Patent Application
20120120650
The present invention relates to lighting devices, more particularly, to lighting devices including optic elements and optic elements holders.
Electrical lighting devices have been used ever since the invention of the electrical light bulb by Thomas Edison in the 19th century.
The era of semiconductors introduced a new lighting device known as a “light emitting diode” (LED) which can produce light using a very compact form factor. The latest LEDs are mounted onto printed circuit boards (PCBs) as surface mounted devices (SMDs) which do not require through holes to be drilled through the PCB.
The SMD LED assembly 101 connects to the electrical circuit by means of an LED assembly cathode 101e and an LED assembly anode 101f.
a of the prior art is a bottom view schematic illustration of an optic element 13 used to disperse the light emitted by an LED 101a.
The light emitted by the LED 101a is placed within the optic element hole 13a and its light is evenly dispersed by the optic element 13. Should the optic element 13 or the LED dome 101d sustain damage (scratches, deformations, pressure, etc.), the light will not disperse evenly from the lighting device or the LED will be damaged.
Part of the optic element 13 can have a cone shape, with a circular cross section, and with an optic element cone angle 13b.
b of the prior art is a top view schematic illustration of an optic element 13 used to disperse the light emitted by the LED 101a upon which the section plane a-a is marked.
c of the prior art is a cross sectional view a-a of an optic element 13.
The present illustration depicts the optic element hole 13a into which the LED assembly 101 is inserted.
a of the prior art is an exploded schematic illustration of a prior art optic holder 90.
The prior art optic holder 90 is composed of a prior art optic holder body 91, an LED assembly 101 and an optic element 13.
b of the prior art is a top view schematic illustration of a prior art optic holder 90. The present illustration shows that the prior art optic holder body longitudinal length 91a and the prior art optic holder body lateral length 91b are smaller than the LED package longitudinal length 101ca and the LED package lateral length 101cb, respectively. This relation between these dimensions increases the risk that the prior art optic holder 90 would damage the LED dome 101d during the assembly process.
The current assembly process includes gluing the prior art optic holder 90 to the LED assembly 101 or to the printed circuit board (PBC) onto which it is assembled. The gluing of the prior art optic holder 90 is messy, time consuming and very inaccurate and placing it with even the slightest misalignment can cause damage to the LED assembly 101.
Offset position of the LED assembly in PCB can cause the optics to be rotated and change the position of the light beam, or malfunction of the lighting device.
There is therefore a need for a lighting device, which has characteristics and an assembly process that minimize the risk of damage to the LED assembly.
The background art does not teach or suggest a lighting device, which has characteristics and an assembly process that minimize the risk of damage to the LED assembly.
The present invention overcomes these deficiencies of the background art by providing a lighting device with a new optic holder.
An embodiment of the present invention is described herein below in which an optic holder which is equipped with several alignment pins, which are longer than the height of the LED assemblies used on the lighting device's printed circuit board (PCB) as well as an opening which is wider than the LED assemblies used on the lighting device's PCB.
The long alignment pins ensures that the optic holder is kept away from the LED assembly's dome until the optic holder is mounted onto the PCB and the wide openings in the optic holder ensure that once the optic holder is mounted onto the PCB there is enough room around the LED assemblies so that the optic holder does not touch the LED assemblies in order to minimize the risk of damaging the LED dome.
Under the PCB is a thermal pad which is used to dissipate part of the heat generated by the LEDs mounted on the PCB, as well as to provide electrical insulation.
The lighting device is also equipped with several open covers and several closed covers. The user of the lighting device may choose the configuration of the open and closed covers in the lighting device, allowing or disallowing light from the LEDs to come out through the covers.
Furthermore, the lighting device is encased in a housing which includes several mount tracks, which enable the user to mount the lighting device at various orientations and angles.
