Strip lighting system that meets AC drive power requirements

Abstract

This invention relates to a strip lighting system comprising a series of LEDs and conforming to AC drive power.

Description

[0001] Cross-reference of related applications

[0002] This application claims priority to each of U.S. Provisional Application No. 62 / 780,545, filed December 17, 2018, and U.S. Provisional Application No. 62 / 915,604, filed October 15, 2019, both of which are incorporated herein by reference in their entirety. Technical Field

[0003] This invention generally relates to lighting, and more specifically, to a strip lighting system comprising a series of LEDs and conforming to AC drive power. Background Technology

[0004] Light-emitting diodes (LEDs) are typically formed from semiconductor materials that have been doped to create pn junctions. LEDs typically emit light in a narrow spectrum (e.g., a spectrum smaller than 100 nanometers), depending on the bandgap energy of the semiconductor material forming the pn junction.

[0005] In some applications, lighting systems may include one or more optical components that receive light emitted from an LED. For example, a lens is one type of optical component that can be used to receive light emitted from an LED and adjust one or more properties of said light. Summary of the Invention

[0006] This article describes a strip lighting system that includes a series of LEDs and meets AC drive power requirements.

[0007] In one aspect, a strip lighting system is provided. The system includes a tray and a circuit board disposed within the tray. One or more light-emitting diodes (LEDs) are mounted to the circuit board. One or more wires are electrically connected to the circuit board and are at least partially disposed within the tray. The system further includes an elastomer that contacts the tray and encapsulates at least a portion of the circuit board and the one or more wires. The system is configured to be directly or indirectly driven by a 60-volt AC power supply.

[0008] In some embodiments, the system further includes a connector assembly electrically connected to the one or more wires. In some cases, at least a portion of the connector assembly may not be encapsulated by the elastomer.

[0009] In some embodiments, the system further includes one or more lenses disposed on the one or more LEDs.

[0010] In some embodiments, the elastomer comprises a silicone material.

[0011] In some embodiments, the tray includes a separator dividing the tray into an upper section and a lower section. The circuit board and the one or more LEDs may be disposed within the upper section of the tray. The separator may include a base on which the circuit board is positioned. The one or more wires may be at least partially disposed within the lower section of the tray.

[0012] In some embodiments, the one or more wires and / or the connector extend through an inlet port in the tray. The inlet port may be formed in an upper section of the tray. The one or more wires pass through the upper section of the tray via one or more openings formed in the separator to reach a lower section of the tray.

[0013] In some embodiments, the system includes more than one strip lighting segment connected together.

[0014] In some embodiments, the lighting system is directly driven by AC power. For example, the voltage source may be a wall-mounted power outlet.

[0015] In some embodiments, the lighting system is indirectly driven by an AC power source. The lighting system may be directly driven by an LED driver electrically connected to the AC power source. In some embodiments, the LED driver is configured to convert AC power to DC power. For example, the LED driver may be a rectifier power supply unit or a high-voltage switching mode power supply (SMPS) unit.

[0016] Other aspects, embodiments, and features will become apparent from the following non-limiting detailed description when considered in conjunction with the accompanying drawings, which are schematic and not intended to be drawn to scale. In the drawings, each identical or substantially identical component illustrated in the various figures is generally represented by a single number. For clarity, not every component is labeled in every figure, nor is every component of every embodiment shown, where the description is not essential to allowing those skilled in the art to understand the invention. In cases where this specification and the documents incorporated by reference contain conflicting disclosures, this specification shall prevail. Attached Figure Description

[0017] Figure 1 A top view of a strip lighting system according to a specific embodiment described herein is shown.

[0018] Figure 2 A cross-section of a strip lighting system according to an embodiment of the features described herein is shown.

