INTERLOCKING LIGHT SHEET TILES

• US 20140226329A1
• Filed: 01/23/2014
• Published: 08/14/2014
• Est. Priority Date: 02/11/2013
• Status: Active Grant

• Current Assignee: NthDegree Technologies Worldwide Inc.
• Original Assignee: NthDegree Technologies Worldwide Inc.
• Inventors: Oraw, Bradley Steven, Meier, Marc Oliver
• Granted Patent: US 9,074,758 B2
• Time in Patent Office: Days
• US Class Current: 362/235
• CPC Class Codes: F21K 9/20 Light sources comprising attachment means
• CPC Class Codes: F21K 9/64 using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
• CPC Class Codes: F21V 21/005 for several lighting devices in an end-to-end arrangement, i.e. light tracks
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00

Abstract

A system of interlocking LED panel tiles includes a first tile having at least one layer of light emitting diodes (LEDs) provided on a substrate, where the substrate is mounted on a substantially rectangular supporting plate having interlocking features. The substrate overlaps the interlocking features. The first tile has a set of positive and negative voltage conductors running between the two sets of opposite edges of the tile as busses. Multiple identical tiles are provided. Each tile has the interlocking features along their edges that firmly physically connect to abutting tiles to create a lamp having any pattern of tiles selected by the user. By interlocking the tiles, the positive and negative conductors are automatically connected to electrically connect the LEDs in the tiles in parallel, and the interlocking features are hidden by the overlying substrate. Additional conductors may be used to provide greater interconnection flexibility.

Claims

1. An illumination structure comprising:

a first tile comprising;

at least one layer of light emitting diodes (LEDs) provided on a top surface of a first substrate;

a substantially rectangular supporting plate, the supporting plate having a first edge, a second edge opposite the first edge, a third edge, and a fourth edge opposite the third edge, wherein a bottom surface of the first substrate is affixed to a top surface of the supporting plate;

a positive voltage conductor running between the first edge and the second edge and between the third edge and the fourth edge;

a negative voltage conductor running between the first edge and the second edge and between the third edge and the fourth edge;

first edge features along the first edge and the third edge, the first edge features having a protruding neck portion and an expanded portion connected to the first tile by the neck portion, the first edge features including at least a first electrical contact electrically coupled to at least one of the positive voltage conductor and the negative voltage conductor;

second edge features along the second edge and the fourth edge, the second edge features having an indented neck portion and an expanded indented portion, the second edge features including at least a second electrical contact electrically coupled to at least one of the positive voltage conductor and the negative voltage conductor,

wherein edges of the first substrate overlie the second edge features along the second edge and the fourth edge;

a second tile identical to the first tile,

wherein the first edge features of the first tile interlock with the second edge features of the second tile to secure the first tile to the second tile when the first tile and the second tile are abutting,

wherein the edges of the first substrate cover the interlocked first edge features and the second edges features after the first tile is interlocked with the second tile,

wherein interlocking the first tile to the second tile causes the positive voltage conductor of the first tile to contact the positive voltage conductor of the second tile, and causes the negative voltage conductor of the first tile to contact the negative voltage conductor of the second tile such that at least some of the LEDs in the first tile are electrically connected to at least some of the LEDs in the second tile upon the first tile being interlocked to the second tile.

2. The structure of claim 1 further comprising:

the at least one layer of LEDs having been printed on the first surface top surface of the first substrate using an LED ink; and

the at least one layer of LEDs having conductive first surface electrodes connected to conductive second surface electrodes, the second surface electrodes electrically contacting the positive voltage conductor and the negative voltage conductor on the supporting plate.

3. The structure of claim 2 wherein the positive voltage conductor and the negative voltage conductor are flat conductors formed on a top side of the supporting plate, wherein the flat conductors are sandwiched between the substrate and the supporting plate and contact the second surface electrodes.

4. The structure of claim 1 wherein the positive voltage conductor and the negative voltage conductor form flat strips across the supporting plate.

5. The structure of claim 1,

wherein the positive voltage conductor terminates in some of the first edge features and some of the second features of the first tile and the second tile, and

wherein the negative voltage conductor terminates in others of the first features and others of the second edge features of the first tile and the second tile,

such that interlocking the first tile to the second tile causes the positive voltage conductor in one first feature of the first tile to contact the positive voltage conductor in one second feature of the second tile, and causes the negative voltage conductor in another first feature of the first tile to contact the negative voltage conductor in another second feature of the second tile.

