Abstract: The present disclosure provides a method of manufacturing a headrest stay formed end. The method includes cutting teeth on the insertion end of a headrest stay and pressing the teeth inwardly to form a chamfered endform on the insertion end. A headrest stay having a chamfered endform comprising a plurality of curved teeth is also provided.

Abstract: An illumination assembly includes a polymeric substrate, an electrical circuit including two conductors supported by the polymeric substrate, an LED electrically coupled to the two conductors, and a heat spreader thermally coupled to the LED. The two conductors can be printed on the polymeric substrate, embedded within the polymeric substrate, or lie atop the polymeric substrate. The illumination assembly may be fabricated in three-dimensional form factors.

Abstract: A method of injection molding uses different mold inserts, such as lead frames, to selectively control material flow in order to produce different parts in a common mold. One mold insert can have a different geometry than another mold insert so that molten material is either blocked or allowed to flow through corresponding portions of the mold inserts. By changing out the insert used for injection molding, insert-molded plastic parts produced in the mold can differ by at least one part feature.

Abstract: The specification discloses a flashing lamp circuit including (1) at least one LED, (2) a dual-BJT astable multivibrator, and (3) a BJT/MOSFET pair that functions as both (a) a switch between the multivibrator and the lamp and (b) a current regulator for the at least one LED.

Abstract: An underwater lamp with improved light distribution for underwater applications. The underwater lamp includes a circuit trace having non-coplanar circuit segments, LEDs mounted on the non-coplanar circuit segments so as to emit light in nonparallel directions, and a lens. The lens includes lens portions aligned with the LEDs on the circuit trace circuit segments. The lens may be a thermoplastic material encapsulating the LEDs and the circuit trace.

Abstract: An LED fault detection circuit is provided for detecting a fault in at least one LED. The circuit may include a test voltage generator for applying at least one test voltage level to the at least one LED, wherein the at least one test voltage level is less than a nominal operating voltage range; a current measuring circuit for measuring at least one current draw by the at least one LED at the at least one test voltage level; and a processing circuit coupled to the test voltage generator for causing the at least one test voltage level to be applied to the at least one LED, the processing circuit coupled to the current measuring circuit for detecting a fault in the at least one LED when the at least one measured current draw has a profile that does not correspond to an expected current draw profile.

Abstract: An illumination assembly including a light pipe and a light supply for use in illuminating shelf dividers on a shelf. The light pipe includes a first end portion including a light inlet, a second end portion including a light outlet, and a body portion extending between the first and second end portions. The light supply directs light into the light inlet, whereby at least a portion of the light subsequently exits the light pipe through the light outlet. When the first end portion is positioned adjacent a rear edge of the shelf, the body portion extends from the rear edge to a front edge of the shelf. The light pipe is configured to transmit at least a portion of the light emitted by the light supply from the light inlet to the light outlet to illuminate an area adjacent the shelf front edge.

Abstract: The specification discloses a step tread luminaire including an optic and a light source directing light into the optic. The optic is a flexible elastomer adapted to be fitted into a hole in a step tread in grommet-like fashion with an upper portion of the optic on the top of the tread and a lower portion of the optic on the bottom of the tread. The optic emits upwardly directed, decorative light from the upper portion of the optic and downwardly directed, functional light from the lower portion of the optic.

Abstract: An illumination assembly including a light pipe and a light supply for use in illuminating shelf dividers on a shelf. The light pipe includes a first end portion including a light inlet, a second end portion including a light outlet, and a body portion extending between the first and second end portions. The light supply directs light into the light inlet, whereby at least a portion of the light subsequently exits the light pipe through the light outlet. When the first end portion is positioned adjacent a rear edge of the shelf, the body portion extends from the rear edge to a front edge of the shelf. The light pipe is configured to transmit at least a portion of the light emitted by the light supply from the light inlet to the light outlet to illuminate an area adjacent the shelf front edge.

Abstract: A light assembly including a light pipe and a plurality of light sources. The light pipe is an elongated, single, unitary piece having a generally linear light-exiting surface along one edge. The light pipe includes a plurality of lens portions along its length. Each lens portion forms a portion of the light existing surface. Each light source is associated with one of the lens portions to emit light into the lens portion and, therefore, the light pipe as a whole. The light from the light sources mixes within the light pipe before exiting the light pipe through the light-exiting surface in a generally linear pattern.

Abstract: A method of fabricating an illuminated optical device includes forming an electrically conductive circuit. A lens at least partially encapsulates the LED. Additional material may be formed around the lens without obstructing a light-transmitting surface of the lens.

Abstract: A vehicle vanity visor assembly including an illuminated mirror. The assembly includes a component including a mirror portion and a light pipe portion, with the two portions separated by an air gap. The component may be a single piece of mirror stock. The light pipe portion includes one or more corners extending around the mirror portion, and the light pipe portion defines air gaps in the corner to assist in guiding light through the corners.

Abstract: A lighted assembly includes a perforated member having a plurality of relatively small openings therethrough. The openings are arranged to provide areas forming letters, designs, or the like. A light source may be positioned adjacent the perforated member whereby light from the light source travels through the openings to form illuminated letters, designs or the like. The perforations may be filled with a light-transmitting polymer material. The light source may comprise an LED and a light guide that distributes light along a lower side of the perforated member. The light source may be positioned in a waterproof housing that is sealed to the perforated member.

Abstract: A flexible light assembly includes a plurality of light guides that may be operably connected to one or more LED light sources. The light guides may include smooth surfaces that internally reflect light except at selected areas having irregular surface features that permit the escape of light to provide illuminated letters, numbers, designs, or the like. The light guides and LED light source may be disposed within a flexible housing.

Abstract: An electrical device such as an LED light assembly includes a conductive circuit and one or more electrical components connected to the circuit. The electrical components and the circuit are at least partially overmolded with a thermoplastic polymer material to encapsulate the components. The material utilized to cover the circuit and/or electrical components may also be utilized to form a housing or other structure of a finished part.

Abstract: An electrical device such as an LED light assembly includes a conductive circuit and one or more electrical components connected to the circuit. The electrical components and the circuit are at least partially overmolded with a thermoplastic polymer material to encapsulate the components. The material utilized to cover the circuit and/or electrical components may also be utilized to form a housing or other structure of a finished part.

Abstract: A device and method for forming notches in tubes or other parts includes a roller that travels along a non-linear path. The roller may include a component of motion away from the part to reduce bulging or other deformations in an outer surface of the part that could otherwise result from a straight roller path.