The present disclosure relates generally to lighting fixtures and systems, and more particularly to LED lighting systems.
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
The use of LEDs and light strips are frequently used in lighting systems. However, light systems frequently need to be mounted on variety of surfaces, at a variety of angles, and directed to provide lighting to a variety of areas. Furthermore, lighting systems often have difficulty integrating both LED strips and control systems within small lighting systems used in confined spaces. Additionally, electrical adapters are frequently used for lighting systems. However, prior art electrical adapters are often complicated and difficult to manufacture, involving several different parts to electrically adapt LED strips to normal electrical wires.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
In one embodiment of the present disclosure, a lighting system is provided including an extrusion, a lighted strip, a control board, and a connector. The extrusion includes a pair of side walls coupled by a connecting member, where the connecting member defines a first shelf for a lighted strip. A pair of flanges project from the side walls forming a second shelf for a control board. The connector includes a shell and a pin arranged within an opening within the shell. The shell includes an outer surface which is configured to be coupled with the extrusion and an inner surface which defines the opening. The pin includes a contact plate arranged adjacent to a second end of the shell to receive the lighted strip. The pin is also adapted to receive a wire through a first end of the shell.
In another embodiment of the present disclosure, a lighting system is provided including an extrusion, a lighted strip, and a connector. The connector includes a shell having an outer surface with slats projecting outward and adapted to be inserted into the extrusion. The connector also includes an inner surface which defines an opening extending from a first end of the shell to a second end of the shell. The inner surface also includes a first ridge and a second ridge. The connector further includes a plurality of pins within the opening. Each pin is adapted to receive a wire through the first end of the shell, and each pin includes a curved contact plate which is adapted to contact a lighted strip adjacent to the second end of the shell. Each pin also includes a foot which rests against the second ridge of the inner surface, and a stop which rests against the first ridge of the inner surface.
In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
Referring to
The extrusion 10 is formed of metal, plastic, or some other rigid material, and comprises a pair of side walls 24 coupled by a connecting member 26. In the embodiment shown, the extrusion 10 is a unitary structure having a uniform profile which extends a length from a first end to a second end, which may vary depending on the length of the lighting system needed. In another example, the extrusion may be multiple pieces that are welded, glued, or otherwise fixedly coupled to form the extrusion 10. The connector 18 may be plastic, nylon or some other rigid material that may be at least partially inserted into at least one of first or second ends of the extrusion 10. The connector 18 comprises a shell 32 which is adapted to be coupled with an end of the extrusion 10, and secured by friction fit. The connector 18 also couples electrical contacts 36 on the lighted strip 12 to an electrical source via a pair of wires 34 extending from a first end of the connector 18. The extrusion 10 may be covered by the diffuser 16 which has a pair of arms 30 coupled to a translucent member 28. The diffuser 16 may be made of metal, plastic or some other rigid material, or a combination of materials. Further, the translucent member 28, may be made of transparent or translucent materials and surrounded by similar material or some other rigid material. The translucent member 28 allows the light from the LEDs 22 to be more evenly spread on the area for which the lighting system is being used to illuminate. The lighted strip 12 comprises a length of circuit-bearing material such as silicon or a polymer. The lighted strip 12 may include a plurality of LEDs 22 arranged on a first surface of the lighted strip 12, and may include a layer of adhesive material on a second surface of the lighted strip 12.
Referring to
The connecting member 26 has a first surface 38 which faces the first cavity 87. At least a portion of the first surface 38 forms a first shelf 42. The first shelf 42 may be adapted to receive a lighted strip 12 which may be inserted into the first cavity 87. The lighted strip 12 may be coupled to the first shelf 42 by an adhesive placed on a surface of the lighted strip 12 contacting the first shelf 42.
