Patent Grant
10443824
Field of the Invention
This invention relates to lighting units using light sources, such as but not limited to light emitting diodes (LEDs) and more particularly to LED based lighting units for illuminating light boxes or sign cabinet lights.
Description of the Related Art
Display units, such as light boxes, cabinet signs and box signs 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 range from being approximately 5 inches to many feet deep. The housing sometimes has a swing open frame to allow for easily changing the advertising graphics within. The illuminated face in the housing, or surface, is typically 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 light box. In some cases the translucent lens itself may be the illuminated graphic.
Some light boxes or sign cabinets have graphics on one face and light only illuminates that face, whereas others are double-faced such that the two opposite faces of the light box each have a translucent or clear lens with a graphic and lighting inside the light box or sign cabinet illuminates both of these faces 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. For example, 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.
LED based light box lighting replacements are available in the marketplace. One such solution comprises a chain of LEDs within a glass tube, mimicking a fluorescent bulb structure. LED based light box lighting is also available from GE Lighting Solutions, East Cleveland, Ohio, under product name Tetra® PowerStrip and Tetra® PowerStrip DS, which comprises overmolded LED lighting modules that each have 3 LEDs. These LEDs are covered by a lens to spread the area of the light outputted. The chain of LED modules is then mounted on a rigid rail or into a rigid tube, each of which is then mounted inside a light box to hold the LEDs in place. In single sided light boxes the light modules can also be mounted directly to the back of the unit.
LED based light box lighting is also available from US LED, Houston, Tex., under product name Tandem2, which comprises pre-assembled 4-foot sections with connector clip and “L-Brackets” for installation. Each light module has several LEDs. The chains of LED modules, in 4-foot sections, are mounted on a rigid rail, each of which is then mounted inside a light box to hold the LEDs in place. 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. Different lengths of the chain can be utilized for a particular channel letter, with the desired length of chain being cut from the rail and mounted within the light box. Each chain is connected to each other by 24″ cables. Power can then be applied to the chain causing the units to emit light. The chains are spaced approximately 9-12″ apart within the light box.
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 light box 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 invention provides various embodiments of lighting units and systems of manufacturing the same. The invention is configured to be efficient, reliable, cost effective and can be arranged to provide illumination for structural lighting, display lighting and ingress/egress lighting, and is particularly applicable for light boxes or sign cabinet lighting. The different embodiments comprise elements to alter or control the light distribution pattern emitted from the light sources within the lighting unit. The elements can comprise many different materials or devices arranged in different ways, with some devices comprising a plurality of electrically connected lighting units.
In one embodiment, as broadly described herein, a lighting system is disclosed that comprises a light box housing including a front surface and a back surface, a plurality of lighting units, and a mounting mechanism such that the plurality of lighting units are mounted within the light box housing. The plurality of lighting units can be interconnected to form an array of lighting units, such that the array of lighting units is mounted within the light box housing. The lighting system can comprise one or more arrays mounted within the light box housing.
The lighting unit comprises a plurality of light emitting elements on a printed circuit board (PCB). The lighting unit further comprises conductors to provide an electrical current to each of the light emitting elements. The light emitting elements are adapted to emit light in a direction away from the PCB, in response to the electrical current supplied by the conductors. The lighting units can further comprise a mounting mechanism to mount the lighting units within the light box housing.
These and other aspects and advantages of the invention will become apparent from the following detailed description and the accompanying drawings which illustrate by way of example the features of the invention.
The invention described herein is directed to different embodiments of a lighting system that can be used in many different applications such as but not limited to structural lighting, display lighting and ingress/egress lighting. The lighting system according to the invention can be arranged in many different ways with many different components, and is generally arranged to provide illumination for light boxes or sign cabinets. In some embodiments, the lighting system comprises a light box housing and plurality of lighting units, wherein the plurality of lighting units are interconnected in a daisy-chain configuration. Electrical conductors are provided to each of the plurality of lighting units so that an electrical signal applied to the conductors spreads to the lighting units, causing each of the light emitting elements to emit light. The lighting unit can be mounted in various locations within the light box housing. Each of the lighting units can comprise a housing including a top side and a bottom side, and a plurality of light emitting elements mounted on a PCB, wherein the PCB is disposed within the housing.