Additional objects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
According to the present invention there is provided a lighting device including: (a) a main assembly including: (i) at least one optic holder, wherein each one of the at least one optic holder includes: (i.i) a holder body, having a holder upper surface and a holder bottom surface, wherein the bottom surface includes at least one holder opening; (i.ii) at least one holder space wall disposed between the holder upper surface and the holder bottom surface, wherein the holder space wall contains a holder space; (i.iii) at least one holder alignment pin disposed on the bottom surface, wherein the holder alignment pin has a predefined holder alignment pin length; (i.iv) at least one holder optic guide, disposed on each one of the holder space walls, inside each one of the at least one holder spaces; (i.v) at least one holder rib disposed on the holder upper surface; (i.vi) at least one holder longitudinal rib disposed on the holder upper surface, and at least one holder lateral rib disposed on the holder upper surface; (i.vii) at least one holder screw hole formed through each one of the holder upper surfaces; and (i.viii) at least one holder pin hole, formed through each one of the holder upper surfaces, wherein each one of the at least one holder openings has a predefined opening longitudinal length, and a predefined opening lateral length, wherein each one of the at least one holder optic guide has an holder optic guide end 11ga, wherein there is a predefined holder optic guide end angle between the holder optic guide end and the holder bottom surface; (ii) at least one printed circuit board, having a printed circuit board body, wherein the at least one printed circuit board, is securely connected to the at least optic holder, wherein each one of the at least one printed circuit board includes: (ii.i) at least one header connector securely connected to the printed circuit board body, wherein the at least one printed circuit board, has at least one printed circuit alignment pin hole formed through each one of the at least one printed circuit board body; (iii) at least one thermal pad having a thermal pad body wherein the at least one thermal pad is disposed on each one of the at least one printed circuit board; (iv) at least one open covers, having an open cover weight value, mounted on the at least one optic holder, the at least one open covers includes: (iv.i) an open cover body; (iv.ii) a cover opening formed through the open cover body; and (iv.iii) at least one open cover pin disposed on the open cover body, wherein the holder body applies force on all of the at least one open cover pins, of one of the at least one open covers; (v) at least one light emitted diode assembly having a light emitting diode assembly height, wherein the at least one light emitted diode assembly is securely connected to the at least one printed circuit board body, and wherein the at least one light emitted diode assembly includes: (v.i) a light emitted diode package having a light emitted diode package longitudinal length, and a light emitted diode package lateral length; (v.ii) a light emitted diode securely connected to the light emitted diode package; and (v.iii) a light emitted diode dome light emitted diode package, wherein each one of the holder openings has a predefined opening longitudinal length, and a predefined opening lateral length, wherein the predefined opening longitudinal length is substantially larger than the light emitted diode package longitudinal length and wherein the predefined opening lateral length is substantially larger than the light emitted diode package lateral length, wherein the at least one holder alignment pin length is substantially larger than the at least one of the light emitting diode package height; (vii) at least one optic element, mounted inside of each one of the at least one holder opening, wherein the at least one optic element has an optic element hole, and wherein the at least one optic element has an optic element cone angle, wherein the optic element cone angle is compatible with the holder optic guide end angle; and (viii) at least one main assembly screw mounted through one of the at least one holder screw hole.
According to the present invention there is provided the lighting device further including: (b) a housing, wherein the main assembly is located inside the housing, and wherein the housing includes: (i) a housing body; (ii) an exterior cover mounted on the housing, wherein the exterior cover is at least partially transparent to light; and (iii) at least one screws holder mounted inside the housing, wherein the at least one main assembly screw is screwed into the at least one screws holder.
The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
a of the prior art is a bottom view schematic illustration of an optic element used to disperse the light emitted by an LED.
b of the prior art is a top view schematic illustration of an optic element used to disperse the light emitted by the LED upon which the section plane a-a is marked.
c of the prior art is a cross sectional view a-a of an optic element. The present illustration depicts the optic element hole into which the LED assembly is inserted.
a of the prior art is an exploded schematic illustration of a prior art optic holder.
b of the prior art is a top view schematic illustration of a prior art optic holder.
a is a top view schematic illustration of a lighting device upon which section planes b-b and c-c are marked, according to the present invention.
b is a cross sectional view b-b of a lighting device, according to the present invention.
c is a cross sectional view c-c of a lighting device, according to the present invention.
a is an isometric schematic illustration of an optic holder, according to the present invention.
b is a top view schematic illustration of an optic holder upon which section planes d-d and e-e are marked, according to the present invention.
c is a bottom view schematic illustration of an optic holder, according to the present invention.
d is a side view schematic illustration of an optic holder, according to the present invention.
e is a cross sectional view e-e of an optic holder, according to the present invention. The illustration marks detail A in a circle, which is magnified in the circle on the bottom side of the illustration.
f is a cross sectional view d-d of an optic holder, according to the present invention.
g is a bottom side isometric schematic illustration of an optic holder, according to the present invention. The illustration marks detail B in a circle, which is magnified in the circle on the bottom side of the illustration.
h is a bottom view schematic illustration of an open cover pin, mounted inside a holder pin hole, according to the present invention.
a is a top view isometric schematic illustration of a closed cover, according to the present invention.
b is a bottom view isometric schematic illustration of a closed cover, according to the present invention.
c is a top view isometric schematic illustration of an open cover, according to the present invention.
d is a bottom view isometric schematic illustration of an open cover, according to the present invention.
e is a right side view schematic illustration of a closed cover, according to the present invention.
f is a left side view schematic illustration of a closed cover, according to the present invention.
a is a front view schematic illustration of an input end cup, according to the present illustration.
b is a back view schematic illustration of an input end cup, according to the present illustration.
c is a back view isometric schematic illustration of an input end cup, according to the present illustration.
d is a top view schematic illustration of an input end cup, according to the present illustration.
