Flexible high-power LED lighting system
First Claim
Patent Images
1. A light emitting diode (LED) light engine comprising:
- a flexible electrical cable including at least three electrical conductors residing in substantially the same plane and insulating covering surrounding the electrical conductors;
a plurality of wire-socket assemblies attached to the cable, each wire socket assembly including at least two insulation displacement connection (IDC) terminals, wherein each IDC terminal displaces the insulating covering of the cable and contacts one of the electrical conductors; and
a plurality of LED modules each selectively attached to a respective wire-socket assembly, each LED module including an LED, a heat sink in thermal communication with the LED, and an assembly receptacle, the LED electrically connects to the IDC terminals when the LED module attaches to the respective wire-socket assembly and the assembly receptacle receives the respective wire-socket assembly.
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Abstract
An LED light engine includes a flexible electrical cable, a wire-socket assembly attached to the cable, and an LED module selectively attached to the wire-socket assembly. The wire-socket assembly includes at least two IDC terminals. The IDC terminal displaces the insulating covering of the cable and contacts one of the electrical conductors. The LED module includes an LED electrically connected to the IDC terminals when the LED module attaches to the wire-socket assembly.
114 Citations
21 Claims
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1. A light emitting diode (LED) light engine comprising:
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a flexible electrical cable including at least three electrical conductors residing in substantially the same plane and insulating covering surrounding the electrical conductors; a plurality of wire-socket assemblies attached to the cable, each wire socket assembly including at least two insulation displacement connection (IDC) terminals, wherein each IDC terminal displaces the insulating covering of the cable and contacts one of the electrical conductors; and a plurality of LED modules each selectively attached to a respective wire-socket assembly, each LED module including an LED, a heat sink in thermal communication with the LED, and an assembly receptacle, the LED electrically connects to the IDC terminals when the LED module attaches to the respective wire-socket assembly and the assembly receptacle receives the respective wire-socket assembly. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A light emitting diode (LED) light engine comprising:
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a flexible electrical cable having at least two electrical conductors and insulating covering surrounding the electrical conductors; an LED module attached to the cable, the LED module including an LED, a thermally conductive support, circuitry disposed on a first surface of the thermally conductive support, an electrical connector disposed on the first surface and in electrical communication with the circuitry and a heat sink in thermal communication with the LED via the thermally conductive support, the LED being in electrical communication with the circuitry; and an IDC terminal inserted into the cable and into the connector, the terminal in contact with the electrical conductors and electrically connected to the LED via the electrical connector. - View Dependent Claims (9, 10, 11, 12)
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13. A light emitting diode (LED) light engine comprising:
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a flexible electrical cable including at least two electrical conductors and insulating covering surrounding the electrical conductors; a first mounting assembly attached to the cable; a first LED module attached to the first mounting assembly and including a first LED and a first heat sink in thermal communication with the first LED; a first insulation displacement connection (IDC) terminal disposed in the first mounting assembly, wherein the first IDC terminal is in electrical communication with the first LED and at least one of the electrical conductors; and a second LED module attached to the cable and in electrical communication with at least one of the electrical conductors, the second LED module being spaced from the first LED module along the cable and including a second LED and a second heat sink in thermal communication with the second LED. - View Dependent Claims (14, 15, 16, 17)
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18. A method for manufacturing an LED string light engine comprising:
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providing an insulated flexible electrical cable including electrical conductors; inserting at least one IDC terminal into the cable to contact at least one of the electrical conductors; inserting the at least one IDC terminal into a connector mounted on a first surface of a support to electrically connect an LED mounted on the first surface of the support to the electrical conductors of the cable via the at least one IDC terminal and the connector; contacting the support with a heat sink such that heat from the LED is drawn through the support into the heat sink; and connecting the heat sink to the cable such that the heat sink is connected to and movable with the cable so that the string light engine can mount to a variety of different structures. - View Dependent Claims (19)
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20. A string light engine comprising:
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a flexible electrical cable including at least three electrical conductors and insulating covering surrounding the electrical conductors; a plurality of wire-socket assemblies attached to the cable, each wire socket assembly including at least two insulation displacement connection (IDC) terminals and a conductor separator for electrically separating at least one of the electrical conductors, wherein each IDC terminal displaces the insulating covering of the cable and contacts one of the electrical conductors; and a plurality of LED modules each attached to the cable via a respective wire-socket assembly, at least one LED module including a thermally conductive support, circuitry disposed on a first surface of the support, at least one LED disposed on the first surface of the support, and a heat sink in thermal communication with the support. - View Dependent Claims (21)
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Specification