[0019] Figure 3A and 3B This document demonstrates the wiring configuration used in a combined strip lighting system according to a specific embodiment described herein. Detailed Implementation

[0020] This document describes a lighting system. The lighting system can be implemented as a strip lighting system having a length (e.g., about 6 inches), a width less than the length (e.g., about 1 inch), and a height less than the width (e.g., about half an inch). As further described below, the lighting system can be directly or indirectly driven by a high-voltage (e.g., 110V, 220V, etc.) alternating current (AC) power supply (e.g., supplied via a wall outlet). Embodiments of the lighting system described herein offer several advantages, including the ability to connect AC power in situ to the LED strip system, the ability to cut and seal the lighting strip to adjust its length in situ for installation, and the ability to use longer strip lengths by connecting several strip segments to each other, among other advantages. Furthermore, the lighting system can be designed to meet the requirements of UL 1598 and a polymer housing structure that meets the UL94 5VA rating.

[0021] In some embodiments, the strip lighting system includes a plurality of LEDs spaced apart along the length of the strip lighting system (e.g., the LEDs may be spaced about 1 inch apart). The strip lighting system may have a construction similar to that described in U.S. Patents Nos. 9,976,710 and 10,132,476, which are incorporated herein by reference in their entirety.

[0022] As further described below, the strip lighting system may include a tray, a circuit board disposed in the tray (e.g., disposed and / or mounted to the surface of the tray), LEDs mounted to the circuit board, and an elastomer (e.g., silicone, rubber, etc.) encapsulating at least a portion of the circuit board and in contact with the tray. One or more wires may extend along at least a portion of the lighting strip (e.g., below the circuit board) and electrically connect the circuit board to an external power source. For example, at one end, the wire may be soldered to the circuit board, and at the opposite end, the wire may be directly or indirectly connected to an AC power source. The AC power source may be a high-voltage source of at least 60 volts (e.g., 60 volts to 240 volts), at least 110 volts (e.g., 110 volts to 240 volts), and the like. For example, the AC power source may provide standard household voltage, such as 110 volts, 115 volts, 120 volts, 220 volts, or 240 volts. In embodiments utilizing direct connection, wiring (and / or electrical connectors connected to said wiring) can be directly connected to a wall port supplying AC power. In embodiments utilizing indirect connection to AC power, the voltage source can be an LED driver power supply (e.g., a rectifier power supply unit, a high-voltage switching mode power supply (SMPS) unit), which converts the standard AC high voltage from the wall port into any high voltage output that can be CV (constant voltage) or CC (constant current). In some of these embodiments, the LED driver power supply can be an external component of the tray assembly; and in other embodiments, the LED driver power supply can be mounted on a PCB and enclosed within the tray assembly. In still other embodiments, the LED driver power supply can be mounted within the tray and enclosed therein.

[0023] In some embodiments, the strip lighting system may further include a lens assembly disposed above the LED and configured to alter at least one characteristic of the light from the LED. The lens assembly may include at least one optical element, such as a lens, a reflector, and / or a light-scattering element. For example, the lens assembly may include only a lens. In another example, the lens assembly may include both a lens and a reflector. The lens assembly may be attached to the strip lighting device via a circuit board (e.g., the lens assembly may be mounted to a circuit board) and / or to an elastomer that at least partially encapsulates the circuit board (e.g., the elastomer may be in direct contact with at least a portion of the lens assembly).

[0024] As noted above, a lighting system may include an elastomer that at least partially encapsulates a circuit board. For example, the elastomer may contact one or more components of the circuit board and lens assembly (e.g., a reflector). The elastomer may not contact any components of the lens assembly. For example, the elastomer may not contact the lens to provide a gap (e.g., an air gap) between the lens and the elastomer. The elastomer protects the circuit board and / or electronic components mounted to the circuit board from environmental influences. Examples of suitable elastomers are further described below and include silicone and rubber.

[0025] It should be understood that the embodiments described herein can be implemented in any of a number of ways. Examples of specific implementations are provided below for illustrative purposes only. It should be understood that these embodiments and the features / capabilities provided can be used individually, all together, or in any combination of two or more, as the aspects of the technology described herein are not limited in this respect.

