Sealed and sealable lighting systems incorporating flexible light sheets and related methods

• US 9,506,633 B2
• Filed: 06/11/2014
• Issued: 11/29/2016
• Est. Priority Date: 09/06/2012
• Status: Active Grant

• Current Assignee: Cooledge Lighting Inc.
• Original Assignee: Cooledge Lighting Inc.
• Inventors: Tischler, Michael A., Palfreyman, Paul
• Primary Examiner(s): Hammond, Crystal L
• Application Number:
  US14/301,859
• Publication Number:
  US 20140362566A1
• Time in Patent Office: 902 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: E04B 9/241 with the slabs, panels, sheets or the like positioned on the upperside of the horizontal flanges of the supporting construction
• CPC Class Codes: E04B 9/32 Translucent ceilings, i.e. permitting both the transmission and diffusion of light E04B9/303 and E04B9/34 takes precedence; lighting F21
• CPC Class Codes: F21S 8/026 intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling
• 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 17/101 permanently, e.g. welding, gluing or riveting
• CPC Class Codes: F21V 19/005 by permanent fixing means, e.g. gluing, riveting or embedding in a potting compound
• CPC Class Codes: F21V 19/02 with provision for adjustment, e.g. for focusing
• CPC Class Codes: F21V 23/001 the elements being electrical wires or cables
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 31/00 Gas-tight or water-tight arrangements
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21V 33/006 General building constructions or finishing work for buildings, e.g. roofs, gutters, stairs or floors; Garden equipment; Sunshades or parasols
• CPC Class Codes: F21V 5/007 Array of lenses or refractors for a cluster of light sources, e.g. for arrangement of multiple light sources in one plane combination of two or more refractors F21V5/008
• CPC Class Codes: F21V 5/008 Combination of two or more successive refractors along an optical axis
• CPC Class Codes: F21V 7/00 Reflectors for light sources characterised by cooling arrangements F21V29/505
• CPC Class Codes: F21V 7/0083 Array of reflectors for a cluster of light sources, e.g. arrangement of multiple light sources in one plane combination of two or more reflectors F21V7/0025
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/46 having LEDs disposed in parallel lines
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 2201/2054 : Light-reflecting surface, e.g. conductors, substrates, coatings, dielectrics
• CPC Class Codes: H05K 3/284 : for encapsulating mounted components H05K1/185 takes precedence

Abstract

In accordance with certain embodiments, lighting systems include flexible light sheets and one or more sealed regions containing light-emitting elements, the sealed regions defined by seals between a top housing and a bottom housing and/or the light sheet.

Claims

1. A lighting system comprising:

a substantially planar flexible substrate having a first surface and a second surface opposite the first surface;

first and second spaced-apart power conductors disposed over the first surface of the substrate;

a plurality of light-emitting strings forming a two-dimensional array over the first surface of the substrate, each light-emitting string (i) comprising a plurality of interconnected light-emitting elements spaced along the light-emitting string, (ii) having a first end electrically coupled to the first power conductor, and (iii) having a second end electrically coupled to the second power conductor, wherein the power conductors supply power to each of the light-emitting strings;

a plurality of conductive traces disposed over the first surface of the substrate and each (i) electrically interconnecting two light-emitting elements, or (ii) electrically connecting a light-emitting element to a power conductor; and

a polymeric top housing disposed over the first surface of the substrate and sealed to the first surface of the substrate at a contact point between the top housing and the first surface of the substrate to form a sealed region between the top housing and the substrate, the sealed region containing therewithin the plurality of light-emitting strings, the plurality of conductive traces, at least a portion of the first power conductor, and at least a portion of the second power conductor,

wherein the lighting system is separable, via a cut spanning the first and second power conductors and not crossing a light-emitting string, into two individually operable partial lighting systems each comprising (i) one or more light-emitting strings, (ii) portions of the first and second power conductors configured to supply power to and thereby illuminate the one or more light-emitting strings of the partial lighting system, and (iii) a sealed region defined by a seal between a portion of the top housing and the substrate.

2. The lighting system of claim 1, further comprising, extending from within the sealed region to outside of the sealed region, one or more conductive couplings for supplying power from an external power source to the light-emitting strings.

3. The lighting system of claim 2, wherein each partial lighting system comprises, extending from within the sealed region of the partial lighting system to outside of the sealed region of the partial lighting system, one or more of the conductive couplings.

4. The lighting system of claim 2, wherein at least one conductive coupling is a portion of at least one of the first or second power conductors.

5. The lighting system of claim 2, wherein at least one conductive coupling comprises a conductive element piercing through at least one of the top housing or the substrate and making electrical contact to at least one of the first or second power conductors.

6. The lighting system of claim 2, wherein at least one conductive coupling comprises an electrical connector terminating outside of the sealed region and configured to receive a complementary connector or wire electrically connected to the external power source.

7. The lighting system of claim 2, wherein at least one conductive coupling is configured to convey a communication or control signal to or from the light sheet.

8. The lighting system of claim 2, further comprising, extending from within the sealed region to outside of the sealed region, one or more second conductive couplings configured to convey a communication or control signal to or from the light sheet.

9. The lighting system of claim 1, wherein the sealed region is water-resistant or waterproof.

10. The lighting system of claim 1, further comprising a plurality of control elements each (i) electrically connected to at least one light-emitting string and (ii) configured to utilize power supplied from the power conductors to control the current to the at least one light-emitting string to which it is electrically connected.

