Patent Application
20100149811
1. Field of the Invention
This invention relates to lighting units using light emitting diodes (LEDs), and more particularly to LED based interconnected lighting units for different illumination applications such as illuminating channel letters.
2. Description of the Related Art
Recent developments in LEDs have resulted in devices that are brighter, more efficient and more reliable. LEDs are rugged, consume less power, have a relatively long life (up to 100,000 hours), operate at low voltage, and are 30 to 70% more energy efficient than conventional lights, such as incandescent, neon or fluorescent bulbs. As a result of these developments, LEDs are becoming utilized in many more lighting applications that were previously the realm of incandescent, neon or fluorescent light sources.
Channel letters are commonly found on the outside of buildings and are often used to advertise the name of the business. They are typically constructed of aluminum or plastic housing having the shape of a letter and are approximately 5″ deep. The housing has a generally U-shaped cross-section, with the top opening in the housing covered by a colored translucent lens that transmits light from within the housing.
Channel letters are typically illuminated with neon or fluorescent light sources that are mounted within the channel letter housing. Neon and fluorescent lights provide a bright and continuous light source that allows the channel letters to be visible at night. These light sources, however, have a relatively short life (20,000 hours), are fragile, operate at high voltage (7,000 to 15,000 volts for neon) and can consume a relatively large amount of power. Neon bulbs can also experience difficulty with cold starting, which can lead to the bulb's failure.
LEDs are more frequently being used as the light source in different sign applications. U.S. Pat. No. 5,697,175, to Schwartz, discloses a low power illuminated sign that is particularly adapted for use with common EXIT signs over doorways. The back of each sign comprises a reflector with a series of cavities with curved surfaces. Each cavity corresponds to a letter and background area in the sign. LEDs are mounted in the center of the cavities to illuminate the letters or background area. The LEDs are provided on a separate perpendicular circuit board or on a central projection formed in the bottom of the cavities, with light from the LEDS directed outward. The letters and background area of the sign are illuminated by light reflecting forward from the curved surfaces of the cavities, so that the only visible light is from the illumination of the cavities.
U.S. Pat. No. 6,042,248, to Hannah et al., discloses an LED assembly for channel letter illuminating signs having an enclosure/housing covered by a translucent lens. Each sign includes a plurality of track moldings at the base of its enclosure, with the moldings running along the longitudinal axis of the sections of the channel letter. Linear arrays of LEDs are mounted on printed circuit boards (PCBs) that are then mounted in the track moldings. Each track molding can hold two PCBs in parallel with each of the PCBs arranged on a longitudinal edge, with the LEDs directed outward.
LED based channel letter lighting is also available from LumiLEDs, Inc., under part numbers HLCR-KR-R0100 and HLCR-KR99-R0200, which comprises LEDs that are each mounted by insulation displacement connectors (IDC) on two inch centers. The chain of LED modules is then mounted into a bendable clip or rail, each of which is then mounted inside a channel letter to hold the LEDs in place. Power is provided by a combination of an AC/DC mother power supply and a DC/DC daughter power supply. A sensing LED is also included as a temperature and current sensor.
U.S. Pat. Nos. 6,932,495 and 7,241,031, both to Sloan et al. and both assigned to SloanLED, Inc., disclose channel letter lighting units and lighting systems utilizing the lighting units. In some embodiments these lighting units can be provided as multiple lighting units interconnected by conductors in a chain so that an electrical signal applied to the chain causes the lighting units to emit light. The chain can be made available to purchasers on different holding devices such as a box, reel or rack. Different lengths of the chain can be utilized for a particular channel letter, with the desired length of chain being cut from the holding device and mounted within the channel letter. Power can then be applied to the chain in the channel letter causing the units to emit light.
Different types of chains can have different numbers of lighting units per a length, or stated differently, a different density of lighting units. These chains are typically sold at a cost per measure of length, and the cost per length is typically greater for lighting systems having higher density. To accommodate the different needs of customers for chains of different densities, many different types of lighting system chains need to be maintained and stored and made available to customers. In some channel letter applications it may be desirable to have different densities of units in different locations. This can require purchasing multiple chains with different densities for the same job.