[0026] Figure 1 and 2 Cross-sectional views of a lighting system 100 according to some embodiments are shown. As shown, the lighting system 100 is configured as a strip lighting system. The strip lighting system includes a plurality of LED assemblies 102 arranged along the length of the system.

[0027] LED assembly 102 includes at least one (and in some cases more) LED 104. Generally, the LEDs used in the system can have any suitable design. For example, an LED can be a semiconductor device configured to emit light. The light emitted from the LED can have an angular CCT deviation, such as in phosphor-converted LEDs. As further described below, the LED can be mounted on a circuit board (e.g., a PCB).

[0028] As noted above, in some embodiments and as... Figure 2The illustration shows that the lighting system may optionally include a plurality of lens assemblies 106 disposed above an LED. Each lens assembly may include at least one optical element, such as a lens, reflector, and / or scattering element. The lens assembly may modify at least one characteristic of the light emitted from the LED. For example, the LED may be a phosphor-converted LED that emits light with angular CCT deviation. In this example, the lens assembly may receive light from the LED and make the color temperature of the light more uniform. Additionally (or alternatively), the lens assembly may adjust the light distribution pattern of the LED. For example, the lens assembly may create a circular beam or an elliptical beam. A detailed description of exemplary embodiments of the lens assembly 106 is provided in U.S. Patent Publication No. 2017 / 0261186, entitled “LIGHTING SYSTEM WITH LENSASSEMBLY,” published September 14, 2017, which is hereby incorporated herein by reference in its entirety.

[0029] It should be understood that lens assemblies can be constructed from any of a variety of materials. For example, lens assemblies can be constructed from one or more of the following materials: plastics (such as acrylic or polycarbonate), glass, and silicone. Furthermore, lens assemblies can be monolithic components.

[0030] It should be understood that various modifications can be made to the lighting system 100 without departing from the scope of this disclosure. For example, the lens assembly 106 may be removed, thereby directly exposing the LEDs beneath the lens assembly 106. Examples of such lighting systems without the lens assembly are described in U.S. Patent Publication No. 2016 / 0201861, entitled "Flexible Strip Lighting Apparatus and Methods," published July 14, 2016, which is hereby incorporated herein by reference in its entirety.

[0031] like Figure 2 As shown, the lighting system includes a tray 108 having a divider 110 that separates the tray into an upper section 112 and a lower section 114. The divider may include a base layer 116 on which a circuit board 118 may be positioned. The base layer may include a similar material (e.g., silicone) forming the sidewalls of the upper section.

[0032] The tray may have a minimum thickness of at least 2.5 mm, and in some sections, a greater thickness. The upper section of the tray may be sized to accommodate optical components (e.g., lens assemblies). The lower section of the tray may have, for example, a rectangular cross-section, but other cross-sectional shapes are also possible.

[0033] The tray (e.g., the upper and / or lower sections) may comprise a silicone material. In some embodiments, the tray is primarily (e.g., greater than 50% by weight, greater than 70% by weight, greater than 90% by weight) or substantially entirely formed of silicone. In some embodiments, the tray may be composed substantially of a silicone material. For example, an extrusion process may be used to manufacture the tray according to a particular embodiment.

[0034] A series of LEDs 104 are mounted at regular intervals along the length of the system on a circuit board in the upper section of the tray. As described above, a lens assembly may be positioned above each LED. Encapsulation material 120 may be added to fill the remaining space in the upper section of the tray. In this way, the encapsulation material 120 may come into contact with the circuit board, the section of the tray, the LEDs and / or the lens assembly, and other components. The circuit board may be at least partially encapsulated using an elastomer. The encapsulation material and / or the tray may be constructed of an elastomer (e.g., silicone). For example, both the encapsulation material and the tray may comprise silicone. It should be understood that the encapsulation material may have a different material composition than the tray. Generally, the tray and encapsulation material are selected and configured to enable the lighting system to meet the UL94 5VA test procedure.

