Flexible surface lighting system with replaceable led module

• US 20050201091A1
• Filed: 03/10/2004
• Published: 09/15/2005
• Est. Priority Date: 03/10/2004
• Status: Active Grant

• Current Assignee: Eric W. Kramer, Kiem Lee, Thomas T. Nagano
• Original Assignee: Eric W. Kramer, Kiem Lee, Thomas T. Nagano
• Inventors: Nagano, Thomas T., Lee, Kiem, Kramer, Eric W.
• Granted Patent: US 7,144,139 B2
• Time in Patent Office: Days
• US Class Current: 362/249.10
• CPC Class Codes: E04F 19/06 specially designed for securing panels or masking the edges of wall- or floor-covering elements E04F19/022, E04F19/026 and E04F19/04 take precedence
• CPC Class Codes: E04F 2011/1048 with lighting means
• CPC Class Codes: F21S 4/20 with light sources held by or within elongate supports
• CPC Class Codes: F21S 6/001 being candle-shaped with varying lighting effect of simulating flames F21S10/04; string of light sources F21S4/00
• CPC Class Codes: F21S 8/032 the surface being a floor or like ground surface, e.g. pavement
• CPC Class Codes: F21V 15/013 the housing being an extrusion
• CPC Class Codes: F21V 21/002 making direct electrical contact, e.g. by piercing F21V21/35 takes precedence
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21V 33/006 General building constructions or finishing work for buildings, e.g. roofs, gutters, stairs or floors; Garden equipment; Sunshades or parasols
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

The present invention is a flexible surface lighting system with replaceable LED module. In particular, the present invention is directed to a system with a set of soft flanges and a more rigid base with a channel for electrical leads and lighting. A preferred embodiment has a base extrusion of polyvinyl chloride (PVC) of 89-98 Duro on the Shore OO scale with a channel. The base is connected, on opposite sides of the channel, to a first flange extrusion and a second flange extrusion of PVC with a hardness of preferably of 90 Duro. Electrical leads are placed in the channel. A lens is inserted into the channel over the leads. A replaceable LED module having a circuit board secured to a module base is attached to the leads. The circuit board preferably has a gasket, an LED and two contact teeth that make electrical contact with the leads.

Claims

1. A flexible surface lighting system comprising:

a base having a first hardness and a channel having opposing sides and a mount surface;

a first flange and a second flange having a second hardness, attached to opposing sides of the channel on the base; and

,

a lens inserted into the channel and between the first and second flanges.

2. The flexible surface lighting system of claim 1 further comprising a lens buffer attached to the mount surface and supporting the lens.

3. The flexible surface lighting system of claim 2 where the lens buffer comprises a third hardness.

4. The flexible surface lighting system of claim 1 where the first hardness is at least 94 Duro on the Shore OO scale.

5. The flexible surface lighting system of claim 1 where the second hardness is less than the first hardness.

6. A flexible surface lighting system comprising:

a base extrusion of polyvinyl chloride having a first hardness and a channel having opposing sides and a mount surface;

a first flange extrusion and a second flange extrusion of polyvinyl chloride having a second hardness, attached to opposing sides of the channel on the base extrusion; and

,

a lens inserted into the channel and between the first and second flange extrusions.

7. The flexible surface lighting system of claim 6 where the first hardness is from 89-98 Duro on the Shore OO scale.

8. The flexible surface lighting system of claim 7 where the second hardness is less than the first hardness.

9. The flexible surface lighting system of claim 6 further comprising a butt seal inserted in the channel.

10. The flexible surface lighting system of claim 6 where the base extrusion, first flange extrusion and second flange extrusion are co-extruded.

11. A flexible surface lighting system comprising:

a base extrusion having a first hardness and a channel having opposing sides and a mount surface;

at least two electrical leads in the channel;

a first flange extrusion and a second flange extrusion of polyvinyl chloride having a second hardness, attached to opposing sides of the channel on the base extrusion;

a lens inserted into the channel over the at least two leads and between the first and second flange extrusions; and

,

an LED module comprising a circuit board secured to a module base;

where the LED module is attached to at least two electrical leads in the channel below the lens;

the circuit board having an LED and at least two contact teeth whereby each contact tooth makes electrical contact with one of the at least two electrical leads.

12. The flexible surface lighting system of claim 11 where the at least two electrical leads further comprise a non-conductive sheath and where each contact tooth pierces the non-conductive sheath to make electrical contact with one of the at least two electrical leads.

13. The flexible surface lighting system of claim 11 where a gasket with a thickness covers a side of the circuit board and where the at least two contact teeth traverse the thickness of the gasket to make electrical contact with the at least two electrical leads.

14. The flexible surface lighting system of claim 11 where the module base further comprises a set of snap tabs whereby the circuit board is secured to the module base by snapping the circuit board onto the base by the set of snap tabs.

15. The flexible surface lighting system of claim 14 where the circuit board further comprises a first support length and a second support length;

where the first support length differs in length from the second support length; and

where the set of snap tabs further comprise a first set of snap tabs separated by a first distance corresponding to the first support length and a second set of snap tabs separated by a second distance corresponding to the second support length.