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

• US 9,927,102 B2
• Filed: 10/18/2016
• Issued: 03/27/2018
• Est. Priority Date: 09/06/2012
• Status: Expired due to Fees

• Current Assignee: Cooledge Lighting Inc.
• Original Assignee: Cooledge Lighting Inc.
• Inventors: Tischler, Michael A., Palfreyman, Paul
• Primary Examiner(s): Hammond, Crystal L
• Application Number:
  US15/296,590
• Publication Number:
  US 20170051898A1
• Time in Patent Office: 525 Days
• Field of Search: None
• 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. The top housing defines a plurality of shaped regions each associated with a light-emitting element and spaced apart from and not in contact with the light-emitting element with which it is associated.

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 substrate;

a plurality of light-emitting strings disposed 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;

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; 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 and at least some of the conductive traces,

wherein the top housing defines a plurality of shaped regions each (i) associated with a light-emitting element and (ii) spaced apart from and not in contact with the light-emitting element with which it is associated.

2. The lighting system of claim 1, wherein the sealed region contains therewithin at least a portion of the first power conductor and at least a portion of the second power conductor.

3. The lighting system of claim 1, wherein at least a portion of the first power conductor and at least a portion of the second power conductor are disposed over the first surface of the substrate.

4. The lighting system of claim 1, wherein a pressure within at least a portion of the sealed region is less than atmospheric pressure.

5. The lighting system of claim 1, 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) one or more control elements, (iii) 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 (iv) a sealed region defined by a seal between a portion of the top housing and the substrate.

6. The lighting system of claim 1, wherein at least one of the control elements is disposed within the sealed region.

7. The lighting system of claim 1, further comprising a plurality of additional conductive traces disposed over the substrate and each (i) electrically connecting a light-emitting element to a control element, or (ii) electrically connecting a control element to the first power conductor or to the second power conductor.

8. The lighting system of claim 7, wherein at least some of the additional conductive traces and at least one of the control elements are disposed within the sealed region.

9. The lighting system of claim 1, wherein the first and second power conductors are disposed entirely within the sealed region.

10. 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.

11. The lighting system of claim 10, wherein the power supply is configured to provide a substantially constant voltage to the first and second power conductors.

12. The lighting system of claim 1, wherein the plurality of control elements are disposed on the substrate.

13. The lighting system of claim 1, wherein at least one of the shaped regions contains therewithin air, an inert gas, and/or a material that is transparent or substantially transparent to a wavelength of light emitted by the light-emitting elements.

14. The lighting system of claim 1, wherein at least one of the shaped regions is shaped as a hemisphere, a portion of a sphere, or a paraboloid.

15. The lighting system of claim 1, further comprising a polymeric bottom housing disposed over the second surface of the substrate, at least a portion of the bottom housing contacting the second surface of the substrate to form a second sealed region disposed between the bottom housing and the second surface of the substrate.

16. 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.

17. The lighting system of claim 16, 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.

18. The lighting system of claim 17, wherein the lighting system has an ingress protection rating of at least IP 65, as specified by International Protection Marking in International Electrotechnical Commission (IEC) standard 60529.

19. The lighting system of claim 16, 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.

20. The lighting system of claim 1, further comprising at least one of (i) control circuitry configured to control at least one emission characteristic of the light-emitting elements, or (ii) communication circuitry configured to transmit information to or from the lighting system.

21. The lighting system of claim 20, wherein (i) the lighting system comprises control circuitry configured to control at least one emission characteristic of the light-emitting elements, and (ii) the at least one emission characteristic comprises at least one of a correlated color temperature, a color rendering index, R9, a luminous flux, a light output power, a spectral power density, a radiant flux, a light-distribution pattern, or an angular color uniformity.

22. The lighting system of claim 1, wherein each light-emitting string is electrically coupled to a different control element.

23. 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 configured to convey a communication or control signal to or from the light sheet.

24. The lighting system of claim 23, wherein the communication or control signal comprises at least one of a light-intensity level, a correlated color temperature, a color rendering index, a luminous-intensity distribution, or an operational state of the light sheet.

25. The lighting system of claim 1, wherein the top housing comprises at least one of polyester, acrylic, polystyrene, polyethylene, polyimide, polyethylene naphthalate, polyethylene terephthalate, polypropylene, polycarbonate, acrylonitrile butadiene styrene, polyurethane, silicone, or polydimethylsiloxane.

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

27. The lighting system of claim 1, wherein a thickness of the lighting system is less than 15 mm.

28. 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.

29. 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%.

30. The lighting system of claim 1, wherein the light-emitting elements in each of the light-emitting strings are separated at a substantially constant pitch.

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

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

33. The lighting system of claim 1, further comprising a desiccant disposed in the sealed region.

34. The lighting system of claim 1, wherein at least one of the light-emitting elements incorporates a light-conversion material for conversion of at least a portion of light emitted by the at least one of the light-emitting elements to light having a different wavelength.

35. The lighting system of claim 1, 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.

36. 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 substrate;

a plurality of light-emitting strings disposed 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;

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;

a polymeric top housing disposed over the first surface of the substrate; and

a polymeric bottom housing disposed over the second surface of the substrate and sealed to the top housing at a contact point between the top housing and the bottom housing to form a sealed region between the top housing and the bottom housing, the sealed region containing the substrate therewithin,

wherein the top housing defines a plurality of shaped regions each (i) associated with a light-emitting element and (ii) spaced apart from and not in contact with the light-emitting element with which it is associated.

37. The lighting system of claim 36, 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) one or more control elements, (iii) 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 (iv) a sealed region defined by a seal between a portion of the top housing and the substrate.

38. The lighting system of claim 36, wherein at least one of the shaped regions contains therewithin air, an inert gas, and/or a material that is transparent or substantially transparent to a wavelength of light emitted by the light-emitting elements.

39. The lighting system of claim 36, 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.