[0035] The lower section of the tray can accommodate wiring 122 for electrical connections within the system. Figure 3A and 3B This illustrates wiring configurations that can be used according to specific embodiments. For example, the wiring may extend along at least a portion of the length of the lighting strip within a lower section of the tray beneath the circuit board. The wiring supplies power to the circuit board, and therefore to the LEDs mounted on said circuit board. In some embodiments, multiple wires (e.g., grounding wires, thermal wires, etc.) are utilized. Generally, any type of wire suitable for use at the mounting site can be used. The wiring may be connected to the circuit board. For example, the wiring may be soldered to bonding pads on the circuit board, which are then electrically connected to the LEDs. During use, the wiring is electrically connected (directly or indirectly) to an AC power source. In some embodiments, the wiring may be connected to one or more electrical connector assemblies. For example, electrical assemblies may facilitate the connection of the wiring to the lighting system. Other embodiments may not utilize separate electrical connector assemblies.

[0036] Encapsulation material may be added to fill the remaining space in the lower section of the tray. This allows the encapsulation material to contact the wiring, electrical connectors (if present), and sections of the tray. The wiring may be at least partially encapsulated using an elastomer. The encapsulation material and / or the tray may be constructed of an elastomer (e.g., silicone). For example, both the encapsulation material and the tray may include silicone. It should be understood that the encapsulation material may have a different material composition than the tray. Generally, the tray and encapsulation material are selected and configured to enable the lighting system to meet the UL94 5VA test procedure.

[0037] In some embodiments, wiring and / or electrical connector assemblies enter the tray through an inlet port in the tray (e.g., see [link]). Figure 3A ).like Figure 1 As shown in B and 3A, the inlet port 124 may be formed in the side wall of the upper section of the tray. It should be understood that the inlet port may be formed in other sections of the tray that include the lower section. In these illustrative embodiments, wiring is connected to an electrical connector assembly 126 extending through the inlet port. In such embodiments, additional wiring is connected to the opposite end of the electrical connector assembly and may extend directly or indirectly to an AC power source. The area of ​​the tray surrounding the inlet port may be reinforced with metal to provide additional support.

[0038] In some embodiments, the wiring extends from the upper section of the tray through an opening 128 formed in the separator to the lower section of the tray. Once in the lower section of the tray, the wiring may extend along at least a portion of the length of the lighting system and through an additional opening 130 formed in the separator to return to the upper section of the tray, wherein the wiring is connected (e.g., by soldering) to bonding pads on the circuit board (e.g., see...). Figure 3B ).

[0039] In some embodiments, more than one wire may be assembled within a cable. In some embodiments, the cable may extend from an AC power source to or near an inlet port. For example, the cable may extend from an AC power source to an electrical connector assembly extending through the inlet port. In some embodiments, the tray may be empty of cables, such that when the wires are in the tray, they are no longer assembled with each other (within a cable). In such embodiments, the wires may extend individually within individual sections of the tray and may be individually connected to individual portions of the circuit board.

[0040] In some embodiments, potting materials (e.g., silicone) and / or RTV adhesive may be used to encapsulate wiring and / or combine wiring with other components (e.g., electrical connector assemblies).

[0041] It should be understood that other wiring configurations may be used. For example, a wiring may enter the tray through an inlet port formed in the lower section and may extend within the lower section until it passes through one or more openings in the separator to enter the upper section, in which the wiring is connected (e.g., by soldering) to a bonding pad on the circuit board. In another embodiment, some wiring may enter the tray through an inlet port formed in the upper section, in which the wiring is connected (e.g., by soldering) to a bonding pad on the circuit board, and other wiring may enter the tray through an inlet port formed in the upper section and may pass through one or more openings in the separator to enter the lower section, in which this wiring may extend along at least a portion of the length of the lighting system and may pass through one or more additional openings formed in the separator to return to the upper section of the tray, in which the wiring is connected (e.g., by soldering) to a bonding pad on the circuit board.

[0042] In some embodiments, the wiring can be connected to the tray via an electrical clamp.

