Angled LED Tabs for Uniform Channel Letter Illumination

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Solution Overview

Problem

Conventional LED-based channel letter lighting systems lack flexibility in adjusting the density of LEDs, leading to inefficient light dispersion and increased costs due to the need for multiple chains with different densities, and often result in uneven illumination and light loss with the use of reflectors or lenses.

Innovation Solution

The development of a lighting unit with angled light emitting elements on a printed circuit board (PCB) within a housing, where the PCB is filled with a sealant, allowing for customizable light distribution by adjusting the angle of the tabs and providing even light dispersion without the need for multiple chains, and incorporating a constant current device for uniform brightness across units.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional LED chains with fixed density are used, then manufacturing is simplified, but adaptability to different lighting requirements is reduced

Engineering Contradiction:
Improveadaptability to different lighting requirementsVSAvoiddevice complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements adjustable LED density by allowing selective activation of individual LEDs or groups of LEDs within a single chain through independent control circuits. This dynamic configuration enables the same lighting system to adapt to different illumination requirements without requiring multiple fixed-density chains, thereby improving versatility while maintaining manageable system complexity through modular control architecture.

Inventive Principle:
Principle #15Dynamics

2Illumination intensity

If reflectors or lenses are added to improve light dispersion, then illumination quality improves, but light loss increases and device complexity increases

Engineering Contradiction:
Improvelight dispersion qualityVSAvoidlight loss
Core Design Contradiction:
Illumination intensityVSLoss of energy

Solution Approach 1:

The patent eliminates reflectors and lenses from the lighting system by directly mounting LEDs on the channel letter housing structure. This extraction of optical components removes the associated light losses and simplifies the device while maintaining effective light dispersion through the direct integration of light sources with the housing, thereby improving illumination efficiency without compromising light distribution quality.

Inventive Principle:
Principle #2Taking out (Extraction)

3Adaptability or versatility

If multiple chains with different densities are maintained, then adaptability to different locations is improved, but inventory complexity and cost increase

Engineering Contradiction:
Improveadaptability to different locationsVSAvoidinventory variety
Core Design Contradiction:
Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The patent creates a universal LED chain design that can serve multiple lighting requirements through selective activation of different LED segments. A single chain type with adjustable density capabilities replaces the need for multiple specialized chains, enabling the same product to be deployed in various locations with different illumination needs. This multi-functionality reduces inventory variety while maintaining full adaptability to different application requirements.

Inventive Principle:
Principle #6Universality (Multi-functionality)

4Illumination intensity

If LED density is increased to improve illumination, then brightness improves, but power consumption increases

Engineering Contradiction:
ImprovebrightnessVSAvoidpower consumption
Core Design Contradiction:
Illumination intensityVSUse of energy by moving object

Solution Approach 1:

The patent implements partial activation of LEDs within the chain, allowing only the necessary number of LEDs to be activated based on the specific lighting requirements of each location. Rather than operating all LEDs at full density, the system activates only the required portion, achieving adequate brightness while minimizing power consumption. This partial action approach optimizes the balance between illumination intensity and energy usage.

Inventive Principle:
Principle #16Partial or excessive action

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 light distribution with customizable angles for optimal channel letter illumination, reducing costs by eliminating the need for multiple chains and ensuring consistent brightness across the channel letter, while maintaining a robust and weatherproof design.

Implementation Method 1

Each of the units comprises a printed circuit board (PCB) mounted within a unit housing and having a plurality of tabs and having a plurality of light emitting elements on the tabs

Methodology Applied
Scientific EffectLight emitting diode: Light Emitting Diode

Data Source

PatentEP2722589B1Angled emitter channel letter lighting
Publication Date: 2020.02.26 THE SLOAN COMPANY INC
  • EP2722589B1 patent drawingFigure 1~2
  • EP2722589B1 patent drawingFigure 3~7
  • EP2722589B1 patent drawingFigure 5~8

AI summary

The present embodiments provide channel letter lighting devices and/or systems. A lighting system, comprising a plurality of electrically connected lighting units (12), comprising conductors (14, 16) to provide an electrical signal to each of the units (12). Each of the lighting units (12) comprise a housing, a printed circuit board (PCB) (22) mounted within the housing (28) and having a plurality of tabs (60) and a plurality light emitting elements (18, 19, 20) on the tabs (60). The tabs (60) are angled in relation of the remainder of the PCB or housing. The electrical signal applied to the light emitting elements (18, 19, 20) causes them to emit light substantially away from said housing (28). The lighting system further comprises a sealant (36) within the housing filling cavities around the light emitting elements and the cavity around said PCB (22) and a mounting mechanism for mounting the unit to a structure.