Light boxes and sign cabinet lighting are generally known in the art and are typically used to illuminate an advertisement or signage within the light box or sign cabinet. Conventional light boxes/sign cabinets comprise a housing, a light source, electronic components to power the light source and a transparent cover. Typical light sources for these conventional light boxes/sign cabinets are, for example, incandescent, neon or fluorescent bulbs. Conventional light boxes/sign cabinets can be mounted to a structure, suspended from a ceiling or mounted to a pole, whereas other conventional light boxes/sign cabinets can be recessed into the structure such that the electronic components are within the structure. These light boxes/sign cabinets can be big and bulky due to the physical dimensions of the necessary high power electronic components and the physical size of the light source. As such, the profile of the conventional light boxes/sign cabinets mounted to or recessed in a wall can extend from the wall such that the light box/sign cabinet is not aesthetically pleasing.
The lighting system of the invention can provide a number of additional advantages beyond those mentioned above. For example, in some embodiments the light emitting elements of the lighting units are LEDs, which are physically smaller than fluorescent and incandescent bulbs typically used in the conventional light boxes/sign cabinets, thereby reducing the profile of the lighting system. Additionally, LEDs operate at a lower power level in comparison to fluorescent and incandescent bulbs and do not need similar high power electronic components, leading to smaller electronic components, a reduction in size of the light box housing and overall weight of the lighting system.
The 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 light emitting elements are placed within or on a housing, but in other embodiments this configuration can be modified. The invention can also be used with different types of lighting units used in different applications beyond light boxes and sign cabinets, and although the invention is described herein with reference to light emitting diodes (LED or LEDs) other light sources can be used.
It is to be understood that when an element or component is referred to as being “on” another element or component, it can be directly on the other element or intervening elements may also be present. Furthermore, relative terms such as “between”, “within”, “adjacent”, “below”, “proximate” and similar terms, may be used herein to describe a relationship of one element or component to another. 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 or components, these elements or components should not be limited by these terms. These terms are only used to distinguish one element or component from another. Thus, a first element discussed herein could be termed a second element without departing from the teachings of the present application. It is understood that actual systems or fixtures embodying the invention can be arranged in many different ways with many more features and elements beyond what is shown in the figures.
Embodiments of the invention are described herein with reference to illustrations that are schematic illustrations. As such, the actual thickness of elements 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. An element illustrated or described as square or rectangular will typically have rounded or curved features due to normal manufacturing tolerances. Thus, the elements 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 light box housing 102 further comprises a mounting mechanism 119 to mount the plurality of lighting units to the light box housing. The mounting mechanism 119 can be comprised of at least one pair of mounting brackets 118 mounted to opposing sidewalls 108 of the light box housing 102. The at least one pair of mounting brackets 118 are adapted to receive an array of lighting units 113. The array of lighting units 113 is received by the at least one pair of mounting brackets 118 by coupling an endpoint 120 of the array to a respective mounting bracket 118. In one embodiment of the invention, the array of lighting units 113 are arranged in a linear array. As such, the pair of mounting bracket 118 are aligned on opposing sidewalls 108 such that the array endpoints 120 can be properly mounted to the pair of mounting bracket 118. Proper alignment of the pair of mounting brackets 118 allows the array of lighting units 113 to be properly positioned within the light box housing 102, which allows the light emitted from the array of lighting units to be evenly emitted out the light transmissive face 104.
