Patent Application
20240178586
The present disclosure relates to light-emitting diode (LED) lighting systems, and more particularly to solderless LED strip connectors.
It is known to provide a connector device for electrically connecting two or more light-emitting diode (LED) strips at electrically conductive ends of the strips. LED strips, which may commonly be referred to as LED tape lights or ribbon lights, are popular lighting solutions for numerous residential, commercial, and industrial projects as they provide discrete, efficient and customizable lighting sources that are relatively easy to install. Common uses and placements include the undersurface of shelves or cabinets, interior surfaces of display cases to illuminate the contents within, recessed wall lighting, staircase illumination and backlighting for advertising signs and billboards.
Generally, LED strips have LEDs arranged linearly along a top surface of the strip. The bottom surface of the strip opposite the LED surface is usually applied directly to an installation surface, such as via an adhesive tape. The LED strip may be rigid or flexible and often appears as an elongated ribbon or tape-like material sold in precut strips or rolls that can be cut to a desired length when installed. The LED strip generally provides an indication or cut line along which an installer may cut the LED strip such that electric contacts are provided on both sides of the cut line and thus both ends of the severed strip. The cut ends may present anywhere from one to six or more electric contacts depending on the functionality of the LED strip. For example, frequently, a higher number of contacts are present on LED strips that provide higher illumination and/or multiple colored diodes per LED emitter. Electric contacts of two LED strips may be electrically connected, such as via soldering or a connector device, to provide continuous lighting along multiple strips. A power supply, such as a DC power supply, is often attached to the electric contacts at one end of the LED strip or strips.
Because LED strips generally can only be cut into straight-line sections, installation of LED strips, such as around corners and over uneven surfaces, often involves cutting and electrically connecting several different lengths of strips. Methods of connecting LED strips known in the art include soldering the electrical contacts at two strip ends together and providing electrically conductive connector devices at two strip ends. However, soldering the electric contacts creates resistance at the connection points and can be difficult and labor-intensive when installation involves connecting several lengths of LED strips together. Additionally, connector devices currently known in the art provide unreliable electrical and retaining connections between the device and each of the strips, reduced durability of the connector device itself, suboptimal connectivity to power supplies, and are limited in the number of electric contacts per LED strip that can be simultaneously connected using a single connector. These problems can result in lengthy and difficult installation, frequent replacement of damaged or disconnected parts, and other issues related to unreliable lighting supplies.
The present disclosure provides a connector for connecting ends of light strips where the connector includes an electrically insulating body with a plurality of slots extending into surfaces of the body to receive separate light strips therein. A plurality of conductive members are disposed within the electrically insulating body, along with at least two sets of screws that threadably engage the conductive members and retaining light strips disposed in the slots. The two sets of screws are electrically connected to one another via the conductive members and provide separate electrical connections between the light strips disposed in the slots and contacted and retained there by the screws. Thus, a solderless LED connector assembly in accordance with the present disclosure provides secure retention of LED strips connected via the connector assembly, a high number of electrical connections provided between LED strips, and significant durability of the connector components.
According to one aspect of the present disclosure, a connector assembly for electrically connecting an end of a first light strip to an end of a second light strip includes an electrically insulating body having a top surface and opposing first and second side surfaces. A first light-strip-receiving slot extends through the first side surface of the electrically insulating body. The first light-strip-receiving slot is configured to receive an end of a first light strip that has electrical contacts. A second light-strip-receiving slot extends through the second side surface of the electrically insulating body. The second light-strip-receiving slot is configured to receive an end of a second light strip that has electrical contacts. A plurality of conductive bars are disposed within the electrically insulating body between the top surface and the first and second light-strip-receiving slots. The plurality of conductive bars are each separated from the first and second light-strip-receiving slots by an intermediate portion of the electrically insulating body. A first set of screws are disposed within the electrically insulating body. Each screw of the first set of screws includes a proximal end, an intermediate section threadably engaged at one of the plurality of conductive bars, and a distal end disposed in the first slot. The distal ends of the first set of screws are configured to discretely contact the electrical contacts of the first light strip. A second set of screws are disposed within the electrically insulating body. Each screw of the second set of screws includes a proximal end, an intermediate section threadably engaged at one of the plurality of conductive bars, and a distal end disposed in the second slot. The distal ends of the second set of screws are configured to discretely contact the electrical contacts of the second light strip. The first set of screws are electrically connected to the second set of screws via the plurality of conductive bars for forming separate electrical connections between the electrical contacts of the first and second light strips.
