LED linear lighting strip

• US 9,279,544 B1
• Filed: 02/19/2014
• Issued: 03/08/2016
• Est. Priority Date: 02/19/2014
• Status: Active Grant

• Current Assignee: Elemental LED, Inc. (Elemental Led LLC)
• Original Assignee: Elemental LED, Inc. (Elemental Led LLC)
• Inventors: Dankelmann, Andreas, Kelley, Mark D
• Primary Examiner(s): Neils, Peggy
• Assistant Examiner(s): Garlen, Alexander
• Application Number:
  US14/184,475
• Time in Patent Office: 748 Days
• Field of Search: 248/220.21, 248/221.11, 248/222.11, 362292-298, 403/294, 403/298
• US Class Current: 1/1
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21S 2/00 Systems of lighting devices, not provided for in main groups F21S4/00 - F21S10/00 or F21S19/00, e.g. of modular construction
• CPC Class Codes: F21S 4/28 rigid, e.g. LED bars
• CPC Class Codes: F21V 15/015 Devices for covering joints between adjacent lighting devices; End coverings
• CPC Class Codes: F21V 21/005 for several lighting devices in an end-to-end arrangement, i.e. light tracks
• CPC Class Codes: F21V 21/044 with elastically deformable elements, e.g. spring tongues
• CPC Class Codes: F21V 21/045 being tensioned by translation of parts, e.g. by pushing or pulling
• CPC Class Codes: F21V 21/088 Clips; Clamps
• CPC Class Codes: F21V 3/061 the material being glass
• CPC Class Codes: F21V 3/062 the material being plastics
• 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]

Abstract

An LED lighting kit comprises an extrusion, an LED strip, a tapered wedge, and a mounting clip. The clip is sized and shaped to springably engage ledges in a first channel of the extrusion when the strip is mounted. In one aspect, two extrusions are butted end-to-end and are aligned by inserting the tapered wedge into the first channel of each extrusion prior to butting them together. The extrusion contains a second channel that houses the LED strip. A translucent diffuser is springably inserted into the second channel, thereby diffusing light that is emitted by the LED strip. End caps are inserted into the ends of the extrusion to complete the light kit. At least one of the end caps has a hole to admit electrical wires to power the LED strip.

Claims

1. A lighting kit, comprising:

a mounting clip for mounting said lighting kit to a mounting surface, said mounting clip including a base and a plurality of flat and flexible members having a main portion extending away from said base and in generally parallel relation;

each of said members having an auxiliary portion that extends toward said base and a bight portion connecting said main and said auxiliary portions;

an extrusion securable to said mounting clip, said extrusion including first and second channels;

an LED light strip secured within said first channel of said extrusion, said second channel of said extrusion having a recess with two overhanging ledges extending toward one-another at the entrance to said second channel and separated by a distance smaller than the maximum width of said auxiliary portions of said mounting clip so that said clip can be inserted into said recess and retained in said recess by said ledges engaging said auxiliary portions;

whereby when mounting said extrusion to said mounting surface, said flat and said flexible members and said auxiliary portions of said mounting clip engage said ledges on said recess, thereby providing a secure attachment of said lighting kit to said mounting surface;

a second extrusion similar to said first-named extrusion so as to provide first and second extrusions; and

a double-tapered wedge having first and second ends, said wedge having a top portion with a first width that is sized to slidably insert between said ledges in said extrusions and a bottom portion with a height that is sized to slidably fit into said second channel of said extrusions and a width that is tapered from a narrow width at its ends to a wider width at its center point;

said width of said wedge at said center point between said first and said second ends being equal to or slightly greater than the width of said second channel so that said wedge is slidably insertable into said second channel up to the center point of said wedge but no further;

whereby when said first end of said wedge is inserted into said second channel of said first extrusion, said second end of said wedge extends outward from said first extrusion so that said second channel of said second extrusion can slidably engage said second end of said wedge until said first and said second extrusions are butted together in a tight fit, thereby securing said first and said second extrusions in alignment.

2. The lighting kit of claim 1, further including at least one end cap,

said end cap further including first and second portions that are parallel to one-another and extend outward from one side of said end cap,

said first portion having a tapered portion so that when said tapered portion is inserted into said first channel of said extrusion, said tapered portion wedges against said ledges in said first channel of said extrusion, and when said second portion is slidably inserted into said second channel of said extrusion while said first portion is inserted into said first channel of said extrusion;

and

said second portion prevents misalignment or rotation of said end cap when said end cap is installed on said extrusion, thereby further securing said end cap in said extrusion;

whereby when said first and said second portions of said end cap are urged into said first and said second channels of said extrusion said end cap is secured to one of said ends of said extrusion.

3. The lighting kit of claim 2, wherein said end cap further includes a hole passing therethrough from a side opposite said first and said second portions of said end cap to the opposite side of said end cap, thereby permitting electrical wires to pass from outside said end cap to a point within said second channel of said extrusion so that electrical energy can be supplied to said lighting strip in said second channel of said extrusion.

4. The lighting kit of claim 1, further including a diffuser,

said diffuser comprising a translucent portion and two arm portions,

said arm portions being sized to springably fit into said second channel of said extrusion, thereby holding said diffuser in place in said extrusion;

whereby when said diffuser is installed in said second channel of said extrusion and said light strip is energized, light passes through said translucent portion of said diffuser.

