Flexible high-power LED lighting system
First Claim
1. A string light engine comprising:
- a flexible power cord comprising an electrical wire and an insulating material for the wire;
a heat sink attached to the power cord;
an IDC terminal inserted through the insulating material and in electrical communication with the wire;
a PCB at least partially received in the heat sink, the PCB including a first surface having circuitry and a second surface opposite the first surface, the circuitry being in electrical communication with the IDC terminal, the second surface being abutted against a surface of the heat sink so that heat is transferred from the LED into the heat sink;
an LED mounted to the first surface of the PCB and in electrical communication with the circuitry; and
a male terminal extending from the first surface of the PCB and in electrical communication with the circuitry of the PCB, and the IDC terminal includes a portion that receives the male terminal to mechanically fasten the IDC terminal to the PCB and to provide for electrical communication between the circuitry of the PCB and the wire.
8 Assignments
0 Petitions
Accused Products
Abstract
A string light engine includes a flexible power cord, a heat sink, an IDC terminal, a PCB, and an LED. The flexible power cord includes an electrical wire and an insulating material for the wire. The heat sink attaches to the power cord. The IDC terminal is inserted through the insulating material and electrically communicates with the wire. The PCB is at least partially received in the heat sink. The PCB includes a first surface having circuitry and a second surface opposite the first surface. The circuitry is in electrical communication with the IDC terminal. The second surface is abutted against a surface of the heat sink so that heat is transferred from the LED into the heat sink. The LED mounts to the first surface of the PCB and is in electrical communication with the circuitry.
244 Citations
21 Claims
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1. A string light engine comprising:
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a flexible power cord comprising an electrical wire and an insulating material for the wire; a heat sink attached to the power cord; an IDC terminal inserted through the insulating material and in electrical communication with the wire; a PCB at least partially received in the heat sink, the PCB including a first surface having circuitry and a second surface opposite the first surface, the circuitry being in electrical communication with the IDC terminal, the second surface being abutted against a surface of the heat sink so that heat is transferred from the LED into the heat sink; an LED mounted to the first surface of the PCB and in electrical communication with the circuitry; and a male terminal extending from the first surface of the PCB and in electrical communication with the circuitry of the PCB, and the IDC terminal includes a portion that receives the male terminal to mechanically fasten the IDC terminal to the PCB and to provide for electrical communication between the circuitry of the PCB and the wire. - View Dependent Claims (2, 3, 4)
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5. A method of manufacturing a string light engine, the method comprising:
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inserting an IDC terminal into a flexible power cord; mechanically attaching the IDC terminal to an electrical connector disposed on a first surface of a PCB, wherein the electrical connector comprises at least one of an electrical receptacle and a male terminal and the IDC terminal provides electrical communication between the flexible power cord and an LED mounted on the first surface of the PCB; inserting the PCB into a heat sink to provide a thermal path for heat to dissipate from the LED into the heat sink. - View Dependent Claims (6, 7, 8)
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9. A string light engine comprising:
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a flexible power cord comprising a first wire, a second wire and insulating material for the wires; and a plurality of LED modules attached to the power cord, each module comprising; a thermally conductive PCB having circuitry printed on a first surface of the PCB; an LED mounted to the first surface of the PCB and in electrical communication with the circuitry; a heat conductive first housing portion receiving the PCB; an electrically insulative second housing portion connected to the first housing portion, the second housing portion retaining the PCB against a surface of the first housing portion; and an IDC terminal operatively connected to the PCB and inserted into the insulating material of the power cord such that the LED is in electrical communication with the first wire via the IDC terminal. - View Dependent Claims (10, 11, 12, 13, 14, 15)
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16. A string light engine comprising:
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a flexible power cord comprising an electrical wire and an insulating material for the wire; a heat sink attached to the power cord; an IDC terminal inserted through the insulating material and in electrical communication with the wire; a PCB at least partially received in the heat sink, the PCB including a first surface having circuitry and a second surface opposite the first surface, the circuitry being in electrical communication with the IDC terminal, the second surface being disposed adjacent a surface of the heat sink so that heat is transferred from the LED into the heat sink; an LED mounted to the first surface of the PCB and in electrical communication with the circuitry; and a thermally conductive potting material contacting at least a portion of the first surface of the PCB and at least a portion of the heat sink for potting the PCB inside the heat sink and providing a thermal path from the first surface of the PCB into the heat sink. - View Dependent Claims (17, 18, 19, 20, 21)
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Specification