Implementations of the disclosure may include one or more of the following optional features. In some implementations, the first and second sets of screws each have substantially consistent diameters along a length between and including the proximal and distal ends. In some examples, the proximal ends have a tool-engaging feature that is an axially-aligned notch across the proximal end of each screw, where the notch is configured to receive a tool to rotate the respective screws. The screws may also include a piercing tip at the distal ends to pierce at least partially into the electrical contacts of the first and second light strips. Additionally, a first and second set of wire-receiving notches extend respectively through the first and second side surfaces of the insulating body, each wire receiving notch adjacent to one of the plurality of conductive bars. The wire receiving notches are configured to receive an electrical wire and there may be two wire receiving notches adjacent each conductive bar.
According to another aspect of the present disclosure, a connector assembly configured to receive a first light strip and a second light strip includes an electrically insulating body. The electrically insulating body has a top surface that forms a first set of screw-receiving openings and a second set of screw-receiving openings. The electrically insulating body also has a first side surface that forms a first set of conductive bar receiving openings and a first light-strip-receiving opening. The electrically insulating body further has a second side surface that forms a second set of conductive bar receiving openings and a second light-strip-receiving opening. The electrically insulating body includes a first set of axial passages extending from the first set of screw-receiving openings, a second set of axial passages extending from the second set of screw-receiving openings, and a third set of axial passages extending from the first and second sets of conductive bar receiving openings. The third set of axial passages are substantially orthogonal to the first set of axial passages and the second set of axial passages. A first light-strip-receiving passage extends from the first light-strip-receiving opening and is orthogonal to the first set of axial passages and separate from the third set of axial passages. A second light-strip-receiving opening extends from the second-light-strip receiving opening and is orthogonal to the second set of axial passages and separate from the third set of axial passages. A plurality of conductive bars are disposed within the third set of axial passages. A first set of screws are disposed within the first set of axial passages and each include a proximal end configured to receive a tool operable to rotate the respective screw, an intermediate section threadably engaged at one of the plurality of conductive bars, and a distal end disposed in the first light-strip-receiving passage and configured to directly engage electrical contacts of the first light strip. A second set of screws are disposed within the second set of axial passages and each include a proximal end configured to receive a tool operable to rotate the respective screw, an intermediate section threadably engaged at one of the plurality of conductive bars, and a distal end disposed in the second light-strip-receiving passage and configured to directly engage electrical contacts of the second light strip.
This aspect may also include one or more optional features disclosed herein. In some examples, the first and second sets of axial passages have interior surfaces void of threading. Also, the plurality of conductive bars have substantially flat faces that, when the conductive bars are disposed in the third set of axial passages, the flat faces are disposed at the first and second sets of conductive bar receiving openings.
The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, advantages, purposes, and features will be apparent upon review of the following specification in conjunction with the drawings.
Like reference symbols in the various drawings indicate like elements.
Referring now to the drawings and the illustrative examples depicted herein, a solderless light emitting diode (LED) strip connector or assembly is shown receiving a connector strip, which will be described in further detail below. The connector assembly may also be used to connect two or more LED strips or connector strips and/or electrical wires connected to a power supply. Thus, in referencing the connector strip, it is understood that it can be replaced by a similarly embodied end of an LED strip.
LED strips or tape lights or ribbon lights include a number of LED emitters typically arranged in a singular straight row along a narrow strip of a printed circuit board (PCB). The strips are cut to a desired length so that electrical contacts are exposed at a cut end of the strip, the strip is applied to a surface, such as via an adhesive backing, and the strip is connected to a power source to provide lighting in often hard to reach or confined areas. LED strips generally have single rows of LED emitters, but may present one to six or more electric contacts. A higher number of contacts generally corresponds to increased functionality of the strips, such as multiple colored diodes per LED emitter. For example, LED strips with two connectors generally only emit white light while LED strips with four or more connectors are needed to provide multi-colored LED strips. Additionally, while varying in functionality, LED strips typically exist only in standard widths (such as 8 mm, 10 mm and 12 mm varieties).
Because LED strips are linear, they are best used to provide lighting at long, straight surfaces. However, it is often desirable to connect two or more lengths of LED strips, such as to connect lighting sources at a corner surface or to bridge a gap between two surfaces or to connect strips along a significant span or with differently colored or oriented LEDs. To provide a continuous lighting source between the two or more LED strips and/or share the connected power source among several strips, it is necessary to provide an electrical connection between each of the electrical contacts on the two strips being connected. Generally, devices and methods for connecting LED strips include soldering conductors (e.g., wires) between the electrical contacts or connecting the strips using inferior connector devices that retain and provide electrical connection between the strips.
