Dual LED board layout for lighting systems

• US 7,365,991 B2
• Filed: 04/14/2006
• Issued: 04/29/2008
• Est. Priority Date: 04/14/2006
• Status: Active Grant

• Current Assignee: ABL IP Holding LLC (Acuity Brands, Inc.)
• Original Assignee: Renaissance Lighting Incorporated (Acuity Brands, Inc.)
• Inventors: Rains, Jack C. Jr., Aldrich, Matthew H.
• Primary Examiner(s): Dinh; Tuan T.
• Assistant Examiner(s): SOON, SHELDON STEWART
• Application Number:
  US11/403,840
• Publication Number:
  US 20070242441A1
• Time in Patent Office: 746 Days
• Field of Search: 361/600, 361/681, 361/808, 361/810, 361/822, 361/782, 362/240, 362/800, 362/249, 362/252, 362/612, 362/231, 257/79, 257/80, 257/88, 257/94, 257/98, 257/99, 257/100
• US Class Current: 361/783
• CPC Class Codes: H05K 1/0295 adapted for choosing between different types or different locations of mounted components
• CPC Class Codes: H05K 1/111 Pads for surface mounting, e.g. lay-out
• CPC Class Codes: H05K 2201/09954 More mounting possibilities, e.g. on same place of PCB, or by using different sets of edge pads
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 2201/10651 Component having two leads, e.g. resistor, capacitor
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

Circuit boards for lighting systems have identical LED landing zones printed on the board. Each zone includes at least two sets of LED contact pads. One pad set is configured to mate with contacts of an LED of a first structural type, e.g. from a first product line or manufacturer. The other pad set is configured to mate with contacts of an LED of a second type, e.g. from a different product line or manufacturer. The layout may enable an easy system re-design, e.g. to shift from one type of LED to another. Alternatively, the layout may enable one system to use LEDs of the two different types in a single LED set or array. Exemplary systems disclosed herein include an element for mixing light produced by LEDs mounted to the landing zones, such as an optical integrating cavity.

Claims

1. A printed circuit board for use in a lighting system, comprising:

a board;

a plurality of identical lighting emitting diode (LED) landing zones printed on the board, wherein;

each of the identical LED landing zones includes two sets of LED contact pads,

a first of the two sets of LED contact pads is configured to mate with a first contact configuration for a LED of a first structural type,

a second of the two sets of LED contact pads is configured to mate with a second contact configuration for a LED of a second structural type different from the first structural type,

the second contact configuration is different from the first contact configuration,

within each identical LED landing zone;

the first set of LED contact pads is arranged along a first axis, and the second set of LED contact pads is arranged along a second axis substantially orthogonal to the first axis,

a portion of the board supporting the identical LED landing zones is circular;

a line between two pads of the first set of LED contact pads is substantially non-tangential with respect to the circular portion of the board; and

a line between two pads of the second set of LED contact pads is substantially tangential with respect to the circular portion of the board.

2. The printed circuit board of claim 1, wherein the board has a central aperture for passage of light.

3. The printed circuit board of claim 1, wherein the board further comprises:

a plurality of electrical terminals for electrical signals to drive the LEDs; and

printed wiring extending from the electrical terminals to the contact pads in each the landing zones.

4. The printed circuit board of claim 1, wherein each identical LED landing zone further comprises:

a third set of LED contact pads configured to mate with a third contact configuration for an LED of a third structural type of LED different from the first and second structural types of LEDs; and

the third contact configuration is different from the first and second contact configurations.

5. The printed circuit board of claim 3, wherein the printed wiring extending to each respective one of the landing zones comprises:

a first wiring lead connected to a first one of the contact pads in the first set and to a first one of the contact pads in the second set; and

a second wiring lead connected to a second one of the contact pads in the first set and to a second one of the contact pads in the second set.

6. An assembly for use in a lighting system, comprising:

a board;

a plurality of identical lighting emitting diode (LED) landing zones printed on the board, wherein;

each of the identical LED landing zones includes two sets of LED contact pads,

a first of the two sets of LED contact pads is configured to mate with a first contact configuration for a LED of a first structural type,

a second of the two sets of LED contact pads is configured to mate with a second contact configuration for a LED of a second structural type different from the first structural type,

the second contact configuration is different from the first contact configuration,

within each identical LED landing zone;

the first set of LED contact pads is arranged along a first axis, and the second set of LED contact pads is arranged along a second axis substantially orthogonal to the first axis,

a portion of the board supporting the identical LED landing zones is circular;

a line between two pads of the first set of LED contact pads is substantially non-tangential with respect to the circular portion of the board; and

a line between two pads of the second set of LED contact pads is substantially tangential with respect to the circular portion of the board; and

a plurality of LEDs mounted on respective landing zones, contacts of each LED being connected to a set of the contact pads of the respective landing zone.

7. The assembly of claim 6, wherein all of the LEDs mounted on the landing zones are of only one of the structural types.