The endpoints 120 of the array 113 are received by a clamp 122, wherein the clamp 122 is coupled to a respective end 124 of the at least one carrier 112. The carrier 112 and clamp 122 combination are coupled to one of the pair of mounting brackets 118 in order to mount the array of lighting units 113 within the light box housing 102. In the embodiment of
The light box housing 102 can be configured such that the light transmissive face 104 includes a transparent, translucent, or graphic covered cover. The light transmissive face can be formed of many different materials, such as but not limited to, plastic, tempered glass or the like. In embodiments where the light transmissive face 104 comprises a translucent or graphics covered cover, the light emitted from the lighting units 110 can be diffused by either the features of the lighting units or the translucent or graphics cover, so as to give the appearance that the lighting system 100 has a continuous light source.
Each of the lighting units can comprise a plurality of light emitting elements 208. The light emitting elements may be arranged in many different ways. The lighting units 110 can have any number of light emitting elements, but the examples shown herein have either 3 or 6 light emitting elements. The light emitting elements 208 emit light out from the lighting unit 110 in response to an electrical signal. The electrical conductors 114, 116 conduct electricity to the lighting units 110 and an electrical signal applied to the conductors 114, 116 is conducted to each of the lighting units 110 so that the light emitting elements 208 on each of the lighting units simultaneously emit light. The lighting units 110 are particularly adapted to being mounted in the light box housing 102 or sign cabinet lighting, wherein the light transmissive face 104 of the light box housing 102 is the light emitting surface of the lighting system 100. In some embodiments, the lighting system 100 is configured to be mounted on a wall or similar structure, such that substantially all light is emitted out the light transmissive face 104 of the light box housing 102. In other embodiments, the lighting system 100 can be recessed mounted into a wall or similar structure, while in other embodiments the lighting system 100 can be mounted to a pole or other stand-alone structures.
The lighting units 110 further comprise conductors 114, 116 in electrical connection with the PCB 206. As shown in
An advantage of the invention is that the conductors 114, 116 can be center-stripped at regular intervals, which provides a continuous length of conductors 114, 116 with exposed center conductors 117 of controlled lengths at regular intervals. Center-stripping the conductors 114, 116 at controlled regular intervals allows the PCB 206 to be separated from adjacent PCBs 206 by a spacing corresponding to the controlled regular intervals. This eases the construction and spacing of the lighting units 110 because the exposed center conductors 117 of the conductors 114, 116 provide a visual indication as to where the PCBs 206 are to be connected to the conductors 114, 116. Using center-stripped conductors 114, 116 also eliminates the need of having to cut and strip numerous conductors, especially when connecting a plurality of PCBs into a daisy chain configuration to form an array of lighting units. The center-stripped conductors significantly reduces the amount of time needed to connect numerous PCBs when forming a long array of lighting units, as well as reducing costs related to manufacturing.
Yet another advantage of using center-stripped conductors is that the exposed center conductors 117 provides a large surface area of exposed center conductor to make positive, reliable contact to the crimp terminals on the PCBs. The crimp terminals 115 when crimped or compressed onto the center conductors 117 firmly holds the conductors 114, 116 in place preventing the center conductor 117 from being released from crimp terminals, which can also provide structural support to the PCB and the lighting units. The conductors 114, 116 being continuous and not cut when connected to the crimp terminals makes pulling the conductors out of the crimp terminal 115 more difficult than if the conductors were cut and crimped in the crimp terminal 115.
The conductors 114, 116 can be electrically connected to the PCB 206 using many different methods, and the invention is not intended to be limited to the embodiments disclosed herein. In other embodiments, the conductors 114, 116 can be electrically connected to the PCB by soldering. In yet other embodiments, Insulation Displacement connectors (IDC) or Insulation Piercing connectors (IPC) can be used to electrically connect the conductors to the PCB 206.
