Method of producing an LED rope light

Abstract

A method of producing a light-emitting-diode (LED) rope light includes the steps of preparing a plurality of light seats defining a recess therein and a plurality of metal wires having two conductive plates connected to two ends thereof; positioning two conductive plates from two different metal wires in each light seat; forming the light seats into light-emitting diodes; serially connecting the light seats to provide an LED light string; positioning the LED light string into a hollow power cord holder with two electrodes of the LED light string connected to two power cords embedded in the power cord holder; and quickly enclosing said power cord holder with a transparent outer tube by way of injection molding to form an LED rope light.

Description

FIELD OF THE INVENTION [0001] The present invention relates to a method of quickly producing a light-emitting-diode (LED) rope light, and more particularly to a method of producing an LED rope light at largely reduced manufacturing cost and shortened time. BACKGROUND OF THE INVENTION [0002] A conventional rope light includes a plurality of bulbs as its light sources. These bulbs are serially connected to one another to form one or two bulb strings, which are then set in a long core tube. The core tube is cut at an outer surface to provide a longitudinal opening, via which the bulb string or strings are positioned into the core tube. Two power cords having different polarities are embedded in two opposite sides of a wall of the core tube. The two embedded power cords are cut at staggered positions to expose bare wires, to which lead wires of the first and the last bulb in the bulb strings are separately electrically connected to emit light. The core tube with bulbs is then drawn into...

AI Technical Summary

Benefits of technology

[0006] A primary object of the present invention is to provide a method that enables production of an energy saving, safe, and environment friendly LED rope light at reduced cost and shortened assembling time.

[0007] To achieve the above and other objects, the method of the present invention for producing an LED rope light includes the steps of preparing a plurality of light seats defining a recess therein and a plurality of metal wires having two conductive plates connected to two ends thereof; positioning two conductive plates from two different metal wires in each light seat; processing the light seats to provide light-emitting diodes (LED); serially connecting the light seats to provide an LED light string; positioning the LED light string into a hollow power cord holder with the metal wires of the LED light string correspondingly connected to positive and negative electrodes of two power cords embedded in the power cord holder; and quickly enclosing said power cord holder with a transparent outer tube by way of injection molding to form an LED rope light.

Problems solved by technology

The existence of the longitudinal opening largely reduces an overall structural strength of the core tube.

When the rope light is used on a stage or at places close to steps and tends to be twisted, deformed, trodden or impacted, the core tube with reduced structural strength is not strong enough to bear such external forces, resulting in damaged bulbs in the core tube.

Moreover, it is difficult and requires increased material and labor costs to mount the insulated sleeves around the lead wires of two adjacent bulb strings that are set in the core tube at the same time.

The conventional rope light with two bulb strings therefore requires increased material cost and is not easy to assemble.

Another problem with the conventional rope light is that the bulbs consume high power and generate a large amount of heat to cause deteriorated core tube and outer tube of the rope light.

Broken bulbs in the deteriorated core tube and outer tube tend to cause short circuit, and the conventional rope light is therefore not safe for use.

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