The present invention is of a lighting device.
The principles and operation of a lighting device according to the present invention may be better understood with reference to the drawings and the accompanying description.
Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, dimensions, methods, and examples provided herein are illustrative only and are not intended to be limiting.
The following list is a legend of the numbering of the application illustrations:
Referring now to the drawings,
The lighting device 1 described in the present illustration contains four open covers 14 and four closed covers 15.
The present invention allows for various combinations of open covers 14 and closed covers 15, according to user requirements, and is not limited in any way to eight covers.
The present illustration shows the two main assemblies in the lighting device 1: the main assembly 10 and the housing 20.
The main assembly 10 contains several open covers 14 and closed covers 15, thermal pads 17, printed circuit boards 16, optic holder 11, optic elements 13 and several main assembly screws 18, which hold the main assembly's 10 components together.
The present invention is not limited in any way to two elements as shown in the specific case of the present illustration, such as the example of two optic holders 11, two thermal pads 17, and two printed circuit boards 16.
According to the present invention, the main assembly 10 can include, for example one optic holder 11 or more than one optic holder 11. Likewise for other elements mentioned here.
According to the present invention, the main assembly 10 includes at least one LED assembly 101, with the present illustration showing eight.
The housing 20 contains a housing body 21, an exterior cover 22, an input end cup 23, an output end cup 24, screws holders 26 and several end cup screws 25 which hold the housing's 20 components together.
a is a top view schematic illustration of a lighting device 1 upon which the section plane b-b and c-c are marked, according to the present invention.
b is a cross sectional view b-b of a lighting device 1, according to the present invention.
The present illustration shows the section plane b-b, which crosses the lighting device 1 at the location of a main assembly screw 18. The main assembly screw 18 is held in place by the screws holder 26, which has corresponding screw threading to accommodate the main assembly screws 18. The main assembly screws 18 go through and optic holder 11, the printed circuit board 16 and the thermal pad 17, and holds them together.
Above the optic holder 11 is a closed cover 15 which is used to block the light emitted by the LED 101a (not shown in the present illustration) located under the closed cover 15, or to cover a place without any installed LED assembly 101 and optic element 13, (both not shown in the present illustration).
In order to allow the light emitted by the LED 101a (not shown in the present illustration) to come out of the lighting device 1, an open cover 14 may be used. Each LED 101a location may have either an open cover 14 or a closed cover 15, according to the users' needs.
The lighting device 1 is closed by an exterior cover 22, which is transparent to allow light through it yet to provide mechanical protection to the main assembly's 10 components of the lighting device 1.
The main assembly 10 is held within the housing body 21, which is closed from the sides with the input end cup 23 and the output end cup 24 (both not shown in the present illustration), which are held in place by the end cup screws 25.
c is a cross sectional view c-c of a lighting device 1, according to the present invention.
The present illustration shows the section plane c-c, which crosses the lighting device 1 at the location of an LED assembly 101. Above the LED assembly 101 is an optic element 13 and an open cover 14.
The present figure shows the assembled view of the main assembly 10.
a is an isometric schematic illustration of an optic holder 11, according to the present invention.
The structure of the optic holder 11 ensures that the LED assembly 101 will not be damaged during the assembly of the lighting device 1. Further details are given in the following figures.
The embodiment of the optic holder 11 of the present figure depicts four openings for optic elements 13, but other configurations may be possible such as one, two, three or more openings in each optic holder.
Each optic holder 11 includes a holder first end 11ie and a holder second end 11je.
b is a top view schematic illustration of an optic holder 11 upon which the section plane d-d and e-e are marked, according to the present invention.
The optic holder's 11 main part is the holder body 11a in which there are several holder openings 11b. Between every two holder openings 11b, there is a holder screw hole 11e and around each holder openings 11b there are four holder pin holes 11d. A different number of holder pin holes 11d can be used.
c is a bottom view schematic illustration of an optic holder 11, according to the present invention.
The bottom side of the optic holder 11 is equipped with a holder end pin 11i (not shown in the present illustration), and a holder end hole 11j. In order to attach two optic holders 11, the holder end pin 11i of one optic holder 11 is inserted into the holder end hole 11j of another optic holder 11.
d is a side view schematic illustration of an optic holder 11, according to the present invention.
