Compact, flexible, LED array

• US 6,371,637 B1
• Filed: 01/03/2000
• Issued: 04/16/2002
• Est. Priority Date: 02/26/1999
• Status: Expired due to Term

• Current Assignee: Radiantz Incorporated
• Original Assignee: Radiantz Incorporated
• Inventors: Valentine, Mitchell A., Atchinson, Geoffrey P.
• Primary Examiner(s): O'Shea, Sandra
• Assistant Examiner(s): WARD, JOHN A
• Application Number:
  US09/477,637
• Time in Patent Office: 834 Days
• Field of Search: 362/240, 362/252, 362/249, 362/295, 362/800, 362/293
• US Class Current: 362/555
• CPC Class Codes: F21S 4/26 of rope form, e.g. LED lighting ropes, or of tubular form
• CPC Class Codes: F21S 9/02 the power supply being a battery or accumulator
• CPC Class Codes: F21V 19/005 by permanent fixing means, e.g. gluing, riveting or embedding in a potting compound
• CPC Class Codes: F21V 21/0808 Adhesive means
• CPC Class Codes: F21V 21/096 Magnetic devices
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A flexible, high density, low profile lighting system includes a flexible printed circuit board substrate which is adapted to support and electrically interconnect surface mount electronic components. Plurality of surface mount light emitting diodes is mounted on the substrate so as to define a conformably bendable lighting array configured for mounting upon surfaces with compound curvature. Each of the surface mount light emitting diodes has a footprint of 5 mm², or less, and, when mounted adjacent and in contact with one another defines a light intensity output of from about 2 to about 20 candles per cm².

Claims

1. A flexible, low profile lighting system, comprising:

a flexible printed circuit board substrate, the substrate adapted to support and electrically interconnect surface mount electronic components, the printed circuit board substrate flexible through at least two axes of rotation;

a plurality of surface mount light emitting diodes; and

wherein the plurality of light emitting diodes are surface mounted on the flexible printed circuit board substrate, so as to define a conformably bendable lighting array configured for mounting upon surfaces with compound curvature substrate, the array outputting a uniform light intensity of at least 2000 millicandles per square centimeter.

2. The lighting system according to claim 1, wherein the flexible printed circuit board substrate comprises a flex circuit, the flex circuit pre-manufactured to define mounting locations for each of the plurality of surface mount light emitting diodes.

3. The lighting system according to claim 1, wherein the flexible printed circuit board substrate comprises a rigid flex circuit, the rigid flex circuit pre-manufactured to define mounting locations for each of the plurality of the surface mount light emitting diodes.

4. The lighting system according to claim 1, wherein each of the plurality of light emitting diodes is disposed on the flexible printed circuit board substrate in a linear array, each of the plurality of surface mount light emitting diodes emitting a light intensity of at least 100 millicandles, evaluated at each diode'"'"'s optical axis.

5. The lighting system according to claim 1, wherein the plurality of surface mount light emitting diodes are disposed on the flexible printed circuit board substrate at a density of approximately 5 light emitting diodes per centimeter.

6. The lighting system according to claim 4, wherein each of the plurality of surface mount light emitting diodes has a length dimension and a width dimension, and wherein the length dimension is no greater than about 3 mm and the width dimension is no greater than about 2 mm.

7. A lighting system according to claim 4, wherein the length dimension is no greater than about 2 mm and the width dimension is no greater than about 1.5 mm.

8. The lighting system according to claim 4, wherein each of the plurality of surface mount light emitting diodes are surface mounted on the flexible printed circuit board substrate so as to contact at least one adjacent surface mount light emitting diode.

9. The lighting system according to claim 4, wherein the plurality of surface mount light emitting diodes are configured in an array, the array comprising regular sets of series-connected diodes, the series-connected sets coupled in parallel fashion to one another, the number of light emitting diodes comprising a series-connected set defining a forward voltage drop for the set, the forward voltage drop, in turn, defining a supply voltage value sufficient to activate the diodes of the series-connected set.

10. The lighting system according to claim 9, wherein each diode has a forward drop in the range of from about 1.7 to about 2.0 volts.

11. The lighting system according to claim 10, wherein each series connected set comprises 6 surface mount light emitting diodes, coupled in series fashion with a resistor element, each series-connected set operable by a 12.0 volt power supply.

12. The lighting system according to claim 9, wherein each diode has a forward drop of from about 4.0 to about 5.0 volts.

13. The lighting system according to claim 12, wherein each series connected set comprises 6 surface mount light emitting diodes, coupled in series fashion with a resistor element, each series-connected set operable by a 30 volt power supply.

14. A flexible, low profile lighting system, comprising:

a flexible printed circuit board substrate, the substrate adapted to support and electrically interconnect surface mount electronic components;

a plurality of surface mount light emitting diodes, wherein the plurality of light emitting diodes are surface mounted on the flexible printed circuit board substrate, the array outputting a uniform light intensity of at least 2000 millicandles per square centimeter; and

a flexible housing enclosing the flexible printed circuit board substrate and the plurality of surface mount light emitting diodes.

15. The lighting system according to claim 14, wherein the flexible printed circuit board substrate is selected from the group consisting of a flex circuit and a rigid flex circuit, each flexible printed circuit board substrate pre-manufactured to define mounting locations for each of the plurality of surface mount light emitting diodes.

16. The lighting system according to claim 14, wherein the flexible housing is colored so as to impart a color component to light emitted from the plurality of surface mount light emitting diodes.

17. A lighting system according to claim 14, wherein the housing is formed of a clear material, each of the plurality of surface mount light emitting diodes emitting light at a particular wavelength so as to define a color.

18. The lighting system according to claim 14, wherein each of the plurality of surface mount light emitting diodes emits a light intensity of at least 100 millicandles, evaluated at each diode'"'"'s optical axis.

19. The lighting system according to claim 18, wherein each of the plurality of surface mount light emitting diodes emits a light intensity of at least 1000 millicandles, evaluated at each diode'"'"'s optical axis.

20. A flexible, low profile lighting system, comprising:

a flexible printed circuit board substrate, having a first end, a second end, and an axis extending between the first and second end, the flexible printed circuit board substrate further including a width dimension measured in a direction transverse to the axis that is less than 5 mm; and

a plurality of surface mount light emitting diodes, disposed on the flexible printed circuit board substrate such that the plurality of diodes emits a uniform light intensity of from about 2000 to about 20,000 millicandles per square centimeter.

21. The lighting system according to claim 20, wherein the flexible printed circuit board substrate is chosen from the group consisting of a flex circuit and a rigid flex circuit, the flexible printed circuit board substrate pre-manufactured to define mounting locations for each of the plurality of the surface mount light emitting diodes.

22. The lighting system according to claim 21, wherein each of the plurality of surface mount light emitting diodes emits light at a viewing angle of at least 30 degrees.

23. The lighting system according to claim 22, wherein each of the plurality of surface mount light emitting diodes emits light at a viewing angle of at least 120 degrees.