LED module and system of LED modules with integral branch connectors

• US 20060215398A1
• Filed: 03/28/2005
• Published: 09/28/2006
• Est. Priority Date: 03/28/2005
• Status: Active Grant

• Current Assignee: U.S. Led, Inc.
• Original Assignee: U.S. Led, Inc.
• Inventors: Farmer, Ronald, Smit, Christiaan
• Granted Patent: US 7,377,669 B2
• Time in Patent Office: Days
• US Class Current: 362/227
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21S 2/005 of modular construction
• CPC Class Codes: F21S 4/10 with light sources attached to loose electric cables, e.g. Christmas tree lights
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G09F 13/22 electroluminescent electroluminescent light sources per se H05B33/00
• CPC Class Codes: G09F 9/33 being semiconductor devices, e.g. diodes
• CPC Class Codes: H01R 13/514 composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
• CPC Class Codes: H01R 13/717 with built-in light source
• CPC Class Codes: H01R 13/7175 Light emitting diodes (LEDs)
• CPC Class Codes: H05K 1/117 Pads along the edge of rigid circuit boards, e.g. for pluggable connectors
• CPC Class Codes: H05K 1/118 specially for flexible printed circuits, e.g. using folded portions
• CPC Class Codes: H05K 1/148 Arrangements of two or more hingeably connected rigid printed circuit boards, i.e. connected by flexible means
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 3/365 by abutting, i.e. without alloying process
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

An LED module provides one or more LEDs mounted in a circuit board assembly, which circuit board assembly includes first and second conductive areas located at each end of the circuit board assembly to attach to electrical connectors mounted on branch wiring to extend to branch LED modules.

Claims

1. An LED module for mounting and powering one or more LEDs for use in lighting displays, comprising:

(a) an LED circuit board assembly comprised of multiple layers including first and second conductive portions of different electrical potential;

(b) one or more LEDs electrically connected to each of said first and second conductive portions;

(c) each of said conductive portions including first and second conductive areas for electrical connection to wire connectors for electrically interconnecting said LED module to adjacently positioned LED modules to form a main string of LED modules; and

(d) each of said conductive portions further including a third conductive area for electrical connection to another LED module.

2. The structure set forth in claim 1, wherein:

said LED circuit board assembly is generally rectangular and includes first and second end portions.

3. The structure set forth in claim 2, wherein:

said third conductive area of each of said first and second conductive portions extends outwardly from said first and second end portions of said generally rectangular board.

4. The structure set forth in claim 1, wherein:

said first, second, and third conductive areas of each conductive portion are located on a common conductive layer.

5. The structure set forth in claim 4, wherein:

said common conductive layer includes a conductive layer of copper.

6. The structure set forth in claim 1, including:

a first branch wire assembly for connection to said third conductive area in said first conductive portion; and

a second branch wire assembly for connection to said third conductive area in said second conductive portion.

7. The structure set forth in claim 1, wherein:

said third conductive areas of each LED module form a protruding tab adapted to receive an electrical connector mounted in a branch wire.

8. The structure set forth in claim 6, including

said first and second branch wire assemblies extending into electrical connection with another LED module in order to form a branch string of LEDs extending from said LED module in said main string of LED modules.

9. A plurality of LEDs mounted on a reel for use in creating a sign or other display, comprising:

(a) a reel or other dispenser which mounts a plurality of LED modules which are interconnected into a dispensing string wherein each LED module includes,

(1) an LED circuit board assembly comprised of multiple layers including first and second conductive portions of different electrical potential;

(2) one or more LEDs electrically connected to each of said first and second conductive portions;

(3) each of said conductive portions including first and second conductive areas for electrical connection to wire connectors for electrically interconnecting said LED module to adjacently positioned LED modules to form a main string of LED modules; and

(4) each of said conductive portions further including a third conductive area, each of said third conductive areas protruding from said board in order to be electrically connected to a branch wire.

10. The structure set forth in claim 9, wherein:

said LED circuit board assembly is generally rectangular and includes first and second end portions.

11. The structure set forth in claim 10, wherein:

said third conductive area of each of said first and second conductive portions extends outwardly from said first and second end portions of said generally rectangular board.

12. The structure set forth in claim 11, wherein:

said first, second, and third conductive areas of each conductive portion are located on a common conductive layer.

13. The structure set forth in claim 12, wherein:

said common conductive layer includes a conductive layer of copper.

14. The structure set forth in claim 9, wherein:

said plurality of LED modules mounted on said reel or other dispenser includes a first LED module forming a first end of a string of LED modules and a second LED module forming a second end of string of LEDs, and an intermediate group of LED modules interconnected to the first and second LED modules.

15. An LED module for mounting and powering one or more LEDs for use in lighting displays, comprising:

(a) an LED circuit board assembly comprised of multiple layers including first and second conductive portions of different electrical potential;

(b) one or more LEDs electrically connected to each of said first and second conductive portions;

(c) each of said conductive portions including first and second conductive areas for electrical connection to wire connectors for electrically connecting said LED module to adjacently positioned LED modules to form a main string of LED modules; and

(d) each of said conductive portions further including a third conductive area for electrical connection to an LED module not in a main string of LED modules.

16. A plurality of LEDs mounted on a reel for use in creating a sign or other display comprising:

(a) a reel or other dispenser which mounts a plurality of LED modules which are interconnected into a dispensing string wherein each LED module includes,

(1) an LED circuit board assembly comprised of multiple layers including first and second conductive portions of different electrical potentials;

(2) one or more LEDs electrically connected to each of said first and second conductive portions;

(3) each of said conductive portions including first and second conductive areas for electrical connection to wire connectors for electrically connecting said LED modules to adjacently positioned LED modules to form a main string of LED modules; and

(4) each of said conductive portions further including a third conductive area for electrical connection to branch wiring extending to a branch LED module.