Electrical connector header for an LED-based light

• US 9,184,518 B2
• Filed: 03/01/2013
• Issued: 11/10/2015
• Est. Priority Date: 03/02/2012
• Status: Active Grant

• Current Assignee: Ilumisys Incorporated (Altair Engineering Incorporated)
• Original Assignee: Ilumisys Incorporated (Altair Engineering Incorporated)
• Inventors: Ivey, John, Meganck, Ryan, Ngo, Hoan, Amrine, James
• Primary Examiner(s): Gramling, Sean
• Assistant Examiner(s): Sufleta, II, Gerald J
• Application Number:
  US13/782,763
• Publication Number:
  US 20130230995A1
• Time in Patent Office: 984 Days
• Field of Search: 362/249.02, 362/404
• US Class Current: 1/1
• CPC Class Codes: F21K 9/278 Arrangement or mounting of circuit elements integrated in the light source
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21V 23/006 the substrate being distinct from the light source holder
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01R 12/71 for rigid printing circuits or like structures
• CPC Class Codes: H01R 43/20 for assembling or disassembling contact members with insulating base, case or sleeve
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing

Abstract

An LED-based light configured for replacing a conventional fluorescent light in a fluorescent light fixture comprises: an LED circuit board including at least one LED; a power supply circuit board configured to supply power to the at least one LED; an end cap carrying at least one pin configured for connection to the fixture; a pin connector header including a first body retentively supporting at least one pin connecting lead and configured to engage the power supply circuit board such that the pin connecting lead is positioned to electrically connect the power supply circuit board and the pin; and a circuit connector header including a second body retentively supporting at least one circuit connecting lead and configured to engage the power supply circuit board such that the circuit connecting lead is positioned to electrically connect the power supply circuit board and the LED circuit board.

Claims

1. An LED-based light configured for replacing a conventional fluorescent light in a fluorescent light fixture, comprising:

an LED circuit board including at least one LED;

a power supply circuit board configured to supply power to the at least one LED;

an end cap carrying at least one pin configured for connection to the fixture;

a pin connector header, the pin connector header including at least one pin connecting lead composed of a substantially shape maintaining material and having a power supply circuit board contacting portion and a pin contacting portion, and a first body retentively supporting the pin connecting lead, the pin connector header configured to engage the power supply circuit board such that the power supply circuit board contacting portion and the pin contacting portion are positioned to electrically connect the power supply circuit board and the pin; and

a circuit connector header, the circuit connector header including at least one circuit connecting lead composed of a substantially shape maintaining material and having a power supply circuit board contacting portion and a LED circuit board contacting portion, and a second body retentively supporting the at least one circuit connecting lead such that the power supply circuit board contacting portion and the LED circuit board contacting portion of the circuit connecting lead project from the second body, the power supply circuit board contacting portion projecting beyond a surface of the second body, wherein;

the circuit connector header is configured to engage the power supply circuit board such that the power supply circuit board contacting portion and the LED circuit board contacting portion are positioned to electrically connect the power supply circuit board and the LED circuit board, the power supply circuit board contacting portion of the circuit connecting lead is positioned within a conditioned power output pad of the power supply circuit board with the surface of the second body abutting the power supply circuit board, and the LED circuit board contacting portion is positioned within a conditioned power receiving pad of the LED circuit board.

2. The LED-based light of claim 1, wherein:

the first body retentively supports the at least one pin connecting lead such that the power supply circuit board contacting portion and the pin contacting portion of the pin connecting lead project from the first body; and

with the engagement between the pin connector header and the power supply circuit board, the power supply circuit board contacting portion of the pin connecting lead is positioned within an input power receiving pad of the power supply circuit board and the pin contacting portion is inserted within a pin cavity defined by the pin.

3. The LED-based light of claim 2, wherein with the engagement between the pin connector header and the power supply circuit board, the pin contacting portion of the pin connecting lead is axially inserted within the pin cavity.