8. The assembly of claim 6, wherein:

a first of the LEDs is of the first structural type and is connected to the first set of contact pads in a first one of the landing zones; and

a second of the LEDs is of the second structural type and is connected to the second set of contact pads in a second one of the landing zones.

9. The assembly of claim 8, wherein:

the first LED is a LED of a first color, and

the second LED is a LED of a second color different from the first color.

10. The assembly of claim 8, wherein the first and second LEDs both emit visible light.

11. The assembly of claim 8, wherein at least one of the first and second LEDs emits light of a wavelength for exciting a phosphor to emit visible light.

12. The assembly of claim 8, wherein the first and second LEDs emit light of substantially the same color.

13. The assembly of claim 8, wherein:

the first LED is from one manufacturer and has a first housing configuration, and

the second LED is from a different manufacturer and has a second housing configuration different from the first housing configuration.

14. The assembly of claim 12, wherein the first and second LEDs both emit substantially white light.

15. An apparatus for emitting light, comprising:

an optical cavity having at least one transmissive path for emission of combined visible light from the cavity;

a plurality of light emitting diodes (LEDs) for emission of light and for thereby producing visible light for combination within the cavity, wherein a first one of the LEDs is of a first structural type having contacts arranged in a first configuration and a second one of the LEDs is of a second structural type different from the first structural type having contacts arranged in a second contact configuration different from the first contact configuration; and

a circuit board for support of and electrical connection to the LEDs;

the circuit board comprising a plurality of identical LED landing zones, wherein;

each of the identical LED landing zones includes two sets of LED contact pads formed on the circuit board,

a first of the two sets of LED contact pads is configured to mate with the first contact configuration for any LED of the first structural type,

a second of the two sets of LED contact pads is configured to mate with the second contact configuration for any LED of the second structural type,

within each identical LED landing zone;

the first set of LED contact pads is arranged along a first axis, and the second set of LED contact pads is arranged along a second axis substantially orthogonal to the first axis,

a portion of the board supporting the identical LED landing zones is circular,

within each respective LED landing zone, a line between two pads of the first set of LED contact pads is substantially non-tangential with respect to the circular portion of the board,

within each respective LED landing zone, a line between two pads of the second set of LED contact pads is substantially tangential with respect to the circular portion of the board,

the first LED is mounted on the circuit board at a first one of the LED landing zones, and electrical connections to the first LED are made via the first set of LED contact pads of the first LED landing zone, and

the second LED is mounted on the circuit board at a second one of the LED landing zones, and electrical connections to the second LED are made via the second set of LED contact pads of the second LED landing zone.

16. The apparatus of claim 15, wherein:

the first LED is a LED of a first color, and

the second LED is a LED of a second color different from the first color.

17. The apparatus of claim 15, wherein the first and second LEDs both emit visible light.

18. The apparatus of claim 15, wherein:

the system further comprises a phosphor for emission of visible light for combination in the cavity; and

at least one of the first and second LEDs emits light of a wavelength for exciting the phosphor to emit visible light.

19. The apparatus of claim 15, wherein the first and second LEDs emit light of substantially the same color.

20. The apparatus of claim 19, wherein the first and second LEDs both emit substantially white light.

21. The apparatus of claim 15, wherein:

the first LED is from one manufacturer and has a first housing configuration, and

the second LED is from a different manufacturer and has a second housing configuration different from the first housing configuration.

22. The apparatus of claim 15, wherein the board has a central opening extending through the board, forming a portion of an aperture of the cavity for the at least one transmissive path for emission of combined visible light from the cavity.

23. The apparatus of claim 15, wherein the board further comprises:

a plurality of electrical terminals for electrical signals to drive the LEDs; and

printed wiring extending from the electrical terminals to the contact pads in each the landing zones.

24. The apparatus of claim 15, wherein each identical LED landing zone further comprises:

a third set of LED contact pads configured to mate with a third contact configuration for an LED of a third structural type of LED different from the first and second structural types of LEDs; and

the third contact configuration is different from the first and second contact configurations.

25. The apparatus of claim 15, wherein:

the apparatus comprises a wall having an inner surface forming the cavity;

the inner surface of the wall has a reflective property with respect to at least visible light; and

the wall has an aperture forming a transmissive path for emission of combined visible light from the cavity.

26. The apparatus of claim 23, wherein the printed wiring extending to each respective one of the landing zones comprises:

a first wiring lead connected to a first one of the contact pads in the first set and to a first one of the contact pads in the second set; and

a second wiring lead connected to a second one of the contact pads in the first set and to a second one of the contact pads in the second set.

27. The apparatus of claim 25, wherein the inner surface of the wall has a diffusely reflective property with respect to the light emitted by the LEDs.

28. The apparatus of claim 25, further comprising an optical processing element coupled to the aperture of the cavity for further processing of combined visible light emitted from the cavity.