In one embodiment, the conductors 114, 116 can be on the same surface of the PCB 206 as the light emitting elements 208. However, in other embodiments, the conductors can be on either side of the PCB 206. The conductors 114, 116 electrically couple the electrical signal on the conductors 114, 116 to their respective one of the lighting units 110. The PCB 206 can also comprise conductive traces (not shown) to conduct electrical signals from the conductors 114, 116 to the light emitting elements 208 so that an electrical signal applied to the conductors is conducted to the light emitting elements through the traces, causing the light emitting elements to emit light. The conductors 114, 116 are arranged such that the length of conductors 114, 116 between adjacent lighting units 110, is longer than the distance between adjacent lighting units 110. In this arrangement, the conductors 114, 116 between adjacent lighting units 110 are relaxed and not taut, such that any forces acting on the conductors 114, 116 is reduced and/or limited. Reducing the force exerted upon the conductors 114, 116 reduces the potential for failure of the conductors 114, 116 due to strain and/or weight of the lighting units when mounted in the light box housing 102 or while being stored.
The light emitting elements 208 are generally mounted along a longitudinal axis of the PCB 206, although they can also be mounted in other locations. In the embodiment of
In some embodiments, the lighting unit 110 can comprise an optical element proximate each of the light emitting elements. The optical element can be in the form of a lens over each of the light emitting elements, a diffuser proximate the light emitting elements, or a reflector proximate the light emitting elements, or a combination thereof. In yet other embodiments, the optical element may be a separate structure or part of the housing 202. In one embodiment, the optical element can be arranged to diffuse the light emitted from light emitting elements 208 so that the light emitted from the lighting unit has an even light distribution pattern. In some embodiments, the optical element can be arranged to have light altering properties such that the light emitted from the lighting unit 110 is redirected in order to produce a desired light distribution pattern, such as but not limited to a uniform light distribution pattern or a directional light distribution pattern. The optical element can be a separately formed structure that is mounted onto the lighting unit 110 proximate the light emitting elements 208. The optical element can be mounted onto the lighting unit using a variety of methods, such as but not limited to glued onto the lighting unit or mechanically fastened (screws, nails, rivets or the like). In yet other embodiments, the optical element can be overmolded onto the lighting unit.
As shown in
An advantage of the invention is that the carrier holes being separated by an equal distance allows the PCB 206 to be separated from adjacent PCBs by a similar distance, which in turn results in the lighting units 110 being separated from adjacent lighting units 110 by an equal distance. Another advantage is that the plurality of lighting units 110 mounted on the carriers 112 forms an array of lighting units 113 wherein each of the plurality of lighting units are substantially aligned, which results in the light emitting elements 208 of each lighting unit 110 being substantially aligned. As such, the light emitted from the array 113 has a consistent light radiation pattern and does not vary from the lighting units 110 on the carriers 112. In one embodiment, each of the lighting units 110 of the array 113 are arranged to be substantially perpendicular to the carrier 112. However, in other embodiments, the lighting units can be arranged in a number of different ways, with respect to the carrier, and is not intended to be limited to being substantially perpendicular.
With reference back to
In yet other embodiments, the lighting unit 110 does not comprise a housing. In such embodiments, the PCB 206 is coupled to the at least one carrier 112 and is exposed in a manner similarly shown in
The embodiment of the lighting unit shown in
The lighting units 300 comprise a housing 302 having a front surface 304 and a back surface 305, a plurality of light emitting elements 208, a PCB 306 within the housing 302, wherein the plurality of light emitting elements 208 are mounted on the PCB 306 and are exposed through the housing 302. The PCB 306 is similar to the PCB 206 and can be made of many different materials, such as but not limited to a flexible material, rigid material, or any other suitable PCB material. The PCB 306 also comprises at least one slot 210 arranged to receive a fastener 212 to couple the PCB to the at least one carrier 112. The PCB 306 can be arranged to be substantially planar such that the PCB provides a substantially planar surface to receive each of the plurality of light emitting elements 208. However, in other embodiments, the PCB 306 can be arranged to provide at least one angled surface to receive at least one of the plurality of light emitting elements 208. The plurality of light emitting elements 208 can be arranged in a linear configuration on the PCB 306, such that the light emitting elements 208 are separated from adjacent light emitting elements by the same or different distance. The light emitting elements 208 can be arranged in many different configurations on the PCB 306 and is not intended to be limited to a linear configuration.