4. The LED-based light of claim 2, wherein:

the power supply circuit board contacting portion of the pin connecting lead projects from the first body to extend beyond a surface of the first body; and

the engagement between the pin connector header and the power supply circuit board at least partially includes the power supply circuit board contacting portion of the pin connecting lead positioned within the input power receiving pad of the power supply circuit board and the surface of the first body abutting the power supply circuit board.

5. The LED-based light of claim 1, wherein the LED circuit board contacting portion of the circuit connecting lead is engaged in spring contact within the conditioned power receiving pad of the LED circuit board.

6. The LED-based light of claim 1, wherein:

the first body includes a projection extending beyond a surface of the first body; and

the engagement between the pin connector header and the power supply circuit board at least partially includes the projection positioned within an aperture defined by the power supply circuit board and the surface of the body abutting the power supply circuit board.

7. The LED-based light of claim 1, wherein:

the second body includes a projection extending beyond a surface of the second body; and

the engagement between the circuit connector header and the power supply circuit board at least partially includes the projection positioned within an aperture defined by the power supply circuit board and the surface of the body abutting the power supply circuit board.

8. The LED-based light of claim 1, further comprising:

a housing, wherein the LED circuit board, the power supply circuit board and the pin are spatially distributed with respect to one another within the housing.

9. An LED-based light configured for replacing a conventional fluorescent light in a fluorescent light fixture, comprising:

an LED circuit board including at least one LED;

a power supply circuit board configured to supply power to the at least one LED;

an end cap carrying at least one pin configured for connection to the fixture; and

a connector header, the connector header including at least one lead composed of a substantially shape maintaining material and having a first contacting portion and a second contacting portion, and a body retentively supporting the lead, the connector header configured to engage the power supply circuit board such that the first contacting portion of the lead is positioned within a pad of the power supply circuit board and the second contacting portion of the lead is positioned within one of;

a pad of the LED circuit board to electrically connect the power supply circuit board and the LED circuit board, wherein the second contacting portion of the lead is engaged in spring contact within the pad of the LED circuit board, and

a pin cavity defined by the pin to electrically connect the power supply circuit board and the pin.

10. The LED-based light of claim 9, wherein the second contacting portion of the lead is axially inserted within the pin cavity.

11. The LED-based light of claim 9, wherein:

the first contacting portion projects from the body to extend beyond a surface of the body; and

the engagement between the power supply circuit board and the connector header at least partially includes the first contacting portion positioned within the pad of the power supply circuit board and the surface of the body abutting the power supply circuit.

12. The LED-based light of claim 9, wherein

the connector header includes a projection extending beyond a surface of the body;

and

the engagement between the power supply circuit board and the connector header at least partially includes the projection positioned within an aperture defined by the power supply circuit board and the surface of the body abutting the power supply circuit board.

13. The LED-based light of claim 9, further comprising:

a housing, wherein the LED circuit board, the power supply circuit board and the pin are spatially distributed with respect to one another within the housing.

14. A method of assembling components of an LED-based light configured for replacing a conventional fluorescent light in a fluorescent light fixture, the components including at least an LED circuit board including at least one LED, a power supply circuit board configured to supply power to the at least one LED and an end cap carrying at least one pin configured for connection to the fixture, comprising:

engaging the power supply circuit board with a connector header including at least one lead composed of a substantially shape maintaining material and having a first contacting portion and a second contacting portion, a body retentively supporting the lead, and a projection extending beyond a surface of the body, wherein the engagement positions the first portion within a pad of the power supply circuit board, axially aligns the second contacting portion with a pin cavity defined by the pin and inserts the second contacting portion within the pin cavity, slidably engages the second contacting portion into spring contact with a pad of the LED circuit board, and inserts the projection within an aperture defined by the power supply circuit board and abutting the surface of the body with the power supply circuit board; and

electrically connecting the power supply circuit board to the one of the LED circuit board and the pin.