The connector devices known in the art for providing connection between LED strips cannot provide reliable connection and/or accommodate LED strips with a high number of electric contacts (three or more). For example, prior art connectors commonly use snap connectors that provide a loose connection. Additionally, the plastic comprising the LED snap connectors often deteriorates (usually at the snap connection) from the heat cycling of the LEDs, especially when used outside. Thus, the LED strip can easily be pulled out of the connector devices, severing the electrical connection between the strips and risking damage to the strip if it falls from the connector. Connector devices that use other connection means (such as screws) are limited at least in the number of electrical connections that the connector device can accommodate and the reliability of the electrical connections provided by the device. The present disclosure provides an improved LED strip connector component and assembly for providing electrical connection between two or more LED strips having one to six or more electrical contacts.
In reference to
The light strip connector assembly 10 includes an electrically insulating body 12, five conductive members or bars 14 disposed within the electrically insulating body 12, a first set of screws 16 disposed in the electrically insulating body 12 and threadably engaging the conductive members 14 and the electrical connections 3 of the connector strip 1 that are disposed in a first light strip receiving slot 26. The connector assembly 10 also includes a second set of screws 18 similarly situated to the first set of screws 16, but configured to engage electrical contacts of an LED strip or connector strip received in a second light strip receiving slot 28. Thus, the connector strip 1 can be electrically connected to an LED strip or connector strip via the first set of screws 16 in electrical connection with the second set of screws 18 via the conductive members 14. The electrically insulating body 12 has a top surface 20 and opposing first and second side surfaces 22, 24. The first light strip receiving slot 26 extends through the first side surface 22 and is configured to receive an end of a strip having electrical contacts. Similarly, the second light strip receiving slot 28 extends through the second side 24 surface and is also configured to receive an end of a strip having electrical contacts. The conductive members 14 are disposed within the body between the top surface 20 and the first and second light strip receiving slots 22, 24 and are separated from the strip receiving slots by an intermediate portion 12a of the electrically insulating body. Each of the first and second sets of screws 16, 18 have a proximal end 16a, 18a exposed at the top surface, an intermediate section 16b, 18b threadably engaged at one of the conductive members 14, and a distal end 16c, 18c configured to discretely contact the electrical contacts disposed respectively in the first and second light strip receiving slots 26, 28. Although shown as a 5-pin light strip connector assembly configured to receive and electrically connect LED strips and connector strips having five electrical contacts, it should be understood that a connector assembly in accordance with the present disclosure can receive strips having any number of electrical connections, such as 2-pin, 3-pin, 4-pin, or 6-pin configurations.
The electrically insulating body 12 as illustrated generally resembles a block or cube of injection molded material. The body has a top surface 20 and opposing first and second side surfaces 22, 24. The top surface forms a first set of screw-receiving openings 30 and a second set of screw-receiving openings 32. Axial passages, which may be referred to as screw holes 34, 36, extend from each of the screw-receiving openings to provide passage through the insulating body 12 to electrically conductive screws 16, 18. As shown, the screw holes are not threaded to prioritize the threaded engagement between the screws and the conductive members over threaded engagement between the screws and insulating body. The first side surface 22 forms a first set of conductive-bar-receiving openings 38 and a first light-strip-receiving opening 42. Axial passages extend from each of the conductive-bar-receiving openings and the first light-strip-receiving opening. These axial passages may be referred to respectively as conductive bar passages 39 and the first light strip or strip connector receiving slot 26. The first strip receiving slot 26 as shown is receiving a connector strip 1 having five electrical contacts 3. Similar to the first side surface, the second side surface 24 forms a second set of conductive-bar-receiving openings 40 and a second light-strip-receiving opening 44, with the axial conductive bar passage 39 extending between the first and second surface conductive-bar-receiving openings. Likewise the second strip receiving slot 28 extends from the second light strip receiving opening 44 into the conductive body.
The conductive bar passages 39 are separated from one another and run parallel to the first and second strip receiving slots 26, 28 and are separated from the strip receiving slots by an intermediary portion 12a of the conductive body 12. The first and second sets of screw holes 34, 36 are substantially orthogonal to the conductive bar passages 39 (but may extend into the conductive body at any suitable angle relative to the conductive bar passages) and pass through the conductive body 12 from the top surface 20 to the respective strip receiving slots. Each of the first and second sets of screw holes 34, 36 intersects one of the conductive bar passages 39. The conductive body 12, aside from the passages and slots described herein, is a solid block of material injection molded as a single piece to provide a durable and solid construction and reduce manufacturing costs.
As shown by
When assembled, (such as shown in
The plurality of conductive members or bars 14 resemble elongated, metallic blocks and pass through the electrically insulating body 12 to electrically connect the first and second sets of screws 16, 18. The screws form such a strong electrical connection because the conductive bars that span between the corresponding pairs have a solid cross-section that allows for a threaded interior surface between the upper and lower surfaces of the bar.
