Patent Grant
11280479
This disclosure relates to light modules using light emitting diodes (LEDs) and more particularly to LED based light modules for illuminating sign boxes.
Display units, such as sign boxes, cabinet signs, and light boxes are commonly found on the outside of buildings or businesses and are often used to advertise the name of the business or products. Typical units are constructed of aluminum or plastic housing having the shape of a box and can be approximately 5″ deep. The housing sometimes has a swing open frame to allow for easily changing the advertising graphics within. The top opening in the housing, or surface, is covered by a translucent or clear lens that transmits light from within the housing. The advertisement graphic is placed under this lens so that it is between the lens and the lighting units inside the light box. This allows the graphic to be illuminated from behind by the lighting units within the sign box. In some cases, the translucent lens itself may be the illuminated graphic.
Some sign boxes or cabinets have graphics on one side and light only illuminates that side, whereas others can be double-faced such that the two opposite sides of the sign box each have a translucent or clear lens with a graphic and lighting inside the sign box or cabinet which illuminates both these sides and graphics.
To enhance the visibility of the advertisement within these units, different types of lighting are incorporated. Various types of lighting systems are used with different light sources such as incandescent bulbs, neon bulbs or fluorescent tubes. One of the problems associated with the conventional lighting units and systems is that their light sources can experience relatively short lifespans and they can have relatively low electrical efficiency. Incandescent bulbs, neon bulbs and fluorescent tubes have a relatively short lifespan, particularly when compared to other light sources, such as typical LEDs. These light sources are also electrically inefficient and providing sufficient lighting, especially in large lighting applications, requires the consumption of significant energy. For example, a standard fluorescent tube 60 inches in length consumes as much as 60 to 70 Watts, and conventional display units can utilize many of these tubes. Neon bulbs can also experience difficulty with cold starting, which can lead to failure of the neon bulb.
More recently, with the advent of the efficient solid-state lighting sources, these display units have been used with LEDs, for example. LEDs are solid state devices that convert electric energy to light and generally comprise one or more active regions of semiconductor material interposed between oppositely doped semiconductor layers. When a bias is applied across the doped layers, holes and electrons are injected into the active region where they recombine to generate light. Light is produced in the active region and emitted from surfaces of the LED.
LEDs have certain characteristics that make them desirable for many lighting applications that were previously the realm of incandescent or fluorescent lights. Incandescent lights are very energy-inefficient light sources with a vast majority of the electricity they consume being released as heat rather than light. Fluorescent light bulbs are more energy efficient than incandescent light bulbs, but are still relatively inefficient. LEDs by contrast, can emit the same luminous flux as incandescent and fluorescent lights using a fraction of the energy.
In addition, LEDs can have a significantly longer operational lifetime. Incandescent light bulbs have relatively short lifetimes, with some having a lifetime in the range of about 750-1,000 hours. Fluorescent bulbs can also have lifetimes longer than incandescent bulbs such as in the range of approximately 10,000-20,000 hours, but provide less desirable color reproduction. In comparison, LEDs can have lifetimes between 50,000 and 70,000 hours.
The increased efficiency and extended lifetime of LEDs is attractive to many lighting suppliers and has resulted in LED lights being used in place of conventional lighting in different sign applications. However, some existing sign boxes may not be equipped to easily allow for installation of new LED based lights. As such, existing sign boxes may need to have portions of the existing lighting fixtures removed or disassembled to allow for new LED based lights to be installed. This may also require additional mounting fixtures to allow the new LED based lights to be installed within existing sign boxes, which can result in increased costs for replacing existing lighting units with LED based lights and could be cost prohibitive.
The disclosure relates to light modules using light emitting diodes (LEDs) and more particularly to LED based light modules for existing sign boxes. In the aspects described herein, light modules and mechanical mounting methods and devices are provided that allow for quick, easy, and reliable mounting of LED light modules within existing sign boxes. This arrangement can allow for mounting light modules while utilizing existing fixtures within the existing sign boxes, without the need for removing all existing fixtures and/or structures and installing new mount mechanisms in order to mount the LED light modules within the existing sign box.
One embodiment of a light module according to the present invention can comprise an elongated support structure having a plurality of surfaces. A plurality of light units can be included wherein at least some of the lighting units comprise a first light unit array on one of the support structure surfaces, and others of the said light units comprise a second light unit array on another one of the support structure surfaces. Conductors are arranged to connect the first light array in a series interconnection and to connect the second light array in a respective series interconnection.
