Illumination system for use with display signage

• US 7,506,995 B2
• Filed: 01/23/2007
• Issued: 03/24/2009
• Est. Priority Date: 09/23/2004
• Status: Active Grant

• Current Assignee: Electraled Incorporated
• Original Assignee: Priscilla G. Thomas
• Inventors: McCarthy, Michael J., Thomas, James G., Warner, Bryan T.
• Primary Examiner(s): Lee; Jong-Suk (James)
• Assistant Examiner(s): MACCHIAROLO, LEAH SIMONE
• Application Number:
  US11/656,641
• Publication Number:
  US 20070115666A1
• Time in Patent Office: 791 Days
• Field of Search: 362/800, 362/219, 362/217, 362/294, 362/391, 362/237, 362/222, 362/221, 362/373, 362/227, 439/391, 439/426, 439/427, 361/688, 361/749
• US Class Current: 362/227
• CPC Class Codes: F21S 4/10 with light sources attached to loose electric cables, e.g. Christmas tree lights
• CPC Class Codes: F21V 15/01 Housings, e.g. material or assembling of housing parts F21V15/02 takes precedence housings forming signs or letters G09F13/04
• CPC Class Codes: F21V 21/002 making direct electrical contact, e.g. by piercing F21V21/35 takes precedence
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/75 with fins or blades having different shapes, thicknesses or spacing
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05K 1/0203 Cooling of mounted components H05K1/0272 takes precedence
• CPC Class Codes: H05K 1/053 the metal substrate being covered by an inorganic insulating layer
• CPC Class Codes: H05K 1/056 the metal substrate being covered by an organic insulating layer
• CPC Class Codes: H05K 2201/0175 Inorganic, non-metallic layer, e.g. resist or dielectric for printed capacitor
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 3/28 Applying non-metallic protective coatings H05K3/0091 takes precedence; methods for intermediate insulating layers for build-up multilayer circuits H05K3/4673
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

The present invention provides a lighting system for use within a display sign, wherein the lighting system comprises a first module having a multi-layer circuit board and an arrangement of components electrically connected to the circuit board. The component arrangement includes a driver control chip that provides regulated voltage to the light emitting diodes, at least one surface mounted resistor, and a pair of light emitting diodes wherein each diode is mounted to a longitudinal end portion of the circuit board. Thus, the driver control chip is positioned between the light emitting diodes. The component arrangement further includes a high-frequency capacitor that filters undesired electrical noise and a rectifying diode that converts electrical potential from alternating current to direct current. A second module is electrically connected to the first module by a pair of flexible conductor wires. The second module includes a multi-layer circuit board and an arrangement of components electrically connected to the circuit board. The component arrangement of the second module is similar to that of the first module, wherein a light emitting diode is mounted to each longitudinal end portion of the circuit board.

Claims

1. A lighting system for use within a display sign, the lighting system comprising:

a first module having a circuit board and an arrangement of components electrically connected to the circuit board, wherein the circuit board includes a dielectric coating layer residing against a metal layer, and wherein the component arrangement includes;

a pair of light emitting diodes wherein each diode is mounted to a longitudinal end portion of the circuit board;

a driver control chip that provides regulated voltage to the light emitting diodes, the control chip positioned at a central portion of the circuit board between the light emitting diodes;

at least one surface mounted resistor wherein the circuit boards includes;

a first hole dimensioned to receive a first elongated fastener, wherein the first hole is positioned between the driver control chip and one of the light emitting diodes; and

,

a second hole dimensioned to receive a second elongated fastener, wherein the second hole is positioned between the driver control chip and the other of the light emitting diodes.

2. The lighting system of claim 1, wherein the component arrangement further includes a high-frequency capacitor that filters undesired electrical noise resulting from operation of the components.

3. The lighting system of claim 1, wherein the component arrangement further includes a rectifying diode that converts electrical potential from alternating current to direct current.

