LED lighting units and assemblies with edge connectors

• US 7,789,529 B2
• Filed: 10/20/2009
• Issued: 09/07/2010
• Est. Priority Date: 11/18/2005
• Status: Active Grant

• Current Assignee: Creeled Incorporated
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Roberts, John K., Sims, Paul E.
• Primary Examiner(s): O'Shea; Sandra L
• Assistant Examiner(s): ALLEN, DANIELLE NICOLE
• Application Number:
  US12/582,372
• Publication Number:
  US 20100039806A1
• Time in Patent Office: 322 Days
• Field of Search: 362235-249, 362/249.01, 362/249.02, 362/249.04, 362/249.11, 362640-659, 362/800, 362/228, 362/576, 257 79-103, 439/260, 439/637, 439/59, 439/493, 439/660, 439/502
• US Class Current: 362/249.02
• CPC Class Codes: G02F 1/133603 with LEDs
• CPC Class Codes: H01R 12/721 cooperating directly with the edge of the rigid printed circuits
• CPC Class Codes: H01R 13/432 by stamped-out resilient tongue snapping behind shoulder in base or case
• CPC Class Codes: H01R 13/6275 Latching arms not integral with the housing H01R13/6276, H01R13/6277, H01R13/6278 take precedence
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

An LED light unit includes a tile, a plurality of discrete LED light sources, and an edge connector. The LED light sources are on and dispersed across a major surface of the tile and are electrically connected to electrical pads along an edge region of the tile. The edge connector includes a plurality of contacts that are connected to a plurality of wires extending away from the edge connector, and is configured to releasably connect to an edge of the tile so that the contacts directly connect to the pads and electrically connect the wires of the edge connector to the LED light sources. An LED lighting assembly includes a plurality of the discrete tiles mounted to a plurality of bars, and a plurality of edge connectors that are each connected to an end one of the tiles along different ones of the bars.

Claims

1. An LED light unit comprising:

a tile;

a plurality of discrete LED light sources that are on and dispersed across a major surface of the tile and are electrically connected to electrical pads along an edge region of the tile; and

an edge connector comprising a plurality of contacts that are connected to a plurality of flexible wires extending away from the edge connector, the edge connector is configured to releasably connect to an edge of the tile so that the contacts directly connect to the pads and electrically connect the wires of the edge connector to the LED light sources, wherein the edge connector comprises a body that is configured to guide a portion of each of the flexible wires away from the tile, wherein each one of the LED light sources comprises at least one LED chip and wavelength conversion element, the at least one LED chip is electrically connected to at least one tile pad, and the edge connector is configured to electrically connect at least one of the flexible wires to the at least one LED chip via the at least one tile pad.

2. The LED light unit of claim 1, wherein each one of the LED light sources comprises an encapsulant that includes a phosphor wavelength conversion element.

3. The LED light unit of claim 2, wherein a height of the edge connector above the major surface of the tile is no more than a height of the encapsulants of the LED light sources above the major surface of the tile.

4. The LED light unit of claim 1, wherein the wavelength conversion element is arranged in a light emission pathway of a plurality of the LED chips.

5. The LED light unit of claim 1, wherein the body comprises a plurality of recessed channels defined therein, each of the recessed channels is configured to releasably connect to a portion of one of the flexible wires and to guide the connected portion of the flexible wire at a non-zero angle away from a plane of the major surface of the tile.

6. The LED light unit of claim 5, wherein each of the recessed channels is configured to guide the connected portion of the flexible wire at about a 90°

angle away from the plane of the major surface of the tile.

7. The LED light unit of claim 5, wherein the plurality of connector wires are separate from one another along a major portion of their length and are independently flexible relative to one another.

8. The LED light unit of claim 5, wherein:

at least one LED chip of a plurality of the LED light sources are electrically connected in series to form a string that is connected on opposite ends to a pair of the pads on the tile; and

the edge connector is configured to electrically connect a pair of the flexible wires to the pair of pads on the tile.