The conductive members 14 comprise first and second end surfaces 14a, 14b having solid cross-sectional areas exposed at the first and second side surfaces 22, 24 of the insulating body 12. Although
Moreover, a top and bottom wire receiving passage 47a, 47b extend inward from U-shaped top wire receiving openings 46a, 48a and U-shaped bottom wire receiving opening 46b, 48b. The top and bottom U-shaped wire receiving openings are formed by the first and second side surfaces 22, 24. The wire receiving passages 47a, 47b extending into the body 12 run adjacent the conductive bar passages 39, exposing side surfaces of the conductive members 14. The notches are configured to receive electric wires, for example, to attach a power supply to power LED strips received at the connector assembly. Embodiments of the connector assembly may have wire notches above and/or below the conductive bar passages. For example, in
Turning now to
To form the electrical connection, the connector 10 has a first set of screws 16 that engage an end of one LED strip or connector strip and a second set of screws 18 that engage the end of another LED strip or connector strip. Corresponding pairs of the first and second set of screws are electrically connected by a plurality of conductive bars 14 that extend through the body 12 of the connector. The first set of screws 16 pass through the electrically insulating body 12 from the top surface 20, each screw threadably engages a conductive bar 14, and engages an electrical contact 3 of the strip 1 positioned in the receiving slot 26 to retain the strip 1 at the connector 10 and provide electrical connection via the screw. Each screw generally has the same diameter along the entire length of the screw. That is, the proximal end 16a (or head), intermediary section 16b, and distal end 16c (or tip) all comprise the same diameter. To engage tightly arranged contacts on ends of the lighting strips (such as especially in the case of three, four, five, and six adjacent contacts on the lighting strips), screws with enlarged diameter heads would not function because the heads of the screws dimensionally prevent tighter clustering of the screws. These “head-less” screws (which share the approximately the same diameter at the head as the threaded shank of the screw) accommodating of the tight spacing.
In reference to
Although the illustrated examples show the conductive members as received at conductive bar passages and exposed at the first and second surfaces of the insulating body, other examples may have the conductive bars encased inside the insulating body. The bars in one example may be insert molded in the body of the connector. In these additional examples, the bar is substantially U-shaped, with one leg of the U disposed in the first strip receiving slot, the second leg of the U disposed in the second strip receiving slot, and the middle portion of the U disposed in a portion of the insulating body between the two slots. One or more sets of screws passes through the insulating material of the body from the top surface so that when the screw engages the U-shaped bar, the bar is biased towards strips received in the first and second receiving slots. Thus, the conductive bar forms the contact point with the electric contacts of the strips rather than the screws. One set of screws may be used to create the biasing force of the U-shaped bar in both the first and second receiving slots or a first set of screws may provide the biasing force to the leg of the U disposed in the first receiving slot and a second set of screws may provide the biasing force to the leg of the U disposed in the second receiving slot.
Returning now to the illustrated embodiments and specifically in reference to
Referring to
Turning now to
Thus, the present disclosure provides a light strip connector assembly comprising an electrically insulating body, a plurality of conductive bars, and first and second sets of screws. The insulating body includes a top surface and opposing first and second side surfaces with first and second light-strip-receiving slots extending respectively through the first and second side surfaces. The first and second light-strip-receiving slots are configured to receive ends of first and second light strips that have electrical contacts. The conductive bars are disposed within the insulating body between the top surface and the light-strip-receiving slots and are separated from the light-strip-receiving slots by an intermediate portion of the insulating body. The first and second sets of screws are disposed within the insulating body and each screw includes a proximal end, an intermediate section threadably engaged at a conductive bar, and a distal end in the first or second light-strip-receiving slot. When the first and second light strips are disposed in the first and second light-strip-receiving slots, the distal ends of the first and second sets of screws respectively contact the electrical contacts of the first and second light strips. Thus, the first set of screws electrically connect to the second set of screws via the conductive bars, forming discrete electrical connections between the first and second light strips.
For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature; may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components; and may be permanent in nature or may be removable or releasable in nature, unless otherwise stated.
In addition, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements in the preceding descriptions. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional implementations that also incorporate the recited features. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by implementations of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.
Also for purposes of this disclosure, the terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “inboard,” “outboard” and derivatives thereof shall relate to the orientation shown in
Changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law. The disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described.
This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/164,149, filed Mar. 22, 2021, the disclosure of this prior application is considered part of this application and is hereby incorporated by reference in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2022/071258 | 3/22/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63164149 | Mar 2021 | US |