5. A method for mounting a lighting kit to a mounting surface, comprising:

providing a mounting clip for mounting said lighting kit to a mounting surface, said mounting clip including a base and a plurality of flat and flexible members having a main portion extending away from said base and in generally parallel relation, each of said members having an auxiliary portion that extends toward said base and a bight portion connecting said main and said auxiliary portions;

providing an extrusion securable to said mounting clip, said extrusion including first and second channels;

providing an LED light strip secured within said first channel of said extrusion;

said second channel of said extrusion having a recess with two overhanging ledges extending toward one-another at the entrance to said second channel and separated by a distance smaller than the maximum width of said auxiliary portions of said mounting clip so that said clip can be inserted into said recess and retained in said recess by said ledges engaging said auxiliary portions;

securing said mounting clip to said mounting surface;

urging said second channel of said extrusion to engage said mounting clip, whereby when said mounting clip is secured to said mounting surface and said second channel of said extrusion engages said mounting clip, said lighting kit is mounted to said surface; and

connecting the extrusion to a similar second, adjacent extrusion by tightly fitting a double-tapered wedge between said extrusion and said second extrusion.

6. The method of claim 5, further including:

providing at least one end cap wherein said end cap further includes first and second portions that are parallel to one-another and extend outward from one side of said end cap, said first portion having a tapered portion so that when said tapered portion is inserted into said first channel of said extrusion, said tapered portion wedges against said ledges in said first channel of said extrusion, and when said second portion is slidably inserted into said second channel of said extrusion while said first portion is inserted into said first channel of said extrusion, said second portion prevents misalignment or rotation of said end cap when said end cap is installed on said extrusion, thereby further securing said end cap in said extrusion; and

inserting said first and second portions of said end cap into said first and second channels of said extrusion, thereby securing said end cap to said extrusion.

7. The method of claim 6, wherein at least one of said end caps further includes a hole, and the method further comprises:

providing wires for connecting said light strip to a power source;

passing said wires through said hole; and

connecting said wires to said light strip and said power source;

whereby when said power source is energized, said light strip is energized and provides light.

8. The method of claim 5, further including:

providing a diffuser for covering said light strip in said first channel of said extrusion;

said diffuser further including a light-emitting portion and two arms extending generally perpendicular to said light-emitting portion;

springably squeezing said arms of said diffuser together; and

inserting said arms of said diffuser into said first channel of said extrusion and urging said arms fully into said first channel of said extrusion;

whereby when said arms of said diffuser are fully inserted into said first channel of said extrusion, said diffuser covers said light strip in said first channel of said extrusion.

9. The method of claim 8, wherein said light-emitting portion of said diffuser further includes a surface selected from the group consisting of clear, translucent, and lenticular surfaces.

10. The method of claim 8, wherein the material of said diffuser is selected from the group consisting of polycarbonate, acrylic, and glass.

11. The method of claim 5, wherein the material of said wedge is selected from the group consisting of plastic, metal, and wood.

12. The method of claim 5, wherein said wedge comprises:

a top portion with a first width that is sized to slidably insert between said ledges in said extrusions;

a bottom portion with a height that is sized to slidably fit into said second channel of said extrusions; and

a width that is tapered from a narrow width at said first and second ends to a wider width at a center point thereof, said width of said wedge at said center point between said first and said second ends being equal to or slightly greater than the width of said second channel so that said wedge is slidably insertable into said second channel up to the center point of said wedge but no further.

13. A lighting kit, comprising:

an extrusion having first and second channels,

an LED light strip secured within said first channel of said extrusion;

mounting means for securing said extrusion to a surface;

said mounting means comprising a base portion, a plurality of slightly separated flat and flexible members comprising a main portion that extends from said base portion, each of said members further including an auxiliary portion that extends toward said base and a bight portion connecting said main and said auxiliary portions, said members and said auxiliary portions being sized to slidably and springably enter said second channel of said extrusion and then springably rebound so that said mounting means is secured within said second channel of said extrusion, whereby when said extrusion is urged against said mounting means so that said flat and flexible members and said main and said auxiliary portions enter said second channel of said extrusion, said extrusion is secured to said surface;

a second extrusion identical in cross-section to said first extrusion; and

a tapered wedge sized to be slidably insertable only half-way into said second channel of each of said first and said second extrusions to connect the extrusion and the second extrusion;

whereby when said wedge is inserted half-way into said second channel of said first extrusion and half-way into said second channel of said second extrusion, said extrusions are butted together and aligned in a tight fit.

14. The lighting kit of claim 13, further including end cap means for capping said extrusion, said end cap means further including a plurality of portions that are parallel to one-another and simultaneously insertable into said first and said second channels of said extrusion, thereby securing said end cap means in said extrusion.

15. The lighting kit of claim 14, wherein said end cap means further includes a hole arranged to admit a wire for connecting said light strip to a power source.

16. The lighting kit of claim 13, wherein said tapered wedge is made of materials selected from the group consisting of wood, metal, and plastic.

17. The lighting kit of claim 13, further including diffuser means for diffusing light emitted by said light strip when said light strip is energized, said diffuser means being springably and slidably insertable into said first channel of said extrusion.

18. The lighting kit of claim 17, wherein said diffuser means is made of a material selected from the group consisting of polycarbonate plastic, acrylic plastic, and glass.