LED module and system of LED modules with integral branch connectors

• US 7,377,669 B2
• Filed: 03/28/2005
• Issued: 05/27/2008
• Est. Priority Date: 03/28/2005
• Status: Expired due to Fees

• Current Assignee: U.S. Led, Inc.
• Original Assignee: US LED, Ltd.
• Inventors: Smit, Christiaan Coenraad Joubert, Farmer, Ronald E.
• Primary Examiner(s): Lee; Jong-Suk (James)
• Assistant Examiner(s): MAY, ROBERT J
• Application Number:
  US11/091,191
• Publication Number:
  US 20060215398A1
• Time in Patent Office: 1,156 Days
• Field of Search: 362219-220, 362/812, 362/800, 362/238, 362/249, 362/225, 362/250, 405/50, 257 88- 89, 439/65, 439/67, 439/66
• US Class Current: 362/249.01
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21S 2/005 of modular construction
• CPC Class Codes: F21S 4/10 with light sources attached to loose electric cables, e.g. Christmas tree lights
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G09F 13/22 electroluminescent electroluminescent light sources per se H05B33/00
• CPC Class Codes: G09F 9/33 being semiconductor devices, e.g. diodes
• CPC Class Codes: H01R 13/514 composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
• CPC Class Codes: H01R 13/717 with built-in light source
• CPC Class Codes: H01R 13/7175 Light emitting diodes (LEDs)
• CPC Class Codes: H05K 1/117 Pads along the edge of rigid circuit boards, e.g. for pluggable connectors
• CPC Class Codes: H05K 1/118 specially for flexible printed circuits, e.g. using folded portions
• CPC Class Codes: H05K 1/148 Arrangements of two or more hingeably connected rigid printed circuit boards, i.e. connected by flexible means
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 3/365 by abutting, i.e. without alloying process
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

An LED module provides one or more LEDs mounted in a circuit board assembly, which circuit board assembly includes first and second conductive areas located at each end of the circuit board assembly to attach to electrical connectors mounted on branch wiring to extend to branch LED modules.

Claims

1. An LED module for mounting and powering one or more LEDs for use in lighting displays, comprising:

an LED circuit board assembly comprising;

an LED;

a generally rectangular circuit board having a first and a second longitudinal end portion, comprising;

a first conductive area, electrically connected to the LED, and electrically connected to a second LED module;

a second conductive area, electrically connected to the LED, and electrically connected to a third LED module; and

a first male connector and a second male connector, each formed as a portion of the circuit board and extending outwardly and coplanarly from one of the first and second longitudinal edge portions of the circuit board in a configuration adapted to physically and electrically connect to a fourth LED module.

2. The LED module set forth in claim 1, further comprising:

a first branch wire assembly for connection to the first male connector; and

a second branch wire assembly for connection to the second male connector.

3. The LED module set forth in claim 2, wherein the LED module, the second LED module, and the third LED module, when electrically connected, form a main string of LED modules, and

wherein the first and second branch wire assemblies when in electrical connection with the fourth LED module form a branch string of LED modules extending from the LED module in the main string of LED modules.

4. The LED module set forth in claim 1, wherein:

the first male connector comprises;

a first protruding tab adapted to receive a first female electrical connector; and

the second male connector comprises;

a second protruding tab adapted to receive a second female electrical connector,

wherein the first protruding tab and the second protruding tab are positioned at opposite ends of the LED circuit board assembly.

5. The LED module of claim 1, further comprising:

a branch wire assembly, comprising;

a wire; and

a pair of female quick connectors, attached to opposite ends of the wire, each configured for attachment to the one of the first and second male connectors for connecting the LED module and the fourth LED module.

6. A plurality of LEDs for use in creating a sign or other display, comprising:

a dispenser which mounts a plurality of LED modules which are interconnected into a dispensing string wherein each LED module includes;

an LED circuit board assembly comprising;

an LED;

a generally rectangular circuit board having a first and a second longitudinal end portion, comprising;

a first conductive area, electrically connected to the LED, and electrically connected to a second LED module in the dispensing string;

a second conductive area, electrically connected to the LED, and electrically connected to a third LED module in the dispensing string; and

a first male connector and a second male connector, each of formed as a portion of the circuit board and extending outwardly and coplanarly from one of the first and second longitudinal edge portions of the circuit board in a configuration adapted to physically and electrically connect to the fourth LED module.

7. The plurality of LEDs of claim 6, further comprising:

a pair of branch wire assemblies, each comprising;

a wire; and

a pair of female quick connectors, attached to opposite ends of the wire, each configured for attachment to one of the first male connector and the second male connector,

wherein each of the pair of branch wire assemblies is connectable to one of the first male connector and the second male connector.

8. An LED module for mounting and powering one or more LEDs for use in lighting displays, comprising:

an LED circuit board assembly comprising;

an LED;

a generally rectangular circuit board having a first and a second longitudinal end portion, comprising;

a first conductive area, electrically connected to the LED, and electrically connected to a second LED module;

a second conductive area, electrically connected to the LED, and electrically connected to a third LED module; and

a first male connector and a second male connector, each formed as a portion of the circuit board and extending outwardly and coplanarly from one of the first and second longitudinal edge portions of the circuit board,

wherein the LED module, the second LED module, and the third LED module when electrically connected form a main string of LED modules; and

wherein the fourth LED module when electrically connected to the LED module branches from the main string of LED modules.

9. A plurality of LEDs mounted on a reel for use in creating a sign or other display comprising:

a dispenser which mounts a plurality of LED modules which are interconnected into a dispensing string wherein each LED module includes;

an LED circuit board assembly comprising;

an LED;

a generally rectangular circuit board having a first and a second longitudinal end portion, comprising;

a first conductive area, electrically connected to the LED, electrically connecting the LED circuit board assembly to a second LED module in the dispensing string;

a second conductive area, electrically connected to the LED, electrically connecting the LED circuit board assembly to a third LED module in the dispensing string; and

a first male connector and a second male connector, each formed as a portion of the circuit board and extending outwardly and coplanarly from one of the first and second longitudinal edge portions of the circuit board in a configuration adapted to physically and electrically connect to the fourth LED module,

wherein the LED module, the second LED module, and the third LED module form a main string of LED modules, and

wherein the fourth LED module forms a branch string when electrically connected to the main string of LED modules.

10. The plurality of LEDs of claim 9, further comprising:

a pair of branch wire assemblies, each comprising;

a wire; and

a pair of female quick connectors, attached to opposite ends of the wire, each configured for attachment to one of the first male connector and the second male connector,

wherein each of the pair of branch wire assemblies is connectable to one of the first male connector and the second male connector of the third conductive area.

11. The plurality of LEDs of claim 9, the LED circuit board assembly further comprising:

a first pair of wires, affixed to the first conductive area and to the second LED module in the dispensing string; and

a second pair of wires, affixed to the second conductive area and to the third LED module in the dispensing string.