6. The structure of claim 1 wherein the first edge features comprise tabs extending from the supporting plate, and wherein the second edge features comprise indentations in the supporting plate.

7. The structure of claim 1,

wherein the supporting plate is rectangular, wherein the first edge and the second edge are longer than the third edge and the fourth edge, and

wherein a pitch of the first features along first edge is different from a pitch of the first features along the third edge, such that only the first edge of the first tile can be interlocked to the second edge of the second tile, and only the second edge of the first tile can be interlocked to the first edge of the second tile, such that only edges of identical lengths can be interlocked.

8. The structure of claim 1 wherein the LEDs in the first tile are electrically connected in parallel to the LEDs in the second tile upon the first tile being interlocked to the second tile.

9. The structure of claim 1 wherein the LEDs in the first tile are electrically connected in series to the LEDs in the second tile upon the first tile being interlocked to the second tile.

10. The structure of claim 1 further comprising additional tiles identical to the first tile and the second tile, wherein the first tile, the second tile, and the additional tiles are interconnected in a two-dimensional pattern.

11. The structure of claim 10 wherein the supporting plate and the at least one layer of LEDs are flexible to allow the two-dimensional pattern to contour to a curved mounting surface.

12. The structure of claim 10 wherein the two-dimensional pattern comprises an overhead lamp for general illumination.

13. The structure of claim 1 further comprising a wavelength conversion layer for converting light from the LEDs into white light.

14. The structure of claim 1 wherein the at least one layer of LEDs comprises LEDs mounted in strips on a substrate, wherein the LEDs in a single strip are connected in parallel, and the LEDs in two or more different strips are connected in series.

15. The structure of claim 1 wherein the positive voltage connector and the negative voltage connector run along a surface of the supporting plate.

18. The structure of claim 1 wherein the indented second edge features along the second edge and fourth edge of the supporting plate are entirely covered by the first substrate, such that when the first tile and the second tile are interlocked, an edge of the first substrate of the first tile and an edge of the first substrate of the second tile oppose one another, and the first substrate of the first tile overlies the interlocked first edge features and second edge features.

19. The structure of claim 18 wherein the edge of the first substrate of the first tile and the edge of the first substrate of the second tile abut to obscure the interlocked first edge features and second edge features.

16. A lighting method using a plurality of identical tiles containing light emitting diodes (LEDs), the plurality of tiles including a first tile comprising at least one layer of LEDs provided on a top surface of a first substrate, a substantially rectangular supporting plate, the supporting plate having a first edge, a second edge opposite the first edge, a third edge, and a fourth edge opposite the third edge, wherein a bottom surface of the first substrate is affixed to a top surface of the supporting plate, a positive voltage conductor running between the first edge and the second edge and between the third edge and the fourth edge, a negative voltage conductor running between the first edge and the second edge and between the third edge and the fourth edge, first edge features along the first edge and the third edge, the first edge features having a protruding neck portion and an expanded portion connected to the first tile by the neck portion, the first edge features including at least a first electrical contact electrically coupled to at least one of the positive voltage conductor and the negative voltage conductor, and second edge features along the second edge and the fourth edge, the second edge features having an indented neck portion and an expanded indented portion, the second edge features including at least a second electrical contact electrically coupled to at least one of the positive voltage conductor and the negative voltage conductor, wherein edges of the first substrate overlie the second edge features along the second edge and the fourth edge, the plurality of tiles also including a second tile identical to the first tile, the method comprising:

interlocking the first edge features of the first tile with the second edge features of the second tile to secure the first tile to the second tile when the first tile and the second tile are abutting,

wherein interlocking the first tile to the second tile causes the positive voltage conductor of the first tile to contact the positive voltage conductor of the second tile, and causes the negative voltage conductor of the first tile to contact the negative voltage conductor of the second tile such that at least some of the LEDs in the first tile are electrically connected to at least some of the LEDs in the second tile upon the first tile being interlocked to the second tile,

wherein the indented second edge features along the second edge and fourth edge of the supporting plate are entirely covered by the first substrate, such that when the first tile and the second tile are interlocked, an edge of the first substrate of the first tile and an edge of the first substrate of the second tile oppose one another, and the first substrate of the first tile overlies the interlocked first edge features and second edge features.

17. The method of claim 16 wherein the first edge features comprise tabs extending from the supporting plate, and wherein the second edge features comprise indentations in the supporting plate.