Each of the lighting units in the chain also has a certain number of LEDs, such as two, four, eight, sixteen, etc., depending on the embodiment. In certain circumstances it may be desirable to have fewer than all the number of LEDs provided on the units, such as in locations where the illumination should be spread. Conventional lighting units, however, offer little flexibility in reducing the number of LEDs in certain ones or all of the LED units in a chain.
The present invention comprises lighting units and systems that can be used to illuminate structures such as illumination of channel letters. One embodiment of a lighting system according to the present invention comprises a plurality of lighting units interconnected by a conductor. Each of the units is coupled to the conductor such that an electrical signal applied to the conductor causes the lighting units to emit light. The length of the conductor between said units is adjustable to vary the distance between adjacent ones of the lighting units.
Another embodiment of a lighting system according to the present invention comprises a plurality of lighting units, each of which further comprises a plurality of emitters. A conductor is included for carrying an electrical signal with the lighting units connected to and interconnected by a conductor. An electrical signal is applied to the conductor which causes the emitters to emit light. The lighting units are separable into sections each of which comprise at least one of the plurality of emitters and each of which remains connected to the conductor. The length of the conductor between the sections is adjustable to vary the distance between adjacent ones of the sections.
Another embodiment of a lighting system according to the present invention comprises a plurality of lighting units connected to and interconnected by a conductor. Each of the lighting units comprises a housing and a printed circuit board (PCB) mounted to the housing. The PCT has having a plurality of light emitting elements arranged so that an electrical signal applied to conductor causes the light emitting elements to emit light substantially away from the housing. A plurality of additional conductor sections is included, each of which is associated with a respective one of the lighting units to increase the length of the conductor between adjacent ones of the lighting units.
Still another embodiment of a lighting system according to the present invention comprises a plurality of lighting units connected to and interconnected by a conductor. Each of the lighting units comprises a printed circuit board (PCB) mounted within a housing, wherein the PCB has a plurality of light emitting elements. A plurality of first additional conductor sections is included, each of which is associated with and extendable from a respective one of the lighting units to increase the length of the conductor between adjacent ones of said lighting units. A plurality of second additional conductor sections is also included wherein at least some of the lighting units are separable into lighting units sections. Each of the lighting unit sections comprises at least one emitter that emits light in response to the electrical signal. At least some of said separable sections have one of the second additional conductors sections that is extendable from the lighting unit section.
These and other further features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings, in which:
The present invention provides a lighting system that can be used in many different applications such as structural lighting, display lighting and ingress/egress lighting, but is particularly applicable to channel letter lighting. The systems according to the present invention provide lighting units that are interconnected in a chain by electrical conductors so that an electrical signal applied to the input end of the conductors spreads to the lighting units, causing them to emit light. According to the present invention, the conductors between the LED units can have an adjustable length to allow for the length of conductors to be altered in the, which allows for the density of the LED units to be customized to meet the particular application. For example, in channel letter applications there may be instances where chains or sections of chains having different densities are desired, and the present invention allows for the density to be altered in the field to meet these different needs.
Other embodiments of the present invention can provide other means for adjusting the density of emitters along the chain of lighting units, and in some embodiments these adjustments can be made in the field. In different embodiments, the number of light sources can be spread along the chain by separating, detaching or breaking apart the lighting units into multiple lighting units, with each of the separated light units having at least one of the light sources from the original unit. The lighting system can also comprise a length of conductor between the separated sections of the lighting units to spread the separated portions of the lighting units. These embodiments not only allow for the number of light sources to be divided between the separated lighting units sections, but also allow for the density to be reduced by having a conductor between the separated units.
The present invention is described herein with reference to certain embodiments but it is understood that the invention can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. In particular, the invention is described with reference to certain embodiments where the length of a conductor can be increased between adjacent lighting units or lighting unit sections, but in other embodiments the length of the conductor can be decreased. In these embodiments, the decreased conductor length increases the density of lighting units and/or light emitter. Further, many different mechanism and arrangements can be used to allow for the density of lighting units or light sources to be adjusted along the length of the chain of lighting units. The present invention can also be used with different types of lighting units used in different applications beyond channel letter lighting, and although the present invention is described herein with reference to light emitting diodes (LED or LEDs) other light sources can be used.