The present illustration shows the holder upper surface 11e, the holder bottom surface 11f and two holder alignment pins 11k (other embodiments may have more or less than two holder alignment pins 11k).
e is a cross sectional view e-e of an optic holder 11, according to the present invention. The illustration marks detail A in a circle, which is magnified in the circle on the bottom side of the illustration.
Detail A illustrates the structure of the holder optic guide 11g used to house an optic element 13, (not shown in the present illustration), in the optic holder 11. The holder optic guide 11g has a holder optic guide end 11ga. The angle between the holder optic guide end 11ga and the holder bottom surface 11f is the holder optic guide end angle 11gb and is designed to fit an optic element 13, which also helps to prevent the infliction of scratches upon LED dome 101d during production of the main assembly 10, (not shown in the present illustration).
In addition, detail A illustrates a holder alignment pin 11k and its length: holder alignment pin length 11ka. The holder alignment pin length 11ka is set so that it is greater than LED assembly height 101 cc, (not shown in the present illustration, shown in
f is a cross sectional view d-d of an optic holder 11, according to the present invention.
In the present illustration, it is possible to see the holder body 11a and the holder alignment pin 11k which is located near the holder opening 11b.
g is a bottom side isometric view schematic illustration of an optic holder 11, according to the present invention.
The illustration marks detail B in a circle, which is magnified in the circle on the bottom side of the illustration. Detail B depicts the smaller details surrounding the holder opening 11b such as the holder lateral ribs 11n and holder longitudinal ribs 11m which are used to enhance the structural integrity of the optic holder 11.
Other embodiments may use solid blocks of material rather than thin ribs for this purpose and the ribs themselves may have other shapes than the ones shown in the present illustration. The ribs may be longitudinal, lateral, diagonal, curved, etc. and the description brought here is not meant to limit the present invention.
Two important dimensions illustrated in detail B are the opening longitudinal length 11ba and the opening lateral length 11bb which are designed to be substantially larger than the LED package longitudinal length 101ca and the LED package lateral length 101cb so that once the optic holder 11 is mounted onto the printed circuit board 16, there is sufficient distance between the optic holder 11 and the LED assembly 101.
h is a bottom view schematic illustration of an open cover pin 14d, mounted inside a holder pin hole 11d, according to the present invention.
The present illustration shows a small segment of a holder body 11a, around the holder pin hole 11d.
The holder body 11a applies force F on the open cover pin 14d. The strength of force F is sufficient to enable manual assembly, without use of any tools, of open cover 14, (not shown in the present illustration, shown in
This also applies to the force F applied to the closed cover pins 15d, (not shown in the present illustration, shown in
a is a top view isometric schematic illustration of a closed cover 15, according to the present invention.
The closed cover 15 has a closed cover body 15a which is solid and does not allow any light to pass through it.
An additional option according to the present invention is using a closed cover 15, which enables filtering light.
LED assembly 101 and optic element 13 (both not shown in the present illustration).
b is a bottom view isometric schematic illustration of a closed cover 15, according to the present invention.
On the bottom side of the closed cover 15 are two (or more) closed cover pins 15d. The closed cover pins 15d are inserted into the holder pin hole 11d (not shown in the present illustration, shown in
In addition, there are closed cover legs 15e which are used to elevate the closed cover 15 from the optic holder 11 (not shown in the present illustration, shown in
c is a top view isometric schematic illustration of an open cover 14, according to the present invention.
The open cover 14 has an open cover body 14a, which includes a cover opening 14b. The cover opening 14b is used to enable light to pass through the open cover 14.
The open cover 14 has an open cover weight 14w.
d is a bottom view isometric schematic illustration of an open cover 14, according to the present invention.
Just like the closed cover 15, the bottom side of the open cover 14 includes two (or more) open cover pins 14d. The open cover pins 14d are inserted into the holder pin hole 11d (not shown in the present illustration, shown in
In addition, there are open cover legs 14e, which are used to elevate the open cover 14 from the optic holder 11 (not shown in the present illustration, shown in
e is a right side view schematic illustration of a closed cover 15, according to the present invention.
The right side view of the closed cover 15 shows the cover longitudinal side wall 15b.
This view also presents open cover 14.
f is a left side view schematic illustration of a closed cover 15, according to the present invention.
The left side view of the closed cover 15 shows the cover lateral side wall 15c.
This view also presents open cover 14.
The closed cover 15 has a closed cover weight 15w.
