Patent Application
20050201068
The present invention is an improved replaceable LED module. In particular, the present invention is directed to an environmentally resistant LED module for mounting on at least one pair of electrical leads with a non-conductive sheath surrounding conductive wire.
Generally, theater and auditorium lighting systems incorporate low voltage lighting strips within extrusions that are then placed on stairs, chairs, chair arms, armrests and walkways in order to illuminate walking areas for patrons and ushers. The prior art has contemplated different ways of arranging the light strips. Typically, the lighting strips are made up of wires soldered to light-emitting diodes (“LEDs”) or LED circuit boards. A number of lighting systems are known including U.S. Pat. Nos. 6,554,446, 6,283,612, 6,145,996, 6,116,748, 6,582,100, 6,386,733, and 5,954,425.
However, the theater and auditorium environments can often be damaging to electrical and lighting systems. For example, patrons can spill liquids on the floors and/or seats of these venues. Moreover, prior art systems, if any, that are resistant to these, often harsh, environmental installed conditions do not generally provide for the efficient replacement of an LED that has malfunctioned or burned out. It is frequently cumbersome to replace an LED from a lighting strip and commonly the entire lighting strip must be replaced and not just the damaged LED. The present invention provides an easier method of installing one or more LEDs while still providing an environmentally resistant module.
The present invention is an improved replaceable LED module. In particular, the present invention is directed to an environmentally resistant LED module for mounting on at least a pair of electrical leads with a non-conductive sheath surrounding conductive wire. A replaceable LED module preferably comprises a circuit board removably secured to a base by a set of snap tabs on the base. The base has two open ends and contains two electrical leads that traverse the base through the open ends. A protective gasket preferably covers the circuit board. The circuit board is preferably coated in acrylic conformal coating. The preferred circuit board has an LED and two contact teeth. Each contact tooth pierces the protective gasket and the non-conductive sheath of an opposing stranded electrical lead and makes electrical contact with the conductive wire. Thus, power is supplied to the LED from the leads while maintaining the protective gasket and sheath.
The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings.
[1] The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the general principles of the present invention have been defined herein specifically to provide an improved replaceable LED module.
[2] Referring now to
[3] Preferably, the base 30 is open-ended and contains at least one pair of electrical leads 100 and 105 passing through the ends of the base 30. Additional leads can be present as well. For example, the use of 3 pairs of leads can provide Red-Green-Blue (RGB) LED functionality. The circuit board 20 is held snugly with the electrical leads 100 and 105 by the set of snap tabs 32. Preferably, a protective gasket 40 creates an environmentally protective seal between the circuit board 20 and the electrical leads 100 and 105.
[4] Referring now to
[5]
[6] The contact teeth 24, 26 are preferably sharp enough to pierce the gasket 40. The preferred gasket material is vinyl foam tape with acrylic adhesive. Thus, the gasket 40 forms a protective barrier on the circuit board 20 while the contact teeth 24, 26 provide a conductive pathway to the circuit board 20 and the LED 25. A preferred embodiment of the gasket 40 installed on the circuit board 20 is shown in
[7] Alternately, the gasket 40 can have pre-cut openings to allow the teeth 24, 26 to pass through the gasket 40 to allow electrical contact between the circuit board 20 and electrical leads. However, the gasket 40 should be sufficiently snug to the teeth 24, 26 to continue to provide protection for the circuit board 20.
[8] Returning to
[9] Thus, an improved replaceable LED module is described above that is capable of easy installation and replacement while offering improved environmental resistance. In each of the above embodiments, the different positions and structures of the present invention are described separately in each of the embodiments. However, it is the full intention of the inventor of the present invention that the separate aspects of each embodiment described herein may be combined with the other embodiments described herein. Those skilled in the art will appreciate that adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention.
[10] For example, the circuit board 20, except for the contact teeth 24, 26, can be coated in a protective sealant and held snugly to the non-conductive sheath of the electrical leads 100 and 105, thereby omitting the gasket 40. Other alternate embodiments could use additional contact teeth. Another alternate embodiment comprises a plastic circuit board with built-in circuit leads and LED(s) that then snaps onto the base. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