It is also understood that when an element such as a layer, region or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. Furthermore, relative terms such as “inner”, “outer”, “upper”, “above”, “lower”, “beneath”, and “below”, and similar terms, may be used herein to describe a relationship of one layer or another region. It is understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.
Although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention.
Embodiments of the invention are described herein with reference to illustrations that are schematic illustrations of embodiments of the invention. As such, the actual thickness of the layers and features can be different, and variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances are expected. Embodiments of the invention should not be construed as limited to the particular shapes of the regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. A region illustrated or described as square or rectangular will typically have rounded or curved features due to normal manufacturing tolerances. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a feature of a device and are not intended to limit the scope of the invention.
The PCB 22 has first and second lighting elements 18, 20 (shown in
The elements 18, 20 are generally mounted along the longitudinal axis of the PCB 22, although they can also be mounted in other locations. In other embodiments the lighting units can comprise more than two lighting elements, such as four, six, and eight or more, that can be mounted in many different locations. The light elements 18, 20 can be any device that emits light in response to an electrical signal, such as incandescent lights, lasers, laser diodes, fluorescent light or neon lights, with the preferred light elements 18, 20 being light emitting diodes (LEDs). The elements 18, 20 can emit different colors of different intensities, with a suitable LED being commercially available emitting high luminous flux white light.
The PCB 22 can be any conventional type made from any conventional material, with a preferred PCB 22 being a metal core type PCB. Different types of metal core boards can be used such as an aluminum core board. By being a metal core, heat from the light elements conducts into the PCB 22 so that the PCB 22 helps draw away heat from the light elements 18, 20. The PCB 22 then provides a larger surface that allows the heat to dissipate into the surrounding ambient. This can help keep the light elements 18, 20 cooler, which can allow them to operate under a higher current so that they can emit a higher luminous flux.
Lighting units according to the present invention can also comprise other elements, with one embodiment comprising constant current devices that can be mounted on the PCB using conventional methods. This allows each of the units to have substantially the same current driving its light elements 18, 20 so that each of the units 12 emits substantially the same amount of light. The light elements 18, 20, and constant current device can be interconnected by conductive traces on the PCB using conventional methods. Without a constant current device, the system 10 can experience light loss as the power signal passes down the conductors 14, 16 through each of the units 12. This can ultimately result in a channel letter exhibiting different brightness across its cover or by different channel letters in a sign having different brightness. By driving each of the light elements 18, 20 in each of the units 12 with the same current, the light elements along the conductor will have the same brightness. Many different constant current devices can be used, with a suitable device being an LM317M 3-Terminal Adjustable Regulator provided by Texas Instruments, National Semiconductor, and Fairchild Semiconductor.
The PCB 22 can also comprise first and second break-away pins 32, 34 which as shown are included on the bottom of the PCB 22. The pins 32, 34 can be formed using many different methods, such as the pins being bonded or molded to the PCB 22 using known methods. The pins 32, 34 can be mounted in many different locations to the PCB 22 or the housing 24 and can comprise many different shapes and sizes. For pins 32, 34 located on the PCB, it is understood the size and location of the pins 32, 34 should be such that they do not interfere with the housing 24. The pins 32, 34 are also sized and positioned so that and additional section 38 of the conductors 14, 16 can be held within the housing 24, with the conductors 14, 16 wrapping around the pins 32, 34 in a serpentine manner. In the embodiment shown, the conductors enter the housing 24 and wrap around the first pin 32. The conductors 14, 16 continue toward and around the second pin 34 and then back to the connectors 30.
This arrangement of the pins 32, 34 and conductors 14, 16 arrangement provides the additional length or section 38 of conductor 14, 16 within the housing 24 that can be used to increase the length of the conductors 14, 16 between the units 12. This in turn can decrease the density of lighting units per length of the system 10, and can be accomplished in the field without having to disassemble the light units 12. To increase the length of conductors 14, 16 a pulling force can be applied to the conductors 14, 16 on the end of the units having the pins 32, 34. When a sufficient force is reached, the pins 32, 34 can break-away from the PCB 22. This frees the wrapped additional section 38 to unwrap from the pins 32, 34 so that it can be pulled out of the housing opening 36. This results in an increase in the length of conductors 14, 16 between the unit 12 with particular unit with the pins broken-away and the unit 12 adjacent to it.
