Jacketed LED assemblies and light strings containing same

A method for making a jacketed light emitting diode assembly, comprising:

• providing a light emitting diode comprising a positive contact and a negative contact of a contact set, each of the contacts having a first end portion and a second end portion, and a lens body containing a semiconductor chip and the first end portions of the positive and negative contacts;
• electrically connecting a first electrical wire and a second electrical wire of an electrical wire set to the second end portions of the positive contact and the negative contact, respectively;
• inserting the light emitting diode through an opening and into a cavity of a light transmissive cover, the opening having at least one of the contact set and the electrical wire set passing therethrough;
• and
• molding a plastic jacket integrally at the opening of the light transmissive cover to provide a seal at the opening against moisture and airborne contaminants.

A light string comprising a plurality of light emitting diode assemblies connected to one another, the light emitting diode assemblies comprising a plurality of jacketed light emitting diode assemblies, comprising:

• a light emitting diode comprising
• a contact set comprising a positive contact and a negative contact, each of the contacts having a first end portion and a second end portion;
• and
• a lens body containing a semiconductor chip and the first end portions of the positive and negative contacts;
• an electrical wire set comprising a first electrical wire and a second electrical wire electrically connected to the second end portions of the positive contact and the negative contact, respectively;
• a light transmissive cover having a cavity with an opening, the cavity receiving the lens body, the opening having at least one of the contact set and the electrical wire set passing therethrough;
• and
• an integrally molded plastic jacket at the opening of the light transmissive cover to provide a seal at the opening against moisture and airborne contaminants along a length of the light string.

A method for moisture sealing a light-emitting diode elements of a light string, comprising:

• providing a light string comprising a plurality of light emitting diodes, the plurality of light emitting diodes comprising a positive contact and a negative contact of a contact set, each of the contacts having a first end portion and a second end portion, and a lens body containing a semiconductor chip and the first end portions of the positive and negative contacts;
• electrically connecting a first electrical wire and a second electrical wire of an electrical wire set to the second end portions of the positive contact and the negative contact, respectively;
• inserting the light emitting diode through an opening and into a cavity of a light transmissive cover, the opening having at least one of the contact set and the electrical wire set passing therethrough;
• and
• molding a plastic jacket integrally at the opening of the light transmissive cover to provide a seal at the opening against moisture and airborne contaminants.