The pair of side walls 24 may include a pair of flanges 44 protruding into either the first cavity 87 or the second cavity 88. These flanges 44 may extend along the entire length of the extrusion 10 or along only one or more portions of the extrusion 10. In the embodiment shown, the pair of flanges 44 are arranged on the pair of side walls 24 to extend outwardly from a respective side wall 24 toward the oppositely positioned side wall 24 at a position on the respective side walls 24 that creates a gap between the first shelf 42 and the flanges 44. The pair of flanges 44 together form a second shelf 46 which may be adapted to receive a control board 14. The control board 14 may be coupled to the second shelf 46 by an adhesive, or may be held in place by supports or electrical wires (not shown) connecting the control board 14, or the electrical contacts 60 thereof, to the lighted strip 12. The control board 14, when coupled directly or indirectly with the lighted strip 12, may be used to control the operation of the lighted strip, including switching the LEDs 22 on or off, or dimming the LEDs 22 as needed or in response to an input.
A pair of interlock members 48 may be formed toward the ends of the portions of the pair of side walls 24 which form the first cavity 87. In the embodiment shown, the interlock members 48 take the form of wedges which protrude into the first cavity 87. In other examples, the interlock members 48 may be any other form of protrusion. These wedges interact with receiving members 68 on the pair of arms 30 of the diffuser 16, such as by snap fit, to couple the diffuser 30 to the extrusion 10.
A pair of mounting projections 54 may be formed at or near the ends of the portions of the pair of side walls 24 which form the second cavity 88. In the embodiment shown, the mounting projections 54 protrude into the second cavity 88 and form a mounting shelf 56 along with a pair of protrusions 52 that extend toward the connecting member 26. At least one purpose of the mounting projections 54 is to define a space within the second cavity 88 in which a protrusion 134 (
The extrusion 10 shown in
A second example method of mounting the lighting system, it may be desirable to mount the lighting system using a pair of attractive magnets. A first magnet 62 may be secured within the extrusion 10 while a second magnet (not shown) may be placed on or behind the mounting surface. In the embodiment shown, the first magnet 62 may be inserted into the second cavity 88, such as by insertion, from the first or second ends of the extrusion 10. The magnet's 62 first surface 64 can contact a second surface 40 of the connecting member 26 which faces the second cavity 88. The mounting shelf 56 can contact the magnet's 62 second surface 66, and the pair of vertical protrusions 52 can restrict the horizontal movement of the magnet 62. In other example embodiments, glue, fasteners, a magnetically attractive extrusion 10, or any other mechanism may be used to maintain the magnet 62 within the second cavity 88. The magnet 62 may extend the entire length or a significant length of the extrusion 10, or there may be one or more separate magnets 62 positioned along the length of the extrusion 10.
The first magnet 62 may be held in place within the channel formed by the second cavity 88 by a smaller positioning magnet (not shown) placed within the mounting groove 58. The positioning magnet should be sized so that when resting in the mounting groove 58, the upper surface of the positioning magnet lies below the first shelf 42 so that it does not interfere with the placement of the lighting strip 12. The positioning magnet may be fixed within the channel formed by the mounting groove 58, by means of tape (not shown) on the first shelf 42 which covers at least a portion of the mounting groove 58. The lower surface of the tape contacts the positioning magnet to fix it in place within mounting groove 58. If the tape is double-sided, the upper surface of the tape may also be used to affix the lighting strip 12 to the first shelf 42.
A third example method of mounting the lighting system, may include a bracket 20. The bracket 20 may be fixedly coupled with the extrusion 10 to secure the lighting system to a mounting surface. In the embodiment shown in
The lighting system shown in
The diffuser 16 may also include a pair of film projections 70 extending from the arms 30 into the first cavity 87 of the extrusion 10. These film projections 70 together form a film shelf 72, on which a diffusing film (not shown) may be slidably inserted adjacent to the translucent member 26. This diffusing film may be desirable to better spread the light from the LEDs 22 so that it is more difficult to distinguish individual LEDs 22 from the lighting system as a whole. Additionally, the diffusing film may be used to tint or color the light coming from the LEDs 22 of the lighted strip 12. The diffusing film may be readily replaced by decoupling the diffuser 16 and the extrusion 10.