The lighting units 300 further comprise a pair of conductors 114, 116 in electrical connection with the PCB 306. The conductors 114, 116 can be a continuous length of center-stripped conductors exposing the center conductor 117 and electrically connected to the PCB 306 using crimp terminals 115, similarly as discussed above for lighting unit 110. The conductors 114, 116 of the embodiment of
The conductors 114, 116 electrically couple the electrical signal on the conductors 114, 116 to their respective one of the lighting units 110. The PCB 306 can also comprise conductive traces (not shown) to conduct electrical signals from the conductors 114, 116 to the light emitting elements 208 so that an electrical signal applied to the conductors is conducted to the light emitting elements through the traces, causing the light emitting elements to emit light.
The light emitting elements 208 are generally mounted along a longitudinal axis of the PCB 306 such that the light emitting elements on one side of the PCB are aligned with the light emitting elements on the other side of the PCB. This results in the lighting unit 300 having a light radiation pattern that is the same for both sides of the lighting unit. However, in other embodiments, the light emitting elements 208 on one side of the PCB 306 can be arranged on the PCB in a different arrangement than the light emitting elements on the other side of the PCB. An advantage of this configuration is that the lighting unit can have a different light radiation pattern for each side of the lighting unit, which could be tailored for different lighting solutions.
The lighting unit 300 comprises six light emitting elements 208, with three on each side of the PCB 306. However, the invention is not intended to be limited to only have six light emitting elements. In other embodiments, the lighting units can have any number of light emitting elements on each side. In some embodiments, the number of light emitting elements on both sides of the PCB is the same, while in other embodiments each side of the PCB has a different amount of light emitting elements. The lighting unit 300 can also be configured to have at least one optical element, as discussed above.
With reference to
Referring back to
In yet other embodiments, the lighting unit 300 does not comprise a housing. In such embodiments, the PCB 306 is coupled to the carrier 112 and is exposed in a manner similarly shown in
The carrier 112 can be arranged in many different configurations. For example, the carrier can comprise a plurality of carrier holes 126, wherein the spacing between adjacent carrier holes is varied. This would allow a lighting unit to be mounted in different arrangements based on the configuration of the light box housing or the lighting solution. For example, the light box housing 102 of
The carrier 112 can be formed of many different materials, such as but not limited to cotton, nylon, polyester, polypropylene or the like or a combination thereof. In some embodiments, the carrier can be a webbing formed of strong fabric woven as a flat strip or tube of varying width and fibers. In some embodiments, the carrier can be a multi-paneled webbing, similarly configured as automotive seat belts. An advantage of the invention is that the carrier provides a light weight and heavy duty material to receive the lighting units. Also, the carrier reduces costs related to manufacturing, shipping and installation. The carrier is flexible and pliable, such that the carrier can bend freely or repeatedly without breaking. The carrier can be bent in many different directions and does not become deformed or broken due to being bent. The carrier can be bent, twisted and/or folded and still be able to return to its original state, such as but not limited to a flat strip. The carrier is strong and durable such that the carrier can withstand the weight of the lighting units coupled to the carrier, thereby providing structural support to the lighting units mounted onto the carrier. Furthermore, the carrier can be mounted within a light box housing such that the carrier is taut and maintains the positioning of the lighting units within the light box housing.