11. The lighting system of claim 10, wherein the plurality of control elements are disposed within the sealed region.

12. The lighting system of claim 10, wherein each partial lighting system comprises one or more of the control elements.

13. The lighting system of claim 1, further comprising, electrically connected to the first and second power conductors, a power supply for powering the light-emitting elements.

14. The lighting system of claim 1, further comprising a polymeric bottom housing disposed over the second surface of the substrate.

15. The lighting system of claim 14, wherein at least a portion of the bottom housing is in contact with the top housing to enclose at least a portion of the substrate, one or more of the light-emitting strings, one or more of the conductive traces, at least a portion of the first power conductor, and at least a portion of the second power conductor.

16. The lighting system of claim 1, wherein a weight per area of the lighting system is less than 5 kg/m².

17. The lighting system of claim 1, wherein at least a portion of the top housing is configured as a diffuser for a wavelength of light emitted by the light-emitting elements.

18. The lighting system of claim 1, wherein a transmittance of the top housing for a wavelength of light emitted by the light-emitting elements is greater than 90%.

19. The lighting system of claim 1, wherein (i) the light-emitting elements in each of the light-emitting strings are separated by a substantially constant pitch and (ii) the top housing is spaced apart from the light-emitting elements by an amount ranging from the pitch between light-emitting elements to twice the pitch between light-emitting elements.

20. The lighting system of claim 1, wherein at least one light-emitting element emits substantially white light.

21. The lighting system of claim 1, wherein at least one light-emitting element comprises a light-emitting diode.

22. The lighting system of claim 1, wherein the sealed region is at least partially filled with a flexible transparent material having a transmittance of at least 90% to a wavelength of light emitted by the light-emitting elements.

23. The lighting system of claim 1, wherein the top housing comprises a plurality of shaped regions each associated with a light-emitting element.

24. The lighting system of claim 1, further comprising an optical element disposed between the light-emitting elements and the top housing.

25. The lighting system of claim 1, wherein (i) the top housing defines a plurality of shaped regions, (ii) each shaped region is associated with a light-emitting element and forms at least a portion of an optical element thereover, and (iii) the top housing has a transmittance greater than 90% to a wavelength of light emitted by the light-emitting elements.

26. The lighting system of claim 1, wherein the lighting system is flexible.

27. The lighting system of claim 1, wherein the top housing comprises a transparent flexible material.

28. The lighting system of claim 27, wherein the transparent flexible material comprises at least one of silicone, polyurethane, or epoxy.

29. The lighting system of claim 1, wherein the top housing conformally coats at least a portion of the first surface of the light sheet.

30. The lighting system of claim 1, wherein at least one light-emitting element is coupled to one or more of the conductive traces with an anisotropic conductive adhesive, the anisotropic conductive adhesive being activatable via application of at least one of pressure, heat, or a magnetic field.

31. The lighting system of claim 1, wherein the top housing conformally coats at least one light-emitting element.

32. The lighting system of claim 1, wherein at least a portion of the top housing is transparent to a wavelength of light emitted by the light-emitting elements.

33. The lighting system of claim 32, wherein the top housing conformally coats at least a portion of the first surface of the light sheet.

34. The lighting system of claim 33, wherein the top housing conformally coats at least one light-emitting element.

35. The lighting system of claim 33, further comprising:

a plurality of control elements each (i) electrically connected to at least one light-emitting string and (ii) configured to utilize power supplied from the power conductors to control the current to the at least one light-emitting string to which it is electrically connected, wherein the plurality of control elements are disposed within the sealed region; and

an electrical connector (i) electrically connected to at least one of the first or second power conductors, (ii) terminating outside of the sealed region, and (iii) configured to receive a complementary connector or wire electrically connected to an external power source.

36. The lighting system of claim 35, wherein the top housing conformally coats at least one light-emitting element.

37. The lighting system of claim 32, wherein the top housing comprises a plurality of shaped regions each associated with a light-emitting element and spaced-apart therefrom.

38. The lighting system of claim 37, further comprising:

a plurality of control elements each (i) electrically connected to at least one light-emitting string and (ii) configured to utilize power supplied from the power conductors to control the current to the at least one light-emitting string to which it is electrically connected, wherein the plurality of control elements are disposed within the sealed region; and

an electrical connector (i) electrically connected to at least one of the first or second power conductors, (ii) terminating outside of the sealed region, and (iii) configured to receive a complementary connector or wire electrically connected to an external power source.

39. The lighting system of claim 1, wherein a transmittance of at least a portion of the top housing to a wavelength of light emitted by the light-emitting elements is greater than 75%.

40. The lighting system of claim 1, further comprising an electrical connector (i) electrically connected to least one of the first or second power conductors and (ii) terminating outside of the sealed region and configured to receive a complementary connector or wire electrically connected to an external power source.

41. The lighting system of claim 1, further comprising:

a plurality of control elements each (i) electrically connected to at least one light-emitting string and (ii) configured to utilize power supplied from the power conductors to control the current to the at least one light-emitting string to which it is electrically connected, wherein the plurality of control elements are disposed within the sealed region; and

an electrical connector (i) electrically connected to at least one of the first or second power conductors, (ii) terminating outside of the sealed region, and (iii) configured to receive a complementary connector or wire electrically connected to an external power source.

42. The lighting system of claim 1, wherein at least a portion of the light emitted by the light-emitting elements is transmitted through the polymeric top housing.

43. The lighting system of claim 42, further comprising a diffuser disposed over the polymeric top housing.

44. The lighting system of claim 1, further comprising a diffuser disposed over the polymeric top housing.