A better understanding of the features and advantages of the disclosure will be obtained by reference to the following description of the disclosure and accompanying drawings which set forth illustrative aspects in which the principles of the disclosure are utilized.
The disclosure provides light modules for lighting systems that can be used in many different applications but is particularly applicable to sign boxes commonly found on the outside of buildings or businesses and often used to advertise the name of the business or products. In some aspects, the light modules comprise a light source mounted onto a support structure wherein the light module can be mounted within a sign box and is arranged for quick, easy, and reliable mounting within the sign box. In some aspects, the light module can be received by existing mounting structures within the sign box in order to mount the light module within the sign box without the need to install new mounting structures for the light module. Different arrangements according to the disclosure can be used for retrofitting existing sign boxes while others can be used with newly constructed sign boxes. The light modules are arranged to be used with existing mounting mechanism previously installed within a sign box and with future mounting mechanisms.
The disclosure is described herein with reference to certain aspects but it is understood that the disclosure can be arranged in many different configurations and is not intended to be limited to the aspects disclosed herein. In some aspects, the light module can be configured to comprise an elongated support structure, but it is understood that the length of the support structure can be various lengths. The light module can have one or more light sources mounted onto the support structure. In some aspects, the light sources are mounted on the same surface of the support structure, while in some aspects, the light sources can be mounted on more than one surface of the support structure. In addition, the light sources can have many different types of emitters, such as but not limited to light emitting diodes (LED or LEDs). The different aspects can comprise different numbers of LEDs and/or can have LEDs emitting different colors or light, such as but not limited to white light.
It is to be 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 disclosure.
Aspects of the disclosure are described herein with reference to illustrations that are schematic illustrations. As such, the actual thickness of elements can be different, and variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances are expected. Aspects of the disclosure 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 rectangle will typically have rounded or curved features due to normal manufacturing tolerances. Thus, the elements/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 disclosure.
The description set forth herein, in connection with the appended drawings, is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The description includes specific details for the purpose of providing an understanding of the various concepts. It will be apparent to those skilled in the art, however, that these concepts may be practiced without these specific details. As described herein, the use of the term “and/or” is intended to represent an “inclusive OR”, and the use of the term “or” is intended to represent an “exclusive OR”.
First and second conductors 106, 108 are arranged to electrically connect the plurality of light units 104 such that the light units 104 emit light in response to an electrical signal. The conductors 106, 108 conduct electricity to the light units 104 and an electrical signal applied to the conductors is conducted to each of the light units 104 so that the at least one light unit emits light. The light units 104 are arranged such that, when installed in a sign box and illuminated, give the appearance that a sign box, which the light module is installed within has a continuous light source.
In the aspect of
The support structure 102 can comprise an elongated support structure designed to receive a plurality of light units on one or more surfaces. In the aspect of
In the aspect of
In some instances, the existing sign box may comprise existing lamp sockets other than T12 sockets. In such an occurrence, the support structure 102 can be configured to receive end caps on the opposing ends of the support structure, wherein the end caps are configured to engage with the existing socket. In some aspects, the end caps can be configured to engage a bi-pin type socket that is commonly used with conventional T8 light bulbs. The end caps are received by the existing socket and assist to securely mount the light module within the existing sockets without the need to install new and/or replacement mounting mechanisms, which also eases installation and can reduce costs, as discussed above. The end cap can be arranged to engage many different light sockets known in the art, and is not intended to be limited to engaging bi-pin type sockets.
In some aspects, the support structure 102 can be comprised of a plurality of support structures 102 that are joined together to form the desired overall length of the support structure 102. The plurality of support structures 102 can be arranged in many different configurations to allow for the plurality of support structures to be attached to each other. In some aspects, a first support structure comprises outer dimensions slightly smaller than the inner dimensions of a second support structure, wherein the first support structure is inserted into the second support structure in order to attach the first and second support structures together. Additional attachment mechanisms can be used to attach the first and second support portions, such as but not limited to set screws. In other aspects, the first and/or second support structure can be tapered such that a compression force is exerted onto the first and/or second support structures when the first support structure is inserted into the second support structure, such that at least the compression force fastens the first and second support structures together.