The front and back plate further comprise at least one recess 402, at least one aperture 404, and a plurality of projections 406. The at least one recess 402 of the front and back plate are arranged to form a pocket 414 when the front plate is received by the back plate, or when the clamp 122 is closed. The pocket 414 is adapted to receive a shoe 207 of the lighting unit 110, to assist in holding the lighting unit. The at least one aperture 404 of the front and back plate are arranged to form a channel 412 when the front plate is received by the back plate, which is when the clamp is closed. The channel 412 is adapted to receive a bolt 424 in order to mount the array to the light box housing 102. The plurality of projections 406 can be arranged to have pointed tips, whereby the carrier 112 is placed on the clamp 122 and the clamp is closed, securing the carrier within the clamp. In such embodiment, the pointed tips of the front and back plate are arranged to contact the carrier 112 and hold the carrier in place. The pointed tips can be arranged to pierce the carrier 112 to further secure the carrier within the clamp 122. Furthermore, when the clamp 122 is closed, the clamp can apply a compression force onto the carrier 112 to further hold the carrier within the clamp. The invention is not intended to be limited to the plurality of projections comprising pointed tips, in other embodiments, the plurality of projections can be arranged to comprise a roughened surface or the like.
With reference to
With reference to
As seen in
The clamp can be configured in many different ways and is not intended to be limited to the embodiments disclosed herein.
The first flange 804 extends from the first extension 802 towards the second flange 808. The second flange 808 extends from the second extension 806 towards the first flange 804. The first extension and flange 802, 804 and the second extension and flange 806, 808 form the clamp bracket 801. The first extension 802 and the second extension 806 are spaced apart from each other wherein the separation between the first and second extensions 802, 806 determines the dimensions of a mounting bracket to be utilized with the clamp bracket 801. The clamp bracket 801 is arranged to allow the clamp 800 to be slidably received by the mounting bracket or similar structure in order to mount the array of lighting units within the light box housing 102.
The mounting bracket 810 in
As seen in
In the embodiment of
At least one advantage of the invention is that the clamp assists in properly aligning the array 113 on the mounting bracket. For example, in the embodiment disclosed in
In the embodiment of
Yet another advantage of the invention is that carrier 112 allows for the array 113 to be easily mounted within the light box housing 102. For example, the array can be easily mounted onto the opposing mounting brackets 810 due to the properties of the carrier 112. In the embodiment of
In the embodiment of
With reference to
The coupler 502 can be arranged in many configurations and is not intended to be limited to the embodiments disclosed herein. In one embodiment, each of the front plates can further comprise an indentation 514 and the back plate can further comprise an opening 503, such that the indentations and opening are arranged to form a groove 516 when the coupler 502 is closed. The groove 516 is adapted to receive a bolt 424 (not shown) in order to mount the coupler 502 to a light box housing or similar structure. In yet other embodiments, the back plate can comprise an aperture 506 aligned with a respective aperture 506 of each of the front plates 510, such that the apertures 506 of the front plates 510 and the back plate 508 form a channel when the coupler 502 is closed. The channel is adapted to receive a bolt 424, wherein the bolt is arranged to pierce the carrier 112 and be received by the aperture of the back plate 508. In yet other embodiments, the ends 124 of the carriers 112 can be arranged to comprise a hole arranged with the channel to receive the bolt 424 in order to couple the carriers to the coupler.
Upon the closure of the clamps 800 on the respective carrier 112, the clamps 800 are arranged to be adjacent each other and arranged to receive a clamp connector 908. In the embodiment of
In the embodiment of
At least one advantage of the invention is that the coupler 502, 902 is arranged to assist in properly spacing the lighting units of the first and second arrays that are adjacent the coupler. The couplers 502, 902 are arranged to separate the lighting units adjacent the couplers a distance substantially similar as the other lighting units of the array. The coupler ensures that the emitted light from the combined array is uniform and does not produce any hot spots and/or dark spots. For example, with reference to
Lighting units according to the present invention can also comprise other elements, with one embodiment comprising heat sinks to dissipate heat from the light emitting elements. In another embodiment, the lighting units can comprise a power supply (not shown) electrically connected to conductors 114, 116. Power supplies are generally known in the art and are only discussed briefly herein. In one embodiment, the power supply is adapted to provide a constant current output. The power supply provides substantially the same drive current to the light emitting elements 208 so that the lighting unit can emit a substantially constant light distribution pattern in accordance with the desired light emission. In some embodiments, the power supply can be installed remote to the lighting unit, whereas in other embodiments, the power supply can be mounted on or within the light box housing. At least one advantage of the invention is that the power supply, while in operation, allows the plurality of lighting units to provide and maintain the desired light output and prevents the lighting system from exhibiting an undesirable light output, such as but not limited to different levels of light brightness, color variations or variations in the light distribution pattern. In yet other embodiments, the lighting unit can comprise constant current drive circuitry electrically connected to the power supply in order to provide the same drive current to the light emitting elements.