9. The LED light unit of claim 8, wherein:

a plurality of strings of the serially connected LED light sources are connected on opposite ends to different pairs of the pads on the tile; and

the edge connector is configured to electrically connect different pairs of the flexible wires to the different pairs of the pads on the tile.

10. The LED light unit of claim 1, further comprising a reflector panel comprising a material with high light reflectivity and defining apertures therein, the reflector panel extending across the major surface of the tile with the apertures being aligned with the plurality of LED light sources, and a height of the edge connector above the major surface of the tile is no more than a height of an outer major surface of the reflector panel above the major surface of the tile.

11. The LED light unit of claim 1, wherein the body of the edge connector comprises a cavity having an inner surface, and a locking mechanism that comprises a flexure lever that extends into the cavity and releasably locks onto an opening in the major surface of the tile while the edge connector contacts are directly connected to the tile pads and electrically connect the wires of the edge connector to the LED light sources.

12. The LED light unit of claim 11, wherein the body is configured to hold the wires along a plane, and the flexure lever extends through at least a portion of the body and separates the wires along the plane into two groups.

13. The LED light unit of claim 12, wherein the flexure lever extends through at least a portion of the body to separate the wires along the plane into two equal groups.

14. The LED light unit of claim 1, wherein the edge connector is configured to align and connect the first group of the wires to tile pads which are connected to anode terminals and not cathode terminals of the LED light sources, and configured to align and connect the second group of the wires to tile pads which are connected to cathode terminals and not anode terminals of the LED light sources.

15. The LED light unit of claim 1, wherein:

each one of the LED light sources comprises a red LED chip connected to a first pair of the tile pads, a green LED chip connected to a second pair of the tile pads, and a blue LED chip connected to a third pair of the tile pads; and

the edge connector is configured to electrically connect a first pair of the wires to the red LED chip via the first pair of tile pads, to electrically connect a second pair of the wires to the green LED chip via the second pair of tile pads, and to electrically connect a third pair of the wires to the blue LED chip via the third pair of tile pads.

16. The LED light unit of claim 1, wherein the edge connector comprises a body having a notched corner adjacent to a closest one of the LED light sources.

17. The LED light unit of claim 1, wherein:

each one of the LED light sources comprises an encapsulant that at least partially encloses the at least one LED chip; and

a height of the edge connector above the at least one LED chip of a nearest one of the LED light sources and a closest distance from the upper surface of the edge connector to the at least one LED chip of the nearest one of the LED light sources are configured so that a tangential light ray angle between the at least one LED chip of the nearest one of the LED light sources to a closest upper surface of the edge connector is no more than 30 degrees relative to horizontal.

18. The LED light unit of claim 17, wherein:

the height of the edge connector above the at least one LED chip of the nearest one of the LED light sources and the closest distance from the upper surface of the edge connector to the at least one LED chip of the nearest one of the LED light sources are configured so that a tangential light ray angle between the at least one LED chip of the nearest one of the LED light sources to the closest upper surface of the edge connector is no more than 7 degrees relative to horizontal.

19. The LED light unit of claim 1, wherein:

the tile comprises at least one notch along an edge portion thereof; and

the body of the edge connector comprises a cavity and at least one elongated member extending from the body along at least a portion of the cavity, the elongated member located in the cavity to slide into the notch in the tile and guide the edge connector to align the edge connector contacts with the tile pads when an upper surface of the edge connector is facing upward relative to an upper surface of the tile, and to prevent connection of the edge connector to the tile when a lower surface of the edge connector is facing upward relative to the upper surface of the tile.

20. The LED lighting unit of claim 1, further comprising:

a plurality of the tiles that are electrically connected in series to receive power supplied by the edge connector when connected to one of the tiles; and

a LCD panel that is connected to the plurality of tiles so that light from the LED light sources is directed through the LCD panel.