LED STRING LIGHT ENGINE AND DEVICES THAT ARE ILLUMINATED BY THE STRING LIGHT ENGINE

• US 20090186516A1
• Filed: 04/01/2009
• Published: 07/23/2009
• Est. Priority Date: 07/13/2005
• Status: Active Grant

• Current Assignee: Current Lighting Solutions, LLC (f/k/a GE Lighting Solutions, LLC) (American Industrial Partners)
• Original Assignee: GE Lighting Solutions LLC (Savant Systems, LLC)
• Inventors: Brengartner, Ronald JR., Mrakovich, Matthew, Pan, Yu, Saha, Koushik, Nall, Jeffrey, Scarlato, Mark, Southard, Paul
• Granted Patent: US 7,677,914 B2
• Time in Patent Office: Days
• US Class Current: 439/417
• CPC Class Codes: F21S 4/10 with light sources attached to loose electric cables, e.g. Christmas tree lights
• CPC Class Codes: F21S 4/20 with light sources held by or within elongate supports
• CPC Class Codes: F21V 21/002 making direct electrical contact, e.g. by piercing F21V21/35 takes precedence
• CPC Class Codes: F21V 23/002 Arrangements of cables or conductors inside a lighting device, e.g. means for guiding along parts of the housing or in a pivoting arm
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 27/02 Cable inlets
• 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: H01R 12/675 with contacts having at least a slotted plate for penetration of cable insulation, e.g. insulation displacement contacts for round conductor flat cables
• CPC Class Codes: H01R 4/2433 one part of the base being movable to push the cable into the slot

Abstract

A string light engine includes a plurality of LEDs, a plurality of IDC connectors, and an insulated flexible conductor. Each IDC connector is in electrical communication with at least one of the plurality of LEDs and is operatively mechanically connected to at least one of the plurality of LEDs. The IDC connectors attach to the conductor.

Claims

1. A flexible LED string light engine comprising:

an insulated flexible electrical power conductor including at least two wires; and

a plurality of LED modules attached in spaced relationship along the length of the conductor, each of said modules comprising a support, at least one LED mounted on a first side of the support, and an IDC connector mounted on a second side of the support and electrically connected to the at least one LED, the IDC connector including an insulation piercing terminal to provide electrical connection between the electrical power conductor and the at least one LED;

wherein the electrical power conductor includes a twist such that the at least two wires of the power conductor reside generally in a first plane and generally in a second plane at a different location along the length of the electrical power conductor, the at least two wires reside in the second plane in an area where the IDC connector connects with the electrical power conductor and in the first plane spaced from the area where the IDC connector connects with the electrical power conductor.

2. The flexible LED string light engine of claim 1 wherein the support comprises a printed circuit board including a dielectric layer and circuitry.

3. The flexible LED string light engine of claim 1 wherein the twist is about a one-quarter twist.

4. The flexible LED string light engine of claim 1 wherein the at least two wires reside generally in the first plane adjacent each LED module.

5. The flexible LED string light engine of claim 1 further comprising one or more strain reliefs associated with the LED modules to limit forces on the flexible electrical power conductor external the LED modules from transferring to the portion of the flexible electrical power conductor connected to the IDC connector.

6. The flexible LED string light engine of claim 1 wherein each LED module comprises a housing surrounding the support and at least a portion of the flexible electrical power conductor.

7. The flexible LED string light engine of claim 6 wherein the housing is an overmolded housing.

8. The flexible LED string light engine of claim 6 wherein the flexible electrical power conductor includes about a one-quarter twist occurring in the housing.

9. The flexible LED string light engine of claim 1 wherein the second plane is substantially parallel to the second side of the support.

10. A flexible LED string light engine comprising:

at least two wires surrounded by an insulating material; and

a plurality of LED modules attached to the wires, each of said modules comprising a support and at least one LED mounted on a first side of the support and electrically connected to at least one of the wires;

wherein the at least two wires reside generally in a first plane in an area of electrical connection with the at least one LED and further reside generally in a second plane that is at an angle other than 180°

as compared to the first plane in an area adjacent the area of electrical connection.

11. The flexible LED string light engine of claim 10 further comprising an IDC terminal mounted on a second side of the support and electrically connected to the at least one LED, the IDC terminal to providing electrical connection between at least one of the wires and the at least one LED.

12. The flexible LED string light engine of claim 10 wherein the at least two wires and the insulating material comprise at least a portion of a continuous power conductor.

13. The flexible LED string light engine of claim 10 wherein the at least two wires are twisted between the first plane and the second plane.

14. The flexible LED string light engine of claim 10 wherein each LED module comprises a housing surrounding the support.

15. The flexible LED string light engine of claim 14 wherein the housing is an overmolded housing.

16. The flexible LED string light engine of claim 14 wherein the at least two wires are twisted on a first side of the electrical connection and are twisted again on a second side of the electrical connection.

17. A flexible LED string light engine comprising:

at least two wires each surrounded by an insulating material;

a plurality of LED modules attached to the wires, each of said modules comprising a PCB, at least one LED mounted on an upper side of the PCB, at least one IDC terminal depending from a lower side of the PCB and electrically connected to the at least one LED, and a housing surrounding the PCB;

wherein the at least one IDC terminal provides an electrical connection between at least one of the at least two wires and the at least one LED;

wherein the at least two wires twist about a one-quarter twist between where the IDC terminal connects with at least one of the wires and an area along the wires spaced from where the IDC terminal connects with at least one of the wires, the at least two wires reside generally in a connection plane that is parallel to a plane in which the PCB resides where the IDC terminal connects with at least one of the wires, and the at least two wires reside generally in another plane that is generally perpendicular to the connection plane at the area spaced from where the IDC terminal connects with at least one of the wires.

18. The flexible LED string light engine of claim 17 wherein the housing is an overmolded housing.

19. The flexible LED string light engine of claim 17 wherein the at least two wires and the insulating material comprise at least a portion of a continuous power conductor.

20. The flexible LED string light engine of claim 17 wherein the at least two wires are twisted on a first side of the IDC terminal and are twisted again on a second side of the IDC terminal.