4. The lighting system of claim 1, further comprising a second module electrically connected to the first module by a pair of flexible conductor wires, the second module having an circuit board and an arrangement of components electrically connected to the circuit board, wherein the circuit board includes a dielectric coating layer residing against a metal layer, and wherein the component arrangement includes a pair of light emitting diodes wherein each diode is mounted to a longitudinal end portion of the circuit board.

5. The lighting system of claim 4, wherein the component arrangement of the second module further includes a high-frequency capacitor that filters undesired electrical noise.

6. The lighting system of claim 4, wherein the component arrangement of the second module further includes at least one surface mounted resistor.

7. A lighting system for use within a display sign, the lighting system comprising:

a first module having a multi-layer circuit board and an arrangement of components electrically connected to the circuit board, wherein the component arrangement includes;

a driver control chip positioned at a central portion of the circuit board;

a pair of light emitting diodes wherein each diode is mounted to a longitudinal end portion of the circuit board, and wherein the driver control chip is positioned between the light emitting diodes and regulates voltage provided to the light emitting diodes; and

,

at least one surface mounted resistor;

a second module electrically connected to the first module by a pair of flexible conductor wires, the second module having a multi-layer circuit board and an arrangement of components electrically connected to the circuit board, the component arrangement including a pair of light emitting diodes wherein each diode is mounted to a longitudinal end portion of the circuit board.

8. The lighting system of claim 7, wherein each circuit board of both the first and second modules includes a metal layer and a dielectric layer coating the metal layer.

9. The lighting system of claim 7, wherein each component arrangement of the first and second modules further includes a high-frequency capacitor that filters undesired electrical noise.

10. The lighting system of claim 9, wherein the component arrangement of the first module further includes a rectifying diode that converts electrical potential from alternating current to direct current.

11. The lighting system of claim 7, wherein each circuit board of the first and second modules includes:

a first hole dimensioned to receive a first elongated fastener, wherein the first hole is positioned adjacent one of the light emitting diodes; and

,

a second hole dimensioned to receive a second elongated fastener, wherein the second hole is positioned adjacent the other of the light emitting diodes.

12. The lighting system of claim 7, wherein the component arrangement of the second module further includes at least one surface mounted resistor.

13. A lighting module comprising:

a heat sink mass;

a circuit board positioned on an upper surface of the mass;

an arrangement of components electrically connected to the circuit board, the component arrangement including a pair of light emitting diodes, a driver control chip configured to regulate the voltage to the light emitting diodes, a resistor, and a rectifying diode that converts electrical potential from alternating current to direct current; and

,

wherein the light emitting diodes are positioned at opposed end portions of the circuit board and the driver control chip is positioned in a central portion of the circuit board between the light emitting diodes.

14. The lighting module of claim 13, wherein the component arrangement further includes a high-frequency capacitor that filters undesired electrical noise resulting from the operation of the electrical components.

15. The lighting module of claim 13, wherein the components are positioned on a central portion of the circuit board, and wherein a cover is positioned over the driver control chip, the resistor and the rectifying diode, while the light emitting diode remains exposed.

16. The lighting module of claim 15, wherein the cover includes at least one tab that releasably engages a rib of the heat sink mass.

17. The lighting module of claim 13, further comprising at least one connector extending downward from the circuit board into the heat sink, wherein the connector electrically connects the component arrangement with a conductor wire.

18. The lighting module of claim 17, wherein the conductor wire extends continuously through a longitudinal channel in the mass, and wherein a lower portion of the connector extends into the channel and electrically connects with the conductor wire to define a single-point connection.

19. The lighting module of claim 13, wherein the circuit board comprises a metal layer and a dielectric coating layer positioned on the metal layer.

20. The lighting module of claim 19,wherein the circuit board further comprises a copper trace pattern layer positioned on the dielectric coating layer.

21. The lighting module of claim 20, wherein the circuit board further comprises both a second dielectric coating layer positioned on the copper trace pattern layer and a ceramic coating layer positioned on the second dielectric coating layer.