[0043] In some embodiments, a strip lighting system may include more than one lighting strip segment connected to each other to form an extended strip. For example, in some embodiments, the strip lighting system includes multiple strip lighting segments 400a. In such embodiments, the segments may be connected to each other using suitable mechanical and / or electrical connection mechanisms. For example, respective segments may be configured to have corresponding engagement features (e.g., on a tray) that can cooperate to mechanically connect adjacent segments. Segments may be connected additionally or individually using, for example, electrical connector assemblies that connect wiring from one segment to wiring from adjacent segments.

[0044] In some embodiments, the strip lighting system may be designed to be flexible, allowing the system to bend during use.

[0045] It should be understood that the embodiments described herein can be implemented in any of a number of ways. This document provides examples of specific implementations for illustrative purposes only. It should be understood that these embodiments and the features / capabilities provided can be used individually, all together, or in any combination of two or more, as the aspects of the technology described herein are not limited in this respect.

[0046] The various aspects of this disclosure may be used individually, in combination, or in various arrangements not explicitly discussed in the embodiments described above, and therefore their application is not limited to the details and arrangements of the components stated or illustrated in the foregoing description. For example, an aspect described in one embodiment may be combined in any way with aspects described in other embodiments.

[0047] The use of ordinal terms such as "first," "second," "third," etc., in the claims to modify the claim elements themselves does not imply any priority, order, or sequence of actions of one claim over another, or the chronological order in which the actions of the methods are performed. Rather, they are merely markers used to distinguish one claim element with a specific name from another element with the same name (but for the use of ordinal terms) to differentiate claim elements.

[0048] The terms “about,” “approximately,” and “substantially” can be used to mean within ±20% of the target value in some embodiments, within ±10% of the target value in some embodiments, within ±5% of the target value in some embodiments, and within ±2% of the target value in some embodiments. The terms “about,” “approximately,” and “substantially” may include the target value.

[0049] Furthermore, the terms and terminology used herein are for descriptive purposes and should not be considered restrictive. The use of “comprising,” “including,” or “having,” “containing,” “involving,” and variations thereof herein is intended to cover the terms listed thereafter and their equivalents, as well as additional items.

[0050] Having described several aspects of at least one embodiment above, it should be understood that various changes, modifications, and improvements will readily occur to those skilled in the art. Such changes, modifications, and improvements are intended to be the subject of this disclosure. Therefore, the foregoing description and figures are merely examples.

Claims

1. A strip lighting system, comprising: A tray having a polymer shell and defining an elongated internal space, the tray including a divider separating the elongated internal space into an upper section and a lower section; A circuit board, which is disposed in the upper section of the elongated internal space; One or more light-emitting diodes (LEDs) are mounted on the circuit board; Wiring, which is electrically connected to the circuit board and is at least partially disposed within the upper and lower sections of the elongated internal space; The entry port of the strip lighting system is located in the upper section of the elongated internal space. The wiring enters the strip lighting system through the entry port. The area surrounding the entry port is reinforced by a U-shaped metal reinforcement, which is attached to the entry port of the polymer housing at the distal end of the strip lighting system. and An elastomer fills the interior of the U-shaped metal reinforcement and encapsulates a portion of the wiring near the metal reinforcement to form a stress-relief portion; The strip lighting system is configured to be driven directly or indirectly by an AC power source.

2. The strip lighting system according to claim 1, further comprising one or more lenses disposed on the one or more light-emitting diodes (LEDs).

3. The strip lighting system of claim 1, further comprising a connector assembly electrically connected to the wiring.

4. The strip lighting system of claim 3, wherein at least a portion of the connector assembly is not encapsulated by the elastomer.

5. The strip lighting system of claim 1, wherein the elastomer comprises a silicone material.

6. The strip lighting system of claim 1, wherein the separator includes a base on which the circuit board is positioned.

7. The strip lighting system of claim 1, wherein the wiring passes through one or more openings formed in the separator between the upper section and the lower section of the elongated internal space.