Referring to
Additionally, the embodiment shown in
Referring to
The flanges 44 of the extrusion 82 shown in
The embodiment shown in
Referring to
For mounting purposes, the extrusion 92 can also include a mounting plate 94 projecting away from a surface of the connecting member 26 at a predetermined angle with respect to the surface of one of the pair of side walls 24. This mounting plate 94 may be secured to a mounting surface with a mounting member, or fastener, such as a screw or a bolt coupled with the mounting plate, such as by a bore 96 through the mounting plate 94. In this way, the lighting system may be mounted on a mounting surface to direct an arc of light centered at a different angle than perpendicular to the mounting surface. On the opposite side of the connecting member 26 from the mounting plate 94, an angled arm 98 may project from the surface of the other of the pair of side walls 24. The angled arm 98, may be positioned at a predetermined complementary angle from the mounted plate 94 so that the angle between the angled arm 98 to the mounting plate 94 is approximately 90 degrees. This angled arm 98 allows the lighting system to be positioned more securely in a corner of a mounting surface that has surfaces at right angles. In a mounting surface with corners having surfaces at angles greater or less than 90 degrees, it may be desirable that the angled arm 98 be set at a predetermined angle wherein the angle between the angled arm 98 and the mounting plate 94 is substantially equal to the angle of the surfaces of the corner of the mounting surface.
Referring to
Referring to
Referring to
Referring to
The shell may also include a lip 122 arranged at or near the first end of the shell 32 projecting outwardly from the outer surface 118 of the shell 32. The lip 122 includes a perimeter 132 which extends about the edge of the lip 122. The perimeter 132 may be arranged so that it substantially covers the profile of the extrusion 10 when the connector 18 is coupled to the extrusion 10.
The lip 122 may also include wire channels 128, 130 as grooves in the surface of the lip 122 opposite from the shell 32. The wire channels 128, 130 may be used to direct the wires 34 in narrow spaces, where the surface of the lip 122 is adjacent to a wall or surface. The wire channel 130 may extend from the opening 128 to the perimeter 132 of the lip and is adapted to receive the plurality of wires 34 protruding from the first end of the shell 32. The wire channel 128 may extend across the opening 128 and to the perimeter 132 on one or both sides of the lip 122 to receive one or a plurality of wires 34 protruding from the first end of the shell 32.
The lip 122 may further include one or more protrusions 134 extending from the same surface of the lip 122 as the shell 32. The protrusion 134 is adapted to be received into the second cavity 88 of an extrusion 10 and may secure the connector 18 to the extrusion 10 by friction fitting.
The shell 32 may further include a tooth 126 positioned within the opening 116 of the shell 32, to separate and isolate each of the plurality of pins 110 from each other. Additionally, the tooth 126 may include an angled portion 136 adjacent to the second end of the shell 32, where the first, shorter end of the angled portion 136 is closer to the second end of the shell 32 than the second, larger end of the angled portion 136. The angled portion 136 should be adapted to direct a lighted strip 12 inserted into the opening 116 towards one portion of the inner surface 120 instead of the other. Accordingly, a lighted strip 12 inserted into the second end of the shell 32 is guided into contact with the pins 110 by the tooth 126 In addition, an inserted lighted strip 12 inserted into the second end may be held by friction fit in the connector 18 by the angled portion 136 of the tooth 126.