The array of lighting units may be mounted proximate to the back 106 of the light box housing or in between the light transmissive face and back 104, 106 of the light box housing 102 when the light box housing has output surfaces on both of the face and back. The array of lighting units can be installed in existing light box housings as a retrofit kit unit such that the array of lighting units replaces conventional light sources. An advantage of the mounting bracket is that the mounting bracket can be positioned over existing light bulb sockets of existing light box housings which allows the positioning of the array of lighting units to correspond with the position of the replaced conventional light.
The array of lighting units can be mounted to the light box housing in many different ways and is not intended to be limited to the embodiments disclosed herein. In one embodiment, as in
The mounting bracket can be made of any suitable material including plastics or metals. In one embodiment, mounting bracket can be attached by any of the above mentioned mounting methods including tape, screws, or nails through mounting holes 423. The mounting bracket may be mounted to the sidewalls 108 of a light box housing or to the back 106 of a light box housing. In some embodiments, the mounting bracket comprises at least one support rib 1001 to maintain the bend between the base 420 and the at least one leg 416. As shown in
In double sided light box housings, which outputs light through the face and back of the light box housing, a plurality of arrays of lighting units 110 may be mounted back-to-back by any of the methods discussed above. In another embodiment wherein the double sided light box housing is used, an array of double-sided lighting units 300 can be used instead of mounting a plurality of arrays of lighting units 110 in a back-to-back configuration.
At least one advantage of mounting the lighting units on the carrier 112 is that the carrier 112 is arranged such that the lighting units mounted on the carrier can be stored in a folded or rolled configuration, thereby making it easy to ship and/or store an extended length of lighting units mounted on the carrier. For example, in one embodiment as shown in
Conventional lighting units are typically arranged as a number of individual lighting units stored in a box or other container, wherein a packaging material has a plurality of slots that receives and holds a respective lighting unit. The packaging material holds the individual lighting units so that the lighting units are not damaged during transit or while they are stored in the box. Each of the conventional lighting units have electrical conductors that are not connected to another conventional lighting unit and would need to be connected to another conventional lighting unit to form an array of lighting units when installed.
In order for an installer to fabricate an array of lighting units on a carrier using the conventional lighting units, the installer would have to measure and cut a blank carrier that does not have anything mounted on it. Typical carriers used with conventional lighting units are rigid and not flexible. Next, each lighting unit would have to be individually mounted onto the carrier and then the electrical conductors of each lighting unit would have to be spliced and soldered to the electrical conductors of adjacent lighting units so that the array of lighting units can be electrically connected. The installer could also form the array first, then mount each individual conventional lighting unit of the array onto the carrier. These processes to fabricate an array of conventional lighting units on a carrier are cumbersome and provide many opportunities for mistakes and/or errors to occur. For instance, the installer could improperly solder the electrical conductors between adjacent conventional lighting units resulting in failure, or the installer could incorrectly measure the length of the carrier necessary thereby creating wasted materials. Furthermore, this process likely causes the soldered connection of electrical conductors between adjacent conventional lighting units to be exposed and not be housed within the conventional lighting unit, whereas the exposed center conductor and the crimp terminals in the invention are arranged in an orderly fashion within the lighting unit.
