LED linear lighting kit

• US 9,565,769 B2
• Filed: 05/08/2015
• Issued: 02/07/2017
• 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, Holleschau, Randall
• Primary Examiner(s): Coughlin, Andrew
• Assistant Examiner(s): GARLEN, ALEXANDER K
• Application Number:
  US14/707,962
• Publication Number:
  US 20150241034A1
• Time in Patent Office: 641 Days
• US Class Current: 1/1
• CPC Class Codes: F21S 4/28 rigid, e.g. LED bars
• CPC Class Codes: F21V 15/013 the housing being an extrusion
• CPC Class Codes: F21V 15/015 Devices for covering joints between adjacent lighting devices; End coverings
• CPC Class Codes: F21V 21/025 Elongated bases having a U-shaped cross section
• CPC Class Codes: F21V 3/049 Patterns or structured surfaces for diffusing light, e.g. frosted surfaces
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2113/00 Combination of light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

An LED lighting kit comprises an extrusion (300), an LED strip (100), a tapered wedge (1500), and a mounting clip (1200). The extrusion itself may have a recessed linear groove of sufficient width and depth to seat the LED strip. The clip is sized and shaped to springably engage ledges (320) in a first channel (310) 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 (315) that houses the LED strip. A translucent diffuser (900) is springably inserted into the second channel, thereby diffusing light that is emitted by the LED strip.

Claims

1. An extrusion kit for LED lighting, comprising:

at least two extrusions adapted to carry linear LED lighting, each of the at least two extrusions having

a first, open channel defined by a first pair of opposed, generally parallel sidewalls spaced from one another with a first channel floor between and connecting the first pair of sidewalls, the first channel floor being generally flat,

a linear, flat-bottomed guide channel recessed into a central portion of the first channel floor and extending along at least substantially the entirety of the first channel, the linear guide channel having a width and depth sufficient to accommodate and seat an LED strip flat against the bottom of the linear guide channel,

a second channel adapted to seat connecting structures, the second channel being spaced or offset from and connected to the first channel such that the first and second channels run an entire length of the extrusion, the second channel having a second pair of opposed, generally parallel sidewalls spaced from one another with a second channel floor between and connecting the second pair of sidewalls, and

a pair of ledges connected to respective outermost portions of the second pair of sidewalls and extending perpendicularly inwardly therefrom without meeting to define an opening for the second channel, the opening for the second channel being smaller than a width of the second channel; and

an insert with first and second ends that tapers from a maximum width between the first and second ends to minimum widths proximate to the first and second ends, the minimum widths being less than the widths of the second channels and the maximum width being equal to or greater than the widths of the second channels such that the insert can be slid into the adjacent second channels of the at least two extrusions to join the extrusions in an abutted, press-fit connection.

2. The extrusion kit of claim 1, further comprising a strip of linear LED lighting with a width just smaller than a width of the guide channels, such that it can be seated in the guide channels once the at least two extrusions are joined.

3. The extrusion kit of claim 1, wherein the first channels are opposite their respective second channels.

4. The extrusion kit of claim 1, wherein the first channels are opposite and angularly offset from their respective second channels.

5. The extrusion kit of claim 1, wherein the sidewalls of the first channels have structure adapted to receive and retain a diffuser, such that the diffuser is mounted above the LED lighting.

6. The extrusion kit of claim 1, wherein the insert comprises a double-tapered wedge.

7. The extrusion kit of claim 1, further comprising one or more mounting clips adapted to engage the respective second channels to mount the at least two extrusions.

8. The extrusion kit of claim 7, wherein each of the one or more mounting clips has a base and a plurality of flat and flexible members having a main portion extending away from said base and in generally parallel relation.

9. An extrusion kit for LED lighting, comprising:

at least two extrusions adapted to carry linear LED lighting, each of the at least two extrusions having

a first, open channel defined by a first pair of opposed, generally parallel sidewalls spaced from one another with a first channel floor between and connecting the first pair of sidewalls, the first channel floor being generally flat,

a raised ridge or abutment on the first channel floor and extending along at least substantially the entirety of the first channel,

a second channel adapted to seat connecting structures, the second channel being spaced or offset from and connected to the first channel such that the first and second channels run an entire length of the extrusion, the second channel having a second pair of opposed, generally parallel sidewalls spaced from one another with a second channel floor between and connecting the second pair of sidewalls, and

a pair of ledges connected to respective outermost portions of the second pair of sidewalls and extending perpendicularly inwardly therefrom without meeting to define an opening for the second channel, the opening for the second channel being smaller than a width of the second channel; and

an insert with first and second ends that tapers from a maximum width between the first and second ends to minimum widths proximate to the first and second ends, the minimum widths being less than the widths of the second channels and the maximum width being equal to or greater than the widths of the second channels such that the insert can be slid into the adjacent second channels of the at least two extrusions to join the extrusions in an abutted, press-fit connection.

10. The extrusion kit of claim 9, further comprising a strip of linear LED lighting adapted to be applied to the floors of the first channels, positioned against the ridge or abutment.

11. The extrusion kit of claim 9, wherein the first channels are opposite their respective second channels.

12. The extrusion kit of claim 9, wherein the first channels are opposite and angularly offset from their respective second channels.

13. The extrusion kit of claim 9, wherein the sidewalls of the first channels have structure adapted to receive and retain a diffuser, such that the diffuser is mounted above the LED lighting.

14. The extrusion kit of claim 9, wherein the insert comprises a double-tapered wedge.

15. The extrusion kit of claim 9, further comprising one or more mounting clips adapted to engage the respective second channels to mount the at least two extrusions.

16. The extrusion kit of claim 15, wherein each of the one or more mounting clips has a base and a plurality of flat and flexible members having a main portion extending away from said base and in generally parallel relation.

17. An extrusion kit for LED lighting, comprising:

at least two extrusions adapted to carry linear LED lighting, each of the at least two extrusions having

a first, open channel defined by a first pair of opposed, generally parallel sidewalls spaced from one another with a first channel floor between and connecting the first pair of sidewalls, the first channel floor being generally flat,

a second channel adapted to seat connecting structures, the second channel being spaced or offset from and connected to the first channel such that the first and second channels run an entire length of the extrusion, the second channel having a second pair of opposed, generally parallel sidewalls spaced from one another with a second channel floor between and connecting the second pair of sidewalls, and

a pair of ledges connected to respective outermost portions of the second pair of sidewalls and extending perpendicularly inwardly therefrom without meeting to define an opening for the second channel, the opening for the second channel being smaller than a width of the second channel; and

an insert with first and second ends that tapers from a maximum width between the first and second ends to minimum widths proximate to the first and second ends, the minimum widths being less than the widths of the second channels and the maximum width being equal to or greater than the widths of the second channels such that the insert can be slid into the adjacent second channels of the at least two extrusions to join the extrusions in an abutted, press-fit connection.

18. The extrusion kit of claim 17, further comprising a strip of linear LED lighting adapted to be applied to the floors of the first channels.

19. The extrusion kit of claim 17, wherein the first channels are opposite their respective second channels.

20. The extrusion kit of claim 17, wherein the first channels are opposite and angularly offset from their respective second channels.

21. The extrusion kit of claim 17, wherein the sidewalls of the first channels have structure adapted to receive and retain a diffuser, such that the diffuser is mounted above the LED lighting.

22. The extrusion kit of claim 17, wherein the insert comprises a double-tapered wedge.