Angled LED Channel Letter Lighting for Even Dispersion
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Solution Overview
Problem
Conventional LED-based channel letter lighting systems lack flexibility in adjusting the density of light emitting diodes (LEDs) and often result in uneven light dispersion, requiring multiple chains with different densities and leading to increased costs and storage needs.
Innovation Solution
The use of lighting units with angled light emitting elements and a sealant-filled housing allows for customizable LED placement and distribution, providing even light dispersion and the ability to adjust the density of LEDs by varying the spacing between units, while also offering weatherproofing and increased ruggedness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional LED chains with fixed density are used, then manufacturing and storage are simplified, but adaptability to different lighting requirements is reduced
Solution Approach 1:
The patent implements adjustable LED density by making the lighting system dynamic and reconfigurable. Individual lighting units can be spaced at variable intervals along the channel letter, allowing the density to be adjusted based on specific application requirements rather than being fixed during manufacturing.
Solution Approach 2:
The lighting system is divided into modular lighting units that can be independently positioned. Each unit contains its own LED array and housing, allowing them to be distributed at different spacings to achieve desired density variations without requiring multiple pre-configured chain types.
2Illumination intensity
If LEDs are mounted facing upward in conventional configurations, then installation is simplified, but light dispersion uniformity deteriorates
Solution Approach 1:
The patent employs asymmetric mounting of LEDs within the lighting units. Instead of uniform upward-facing orientation, LEDs are positioned at different angles and orientations to optimize light distribution patterns, creating more even dispersion across the channel letter surface.
Solution Approach 2:
The lighting units are positioned at varied depths and angles relative to the channel letter surface, utilizing three-dimensional spatial arrangement rather than simple two-dimensional planar mounting. This dimensional variation enhances light dispersion uniformity by distributing light from multiple angles and positions.
3Quantity of substance
If LED spacing is increased to reduce density, then cost and complexity are reduced, but illumination coverage may be insufficient
Solution Approach 1:
The patent applies local quality by varying LED density in different regions of the channel letter based on specific illumination requirements. Areas requiring higher brightness or broader coverage can have denser lighting unit spacing, while other areas can use sparser spacing, optimizing both coverage and resource usage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables flexible and efficient LED placement, ensuring even light distribution across channel letters, reducing the need for multiple chains and enhancing the durability and appearance of the lighting system.
Implementation Method 1
a sealant within the housing, filling the cavity around the PCB and cavities around the light emitting elements
Implementation Method 2
a plurality of light emitting elements on the tabs. These tabs and light emitting elements are angled in relation to the remainder of the PCB or the housing. An electrical signal applied to the light emitting elements causes them to emit light
Data Source
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AI summary
The present embodiments provide channel letter lighting devices and/or systems. A lighting system (10), comprising a plurality of electrically connected lighting units (12), comprising conductors (14, 16) to provide an electrical signal to each of the units. Each of the lighting units comprise a housing, a printed circuit board (PCB) (22) mounted within the housing (24) and having a plurality of tabs (60) and a plurality light emitting elements (18, 19, 20) on the tabs. The tabs are angled in relation of the remainder of the PCB or housing. The electrical signal applied to the light emitting elements causes them to emit light substantially away from said housing. The lighting system further comprises a sealant (36) within the housing filling cavities around the light emitting elements and the cavity around said PCB and a mounting mechanism for mounting the unit to a structure.