The circuit board 16 has a circuit board body 16a. In order to use modular components it is preferred to have short printed circuit boards 16 which normally consist of three or four LED assemblies 101. When longer lighting devices 1 are needed it is possible to connect several circuit boards 16 in series using several circuit boards connectors 16c. The present illustration depicts two printed circuit boards 16 connected to each other using four circuit boards connectors 16c.
The header connectors 16b are used to connect the lighting device 1 to an external control unit.
Each printed circuit board 16 is equipped with several printed circuit board screw holes 16d and several printed circuit board alignment pin hole 16e. According to the number of LED assemblies 101 mounted on the printed circuit boards 16.
The thermal pad 17 is designed so that its size corresponds to the size of the printed circuit board 16 as the thermal pad 17 is assembled directly under the printed circuit board 16. The thermal pad 17 has a thermal pad body 17a and several thermal pad screw holes 17b according to the number of printed circuit board screw holes 16d (not shown in the present illustration, shown in
In addition, the thermal pad 17 is used to electrically isolate the printed circuit board 16, (not shown in the present figure, shown in
The present illustration shows an assembled housing 20, absent the main assembly 10.
The major components of the housing body 21 are the exterior cover track 21a, end cup screws track 21b, screws holder track 21c, tunnel 21d, mount track 21e and carrier 21f.
Mount track 21e also serves as a cooling rib and for the purpose of attachment to infrastructure.
a is a front view schematic illustration of an input end cup 23, according to the present illustration.
The input end cup 23 has an end cup front wall 23a on which the “INPUT” designation may be noted for ease of use.
b is a back view schematic illustration of an input end cup 23, according to the present illustration.
On the back side of the input end cup 23 is the end cup partition 23e.
c is a back view isometric schematic illustration of an input end cup 23, according to the present illustration.
Depicted in the present illustration are the end cup front wall 23a, end cup side wall 23b, end cup opening 23d, end cup partition 23e, and end cup pins 23f.
d is a top view schematic illustration of an input end cup 23, according to the present illustration.
The top view of the input end cup 23 shows the end cup front wall 23a, end cup side wall 23b, end cup partition 23e and end cup pins 23f.
The screws holder 26 includes a screws holder base rib 26a which serves as the basis of the screws holder 26. The top part of the screws holder 26 is the screws holder perpendicular rib 26b into which several screws holder internal thread 26c are formed. The number of screws holder internal thread 26c is the same as the number of main assembly screws 18 (not shown in the present illustration, shown in
The lighting device 1 shown in the present illustration includes eight possible locations for LED assemblies 101. Of these eight locations, two are covered with open covers 14 and two are covered with closed covers 15. The other four locations do not have any covers and the optic holder 11 is visible at these locations. At two locations there are LED assemblies 101 mounted on the printed circuit board 16.
The present invention is very versatile with regard to many other possible combinations
In the present illustration, the optic holder 11 has only one location for a LED assembly 101 but other embodiments may have more locations.
The present illustration shows that the LED assembly 101 is located in the middle of the holder opening 11b. It is also possible to see that the opening longitudinal length 11ba and the opening lateral length 11bb are substantially larger than twice the LED package longitudinal length 101ca and the LED package lateral length 101cb, respectively. These size differences contribute to the minimization of risk to the LED dome 101d.
This cross-section shows that the holder body 11a has a holder alignment pin 11k that only if the holder alignment pin 11k is inserted into the printed circuit alignment pin hole 16e, will the optic holder 11 be able to be mounted onto the printed circuit board 16. The locations of the holder alignment pin 11k and printed circuit alignment pin hole 16e are designed so that the LED assembly 101 would be located in the center of the holder opening 11b.
The holder alignment pin length 11ka is larger than the LED assembly height 101cc, to ensure no contact between the LED assembly 101 and the holder bottom surface 11f at any stage prior to insertion of the holder alignment pin 11k into the printed circuit alignment pin hole 16e.
In the underside of the optic holder 11 it is possible to see the holder longitudinal ribs 11m and holder lateral ribs 11.
This structure of the optic holder 11 ensures good fastening to the thermal pad 17.
The present illustration depicts the way the optic element 13 is inserted into the optic holder 11. The optic element 13 is inserted into the holder space 11p which is designed to accommodate the optic element 13 and includes several holder optic guides 11g (normally, four or more) that while the optic element 13 is inserted into the holder space 11p, ensuring that the optic element 13 slides directly into its place without touching the LED dome 101d thereby possibly damaging it.
Furthermore, the holder optic guides 11g provide leverage to the optic element 13 after assembly.
The bottom of the holder space 11p is the holder opening 11b and the holder space walls 11q enclose the holder space 11p.
While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made.
