Pixilated LED Light Source for Channel Letter Illumination

• US 20100117560A1
• Filed: 01/14/2010
• Published: 05/13/2010
• Est. Priority Date: 10/03/2006
• Status: Active Grant

• Current Assignee: Epistar Corporation (Ennostar, Inc.)
• Original Assignee: CAO Group, Inc.
• Inventors: Cao, Densen
• Granted Patent: US 9,297,525 B2
• Time in Patent Office: Days
• US Class Current: 315/294
• CPC Class Codes: F21K 9/20 Light sources comprising attachment means
• CPC Class Codes: F21S 2/005 of modular construction
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 31/04 Provision of filling media
• CPC Class Codes: F21Y 2113/13 comprising an assembly of point-like light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G09F 9/33 being semiconductor devices, e.g. diodes

Abstract

The present invention is an LED module for channel letter illumination utilizing multiple through-hole LEDs in a pixel formation as a light source where one surface mounted LED or other forms of LEDs were previously used. The use of a number of small through-hole LEDs ideally requires that a beam angle between and including 15° and 180° in vertical and horizontal directions, respectively, be utilized. When multiple light sources are used on a module, the distance between light sources is to be between 20 mm and 1 cm. The use of several smaller LEDs reduces the current needed to generate light of appropriate intensity and, thus reduces energy cost and heat generation. The use of smaller LEDs also assists in excess heat dissipation.

Claims

1. A light source module for providing light to a channel letter device, comprising:

a first plurality of through-hole LEDs;

a casing, the casing having a first surface and an attachment element configured for attaching the casing to the channel letter device;

the first surface having a length and a first plurality of through-holes extending through the first surface, the first plurality of through-holes being arranged among a sequence of pixel groups;

each one of the sequence of pixel groups having a cluster of through-holes confined to a corresponding one of a sequence of regions set apart a distance from one another along the length of the first surface, wherein the number “

M”

of through-holes in each cluster is greater than or equal to 3 and wherein the number “

N”

of regions in the sequence of regions is greater than or equal to 2;

each one of the sequence of pixel groups further having a second plurality of through-hole LEDs, each one of the second plurality of through-hole LEDs extending through a corresponding one of the cluster of through-holes, wherein the second plurality of through-hole LEDs equals “

M”

in number; and

a printed circuit board housed within the casing, each one of said first plurality of through-hole LEDs being electrically connected to said printed circuit board.

2. The light source module of claim 1, the module having a driving circuit connected to the printed circuit board to regulate the current and voltage to the first plurality of LEDs.

3. The light source module of claim 2, each one of the first plurality of through-hole LEDs being elliptically shaped.

4. The light source module of claim 3, each one of the first plurality of through-hole LEDs has a diameter equal to about 5 mm.

5. The light source module of claim 4, wherein each one of the clusters of through-holes is arranged in a pattern duplicating a shape chosen from the set of shapes consisting of:

stars, asterisks, triangles, squares, rectangles, ellipses and arcs.

6. The light source module of claim 5, wherein each one of the first plurality of through-hole LEDs has a color selected from the set of colors consisting of:

red, green, blue, yellow, purple and white.

7. The light source module of claim 6, wherein the printed circuit board and first plurality of through-hole LEDs are coated with a waterproof epoxy coating.

8. The light source module of claim 1, each one of the first plurality of through-hole LEDs being elliptically shaped.

9. The light source module of claim 1, wherein each one of the first plurality of through-hole LEDs has a diameter of about 5 mm.

10. The light source module of claim 1, wherein each one of the clusters of through-holes is arranged in a pattern duplicating a shape chosen from the set of shapes consisting of:

stars, asterisks, triangles, squares, rectangles, ellipses and arcs.

11. The light source module of claim 1, wherein each one of the first plurality of through-hole LEDs has a color selected from the set of colors consisting of:

red, green, blue, yellow, purple and white.

12. The light source of claim 1, wherein the set-apart distance between each region in the sequence of regions is between about 20 mm to about 1 cm.

13. The light source module of claim 1, wherein the printed circuit board and first plurality of through-hole LEDs are coated with a waterproof epoxy coating.

14. A light source module for providing light to a channel letter device, comprising:

a first plurality of through-hole LEDs;

a casing, the casing being enclosed and having a first surface for attaching the first plurality of through-hole LEDs;

attachment means for securing the light source module to a wall of the channel letter device;

the first surface having a length and a first plurality of through-holes extending through the first surface, the first plurality of through-holes being arranged among a sequence of pixel groups;

each one of the sequence of pixel groups having a cluster of through-holes confined to a corresponding one of a sequence of regions set apart a distance from one another along the length of the first surface, wherein the number “

M”

of through-holes in each cluster is greater than or equal to 3 and wherein the number “

N”

of regions in the sequence of regions is greater than or equal to 2;

each one of the sequence of pixel groups further having a second plurality of through-hole LEDs, each one of the second plurality of through-hole LEDs extending through a corresponding one of the cluster of through-holes, wherein the second plurality of through-hole LEDs equals “

M”

in number;

a printed circuit board housed within the casing, each one of said first plurality of through-hole LEDs being electrically connected to said printed circuit board;

epoxy coating applied to the printed circuit board and the first plurality of through-hole LEDs; and

connection wires electrically connected to the printed circuit board and extending out of the casing for supplying power to the light source module.

15. A light source module for providing light to a channel letter device, comprising:

a first plurality of through-hole LEDs;

a casing, the casing being enclosed and having a first surface for attaching the first plurality of through-hole LEDs;

attachment means for securing the light source module to a wall of the channel letter device;

the first surface having a length and a first plurality of through-holes extending through the first surface, the first plurality of through-holes being arranged among a sequence of pixel groups;

each one of the sequence of pixel groups having a cluster of through-holes confined to a corresponding one of a sequence of regions set apart a distance from one another along the length of the first surface, wherein the number “

M”

of through-holes in each cluster is greater than or equal to 3 and wherein the number “

N”

of regions in the sequence of regions is greater than or equal to 2;

each one of the sequence of pixel groups further having a second plurality of through-hole LEDs, each one of the second plurality of through-hole LEDs extending through a corresponding one of the cluster of through-holes, wherein the second plurality of through-hole LEDs equals “

M”

in number;

a printed circuit board housed within the casing, each one of said first plurality of through-hole LEDs being electrically connected to said printed circuit board;

epoxy coating applied to the printed circuit board and the first plurality of through-hole LEDs;

connection wires electrically connected to the printed circuit board and extending out of the casing for supplying power to the light source module; and

wherein said first plurality of through-hole LEDs is equal in number to M*N.