Each lighting unit 12 can be mounted within a channel letter by many different methods such as by glue, clamp, bolt, weld, etc. As shown, the housing 24 can be provided with double sided tape 40 on its bottom surface for mounting. Many different double sided tapes can be used, with a preferred tape being a commercially available double sided foam tape provided by 3M Corporation. The housing 24 can also be provided with an alternative mounting method that can be used alone or in conjunction with the double sided tape 40. The housing includes a housing mounting hole 42 through which a screw, nail or rivet can pass to mount the housing 24. The PCB 22 also comprises a PCB mounting hole 44 in alignment with the housing mounting hole 42. In one embodiment according to the present invention a screw can pass through the PCB mounting hole 44 and into the housing mounting hole 42. A screwdriver can then pass through the PCB mounting hole 44 to turn the screw into the channel letter, through the housing mounting hole 42.
The units 52 comprise a housing 24 with a PCB 22 mounted within the housing 24. The PCB 22 holds two light emitters (not shown) on one side and connectors 30 on the other. Conductors 14, 16 enter the housing 24 and are electrically connected to the PCB by connectors 30 as described above. In this embodiment, an additional section 54 of the conductors 14, 16 is held in the housing 24 in a coiled or serpentine manner, although it is understood that the conductors 14, 16 can be arranged in many different ways. In this embodiment, the housing's first conductive opening 56 is sized to closely fit around the conductors 14, 16. The close fit causes the opening 56 to pinch around the outside of the conductors 14, 16 to hold the conductors in place within the opening 56. To expand lengthen the conductors 14, 16 between adjacent ones of the units 52, a pulling force is applied to the conductors 14, 16 sufficient to overcome the pinching force. This allows for the section 54 to be pulled out of the housing 24, effectively increasing the length between the adjacent ones of the units 52. It is noted that for this and other embodiments, all or part of the conductor section 54 to be pulled from the housing to provide flexibility in the length between adjacent units 52.
In other embodiments, a section of the conductors can be arranged in many different ways to allow for increasing length of conductors between adjacent units.
To increase the length between adjacent units 72, a pulling force is applied to the conductors 14, 16 sufficient to overcome the holding force between the conductors 14, 16 and the clip 76. This results in the section 74 being released from the clip 76 increasing the length between the adjacent units 72. In different embodiments the force can release all or part of the section 74 from the clip 76 allowing for different additional lengths of conductors 14, 16. This provides flexibility in the different lengths between adjacent units 72, and flexibility in lighting unit density.
In other embodiments, different types of conductors can be provided between adjacent units to allow for different conductor length.
Lighting systems according to the present invention can be arranged in many different ways to allow for reducing the density of lighting units or lighting elements in a chain of lighting units. In the embodiments described above, the density can be decreased by increasing the length of conductor between different ones of the lighting units.
Referring to
Referring now to
Alternatively, as shown in
The PCBs can be have different break or dividing lines 166 that facilitate separation or breaking apart of the PCBs into different sections.
It is further understood that different applications of different combinations of PCB (lighting unit) separation and PCB (lighting unit) detachment can be utilized to achieve the desired lighting density for the lighting system. For example, two adjacent PCBs can be separated by extending the additional conductor, while adjacent PCBs can be detached or broken apart. These variations can continue down the LCB or lighting unit chain.
Although the present invention has been described in considerable detail with reference to certain preferred configurations thereof, other versions are possible. Lighting units according to the invention can be used for many different applications beyond channel letters. A separate power supply can be used for each channel letter or multiple letters can be powered by a single power supply. In other embodiments, a variable power supply can be used to control the intensity of the light emitters. The lighting unit can be many different sizes and can be used in many different applications beyond channel letters. The PCB can have different numbers of LEDs and can have different electronic components arranged in different ways. The conductors can be different lengths and instead of running uninterrupted between the units, the conductors can have connectors. This would allow the units to be supplied separately and then connected together when installed. Therefore, the spirit and scope of the invention and should not be limited to the preferred versions described above.