An advantage of the invention is that the configuration of the flexible carrier 112 and the lighting units 110, 300 mounted on the flexible carrier eliminates the opportunities for mistakes and errors in assembling the array of lighting units because the array of lighting units 152, 153 on the flexible carrier 112 is prefabricated and tested to ensure proper operation. Assembly of the array of lighting units on the flexible carrier merely requires the installer to cut the flexible carrier to create the desired array length of lighting units on the flexible carrier. The desired array length of lighting units can then be mounted in the light box housing 102 using any of the methods discussed above. The invention reduces the amount of time required to install the array of lighting units, which is a time and cost-savings advantage over conventional lighting units. There is no need to mount each individual lighting unit 110, 300 onto the flexible carrier 112, or to splice and solder the electrical conductors between adjacent lighting units 110, 300, because such work has already been performed.
The coiled array of lighting units 152 is arranged to be easily packaged in a box 150.
The storage support structure 154 can be made of many different materials, such as but not limited to, cardboard, metal, plastic, paper, foam or the like. The storage support structure 154 shown in
In other embodiments, the coiled array 152 could be stored within the box 150 without the storage support structure 154, wherein at least one bracket 156 is wrapped around part of the coiled array 152 in order to maintain the coiled shaped. The at least one bracket 156 can be made of many different materials, such as but not limited to, plastic, rubber, paper, metal, steel or the like. Additionally, the at least one bracket 156 can be in many different forms, for example, the at least one bracket 156 can be overmolded material that wraps around part of the coiled array 152, a rubber band, a clip, tape, zip-ties, string, wire, rope or the like. Furthermore, the at least one bracket 156 can be configured to be reusable such that the at least one bracket 156 can be removed from the coiled array 152 and then placed back on the coiled array 152. While in other embodiments, the at least one bracket 156 is arranged to be a one-time use bracket. In yet other embodiments, the coiled array 152 could be stored within the box 150 using both the storage support structure 154 and the at least one bracket 156.
The flexible carrier 112 of the coiled array 152 is also arranged such that the flexible carrier 112 is not permanently shaped or bent due to being coiled, or due to being coiled for an extended period of time. The flexible carrier 112 has sufficient elasticity such that when a desired length of the coiled array 152 is uncoiled and detached from the coiled array 152, forming an array of lighting units of desired length, the flexible carrier 112 of the newly formed array is substantially flat and is not permanently curved or bent in a shape that is similar to the shape of the coiled array 152.
The coiled flexible carrier 112 and plurality of lighting units 110, 300 provide an extended length of coiled lighting units 110, 300 that can be cut to a desired length of an array of lighting units. The desired length of the array of lighting units are easy to install in a light box housing due to the array of lighting units being prefabricated, thereby eliminating the need for an installer to measure and cut a desired length of a carrier and then mount the lighting units onto the desired length of the carrier. As such, the flexible carrier and plurality of lighting units increases the efficiency of installing the array of lighting units in light box housings 102 or the like.
Although the invention has been described in considerable detail with reference to certain configurations thereof, other versions are possible. Lighting units according to the invention can be many different sizes and can be used for many different applications beyond light boxes. In other embodiments, a variable power supply can be used to control the intensity of the light emitting elements. The conductors can be different lengths and instead of running uninterrupted between the units. This would allow the power of the lighting units to be supplied separately and then connected together when installed. Therefore, the spirit and scope of the invention should not be limited to the versions described above.
This application is a continuation in part application of Ser. No. 14/100,983 to Quaal et al., filed on Dec. 9, 2013, which claims the benefit of U.S. Provisional Application Ser. No. 61/794,517 to Quaal et al., filed on Mar. 15, 2013. The contents of Ser. Nos. 14/100,983 and 61/794,517, including the drawings, schematics, diagrams and written description, are hereby incorporated in their entirety by reference.
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| Child | 14101182 | US |