In the aspect shown in
The light module 100 can comprise a plurality of light units 104 mounted on the support structure 102, as shown in
The light units 104 can comprise a housing 200 and one or more light elements 202 mounted on a printed circuit board (PCB), wherein the one or more light elements 202 and PCB are within the housing 200. The light units can further comprise an optical element 204 proximate the one or more light elements 202, and a lens 206 covering the one or more light elements 202. In some aspects, the optical element 204 can be arranged to reflect the light emitted from the light element 202. In some aspects, the optical element 204 can be arranged to redirect the light emitted from the light element such that the light emitted from the light unit is emitted in a desired light distribution pattern. The lens 206 can also be arranged to redirect light in a desired light distribution pattern. In some aspects, the lens 206 can be configured to diffuse the light emitted from the light element.
With reference to
The first and second arrays 104a,104b are joined together at a respective end of the arrays to form the double-sided light module. The ends of the arrays 104a,104b can be proximate the same end of the support structure 102. For example, the wiring scheme of the first and second arrays 104a,104b can be arranged such that the first conductor 106 of the first array 104a and the second conductor 108 of the second array 104b are connected together, as shown in
At least one advantage of the first and second arrays being wired in series is that the light module 100 can be a double-sided light module while remaining within the Class 2 wiring guidelines of Class 2 circuits. In general, a Class 2 circuit can operate with a 24V power supply, have a maximum current of 5 Amps, and have a maximum power of 100 Watts. Conventional arrays of light units utilize a 12V power supply with a maximum power of 60 Watts. The wiring scheme of the first and second arrays of the light module adheres to the Class 2 circuit requirements, which allows for the use of a 24V power supply with a maximum power of 100 Watts. The wiring scheme of the disclosure allows for an increase in power over that of conventional arrays, which in turn allows for more light modules to be connected to a power supply than that of conventional arrays. For example, a single 12V power supply can only be connected to one double-sided conventional array that is 8 feet in length, due to the Class 2 circuit requirements. Conventional double-sided arrays are essentially a single array folded in half at a desired point to form the double-sided array, without altering the wiring of the array. As such an 8-foot doubled-sided array is formed by bending a 16-foot array of light units in half to form two 8-foot arrays.
The wiring scheme disclosed herein allows for a 24V power supply to be connected to two double-sided light modules 100 that are 8 feet in length. As such, the wiring scheme disclosed herein allows for more light modules 100 to be connected to a single power supply than that of conventional arrays. This improvement reduces overall costs of installation, because less power supplies would be needed to provide power to the light modules 100, which in turn reduces material costs. The above example is a non-limiting example of the improvements provided by the disclosure, and the disclosure is not intended to be limited to the example discussed above. The disclosure in essence provides the advantage of at least doubling the number of light modules 100 that can operate on a single power supply.
In some aspects, the light module 100 can be installed in a new construction sign box and/or in a sign box that does not have an existing light socket and/or the existing light socket is damaged and needs to be removed. In such aspects, the sign box may not comprise a viable light socket to receive the light module. As such, mount brackets are used to mount the light module 100 to the sign box. The mount brackets can be arranged in many different configurations to receive the light module. In some aspects, the mount bracket can be L-shaped wherein the mount bracket is mounted within the sign box and the extended portion of the support structure of the light module is mounted to the mount bracket. The mount brackets can be arranged in many different configurations and are not intended to be limited to the aspects disclosed herein.
The light module 100 of
Although the disclosure has been described in considerable detail with reference to certain configurations thereof, other versions are possible. Light modules according to the disclosure can be many different sizes and can be used for many different applications beyond sign boxes. The light units according to the disclosure can be arranged in many different configurations and can be arranged to emit different lighting effects. In some aspects, the light units can be configured to emit the same and/or different color of lights. The light units can be configured to have the same and/or different light distribution pattern. In some aspects, a variable power supply can be used to control the intensity of light emitted from the light units and/or light modules. Therefore, the spirit and scope of the disclosure should not be limited to the versions described above.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/574,090, filed on Oct. 18, 2017.
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| Number | Date | Country | |
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| 20190186716 A1 | Jun 2019 | US |
| Number | Date | Country | |
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| 62574090 | Oct 2017 | US |