8. The strip lighting system of claim 1, comprising more than one strip lighting segment connected together.

9. The strip lighting system according to claim 1, wherein the strip lighting system is directly driven by the AC power supply.

10. The strip lighting system of claim 1, wherein the AC power supply comprises a wall-mounted power outlet.

11. The strip lighting system according to claim 1, wherein the strip lighting system is indirectly driven by the AC power supply.

12. The strip lighting system of claim 11, wherein the strip lighting system is driven by an LED driver electrically connected to the AC power supply.

13. The strip lighting system of claim 12, wherein the LED driver is configured to convert AC power to DC power.

14. The strip lighting system of claim 12, wherein the LED driver is a rectifier power supply unit or a high-voltage switching mode power supply (SMPS) unit.

15. The strip lighting system of claim 1, wherein the strip lighting system has a first distal end and a second distal end opposite to the first distal end in a length direction of the strip lighting system, and wherein the wiring extends along at least a portion of the length of the strip lighting system within the lower section of the elongated interior space.

16. The strip lighting system of claim 1, wherein the tray is formed by a wall defining the elongated interior space and extending along the length of the strip lighting system from a first distal end to a second distal end opposite to the first distal end, the wall comprising a base forming a bottom surface of the strip lighting system, and comprising a first sidewall extending upward from the base toward a top surface of the strip lighting system, and comprising a second sidewall spaced across the base from the first sidewall and extending upward from the base toward the top surface of the strip lighting system.

17. A strip lighting system comprising: A tray having a polymer shell and defining an elongated internal space, the tray including a divider separating the elongated internal space into an upper section and a lower section; A circuit board, which is disposed in the upper section of the elongated internal space; One or more light-emitting diodes (LEDs) are mounted on the circuit board; Wiring, which is electrically connected to the circuit board and is at least partially disposed within the upper and lower sections of the elongated internal space; The entry port of the strip lighting system is located in the lower section of the elongated internal space. The wiring enters the strip lighting system through the entry port. The area surrounding the entry port is reinforced by a U-shaped metal reinforcement, which is attached to the entry port of the polymer housing at the distal end of the strip lighting system. and An elastomer fills the interior of the U-shaped metal reinforcement and encapsulates a portion of the wiring near the metal reinforcement to form a stress-relief portion; The strip lighting system is configured to be driven directly or indirectly by an AC power source.

18. The strip lighting system of claim 17, wherein the wiring passes through one or more openings formed in the separator between the upper section and the lower section of the elongated internal space.

19. The strip lighting system of claim 17, comprising more than one strip lighting segment connected together.

20. The strip lighting system of claim 17, wherein the strip lighting system is directly driven by the AC power supply.

21. The strip lighting system of claim 17, wherein the AC power supply comprises a wall-mounted power outlet.

22. The strip lighting system of claim 17, wherein the strip lighting system is indirectly driven by the AC power supply.

23. The strip lighting system of claim 17, wherein the strip lighting system is driven by an LED driver electrically connected to the AC power supply.

24. The strip lighting system of claim 23, wherein the LED driver is configured to convert AC power to DC power.

25. The strip lighting system of claim 23, wherein the LED driver is a rectifier power supply unit or a high-voltage switching mode power supply (SMPS) unit.

26. The strip lighting system of claim 17, wherein the strip lighting system has a first distal end and a second distal end opposite to the first distal end in a length direction of the strip lighting system, and wherein the wiring extends along at least a portion of the length of the strip lighting system within the lower section of the elongated interior space.

27. The strip lighting system of claim 17, wherein the tray is formed by a wall defining the elongated interior space and extending along the length of the strip lighting system from a first distal end to a second distal end opposite to the first distal end, the wall comprising a base forming a bottom surface of the strip lighting system, and comprising a first sidewall extending upward from the base toward a top surface of the strip lighting system, and comprising a second sidewall spaced across the base from the first sidewall and extending upward from the base toward the top surface of the strip lighting system.

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