit light which meets the government regulations for warning lights such as taillights. Furthermore, a system is needed which is able to replace a conventional bulb without having to use special housings, or requiring the replacement of an existing warning light assembly. What is further needed is a system which is inexpensive and easy to install. The present invention fulfills these needs and provides other related advantages.
SUMMARY OF THE INVENTION
The present invention resides in method for replacing the incandescent bulb of a conventional vehicle warning assembly with a light-emitting diode (LED) array. The LED array is installed by removing the lens and conventional light bulb from the vehicle warning light assembly. Electrical leads for the warning light assembly are then accessed and electrically connected to an electrical connector of the LED array. A license plate illuminating bulb may also be electrically connected to the warning light leads directly or indirectly through the electrical connection of the LED array. The array is then typically secured to the warning light assembly and finally the lens is replaced to complete the replacement process.
The light-emitting diode (LED) array includes, generally, a mounting member and an electrical connector connected to a circuit board having, in circuit, a plurality of LEDs, at least one resistor, and at least one diode. The LEDs may be arranged in an array of one side or both sides of the circuit board. The array can be secured to the warning light assembly by screws inserted through mounting member apertures and threaded into apertures in the assembly. Assembly apertures are drilled into the assembly if there are no existing apertures, or if the existing apertures do not align with the mounting member apertures.
In one embodiment, the electrical connector of the array includes wires which are spliced to the electrical leads of the warning light assembly, forming the electrical connection between the array and the assembly. The array is attached to the warning light assembly and the lens is replaced.
In another embodiment, the electrical connector is comprised of a bayonet connector capable of being inserted into a bayonet connector receiver of the warning light assembly. The lightbulb is removed from the bayonet connector receiver of the warning light assembly and the bayonet connector, which is electrically and physically connected to the array, is inserted and secured into the mating bayonet connector receiver. The array is then attached to the warning light assembly and the lens is replaced.
Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.


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