Referring to
Referring to
The female portion 112 of the pin 110 is curved to define a trough 152 adapted to receive the exposed portion 160 of a wire. The female portion 112 may have one or more crimping elements 148 coupled to the trough 152 and arranged to be bent by a compressive force to forcibly couple the wire 34 to the contacting surface 156 of the trough 152 and create an electrical connection between the wire 34 and the pin 110. To further facilitate a secure electrical connection, the contacting surface 156 of the trough 152 may also include one or more blades 154 which project from the contacting surface 156. When the crimping elements 148 have compressed the wire 34, the blades 154 provided direct force to specific points of the wire 34 to further secure the electrical connection. A second set of crimping elements (not shown) may be included which may be bent by a compressive force to forcibly couple the insulated portion 158 of the wire 34 to the connector and fix the position of the wire 34 with respect to the pin 110.
The female portion 112 of the pin 110 may also comprise a plurality of positioning elements 146, 150 extending from the trough 152 to secure the vertical position of the pin 110 within the shell 32. The trough 152 rests on a first portion of the inner surface 120, while the positioning elements 146, 150, extend from the trough 152 to contact a second portion of the inner surface 120 which is opposite from the first portion. Positioning members 146, 150 may vary in size depending on their intended placement within the shell 32. For example, positioning elements 150 adjacent to the first end of the shell 32 may have a different size from positioning elements 146 further from the first end of the shell 32, as the opening 116 varies in size from the first end to the second end of the shell 32.
The curved contact plate 114 of the pin 110 is adapted to be positioned adjacent to the second end of the shell 32, and is curved outwardly towards the second end. The curved contact plate 114 is configured to exert an expansive force on the inner surface 120 of the shell 32 so that, when a lighted strip 12 is inserted into the opening 116 of the connector 18, electrical contacts 36 on the lighted strip 12 will slide under the curved contact plate 114 and be compressively secured between the inner surface 120 of the shell 32 and the curved contact plate 114. The contact elements 36 of the lighted strip 12 are arranged to contact the curved contact plate 114 instead of the inner surface 120 due to the side walls 24, etc.
The foot 144 of the pin 110 may be arranged to project outward from the pin 110 and include a surface facing the second ridge 140. In this way, the surface of the foot 144 will rest against the second ridge 140 and prevent movement of the pin 110 in one direction. In the embodiment shown, the foot 144 projects outward from the pin 110 as an edge arranged between the female portion 112 and the curved contact plate 114.
The stop 142 of the pin 110 may be arranged to project outward from the pin 110, and have a surface which faces the first ridge 138. In this way, the surface of the stop 142 rests against the first ridge 138 and prevents movement of the pin 110 in the opposite direction of the one direction of movement prevented by the foot 144. Thus the cooperative operation of the second ridge 140 and the first ridge 138 securely and fixedly positions the pin 110 within the shell 32. In addition, when slidably mounted in the shell 32, the pin 110 is locked in place and arrested from further sliding upon contacting the second ridge 140 and the first ridge 138. In the embodiment shown, the stop 142 takes the form of a surface at the end of the curved contact plate 114. The curved contact plate 114 curves toward and eventually rests in the first ridge 138. One advantage of such an embodiment is that if the pin 110 must be removed from the shell 32, the curved contact plate 114 can be compress to unseat the stop 142 from the first ridge 138 so that the pin 110 may be extracted from the first end of the shell 32. The stop 142 and the foot 144 may project outward from the pin 110 in the same direction, or in opposite directions on either side of the pin 110.
Referring to
Similarly, the shell 162 shown in
The shell 166 shown in
The shell 170 shown in
Referring to
Accordingly, it is now apparent that there are many advantages of the invention provided herein. In addition to the advantages that have been described, it is also possible that there are still other advantages that are not currently recognized but which may become apparent at a later time.
While preferred embodiments of the invention have been described, it should be understood that the invention is not so limited, and modifications may be made without departing from the invention. The scope of the invention is defined by the appended claims, and all devices that come within the meaning of the claims, either literally or by equivalence, are intended to embrace them.
The present disclosure is related to and claims all benefit pursuant to 35 U.S.C. §119 of U.S. Provisional Application Ser. No. 62/039,748, filed Aug. 20, 2014, which is incorporated by reference in its entirety.
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