LED extrusion light engine and connector therefor

• US 20020174995A1
• Filed: 05/25/2001
• Published: 11/28/2002
• Est. Priority Date: 05/25/2001
• Status: Active Grant

• Current Assignee: Current Lighting Solutions, LLC (f/k/a GE Lighting Solutions, LLC) (American Industrial Partners)
• Original Assignee: Gelcore (General Electric Company)
• Inventors: Petroski, James T., Aanegola, Srinath K., Southard, Paul W.
• Granted Patent: US 6,660,935 B2
• Time in Patent Office: Days
• US Class Current: 174/48
• CPC Class Codes: F21S 4/20 with light sources held by or within elongate supports
• CPC Class Codes: F21V 21/002 making direct electrical contact, e.g. by piercing F21V21/35 takes precedence
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G09F 13/0404 the light source being enclosed in a box forming the character of the sign
• CPC Class Codes: G09F 13/0413 Frames or casing structures therefor
• CPC Class Codes: G09F 13/22 electroluminescent electroluminescent light sources per se H05B33/00
• CPC Class Codes: G09F 9/33 being semiconductor devices, e.g. diodes
• CPC Class Codes: Y10S 362/80 Light emitting diode
• CPC Class Codes: Y10S 362/812 Signs

Abstract

An LED light engine includes an electrical conductor, a flexible, electrically insulating covering surrounding the electrical conductor, and an LED. The electrical conductor includes a plurality of conductive elements. A connector is mechanically secured to the flexible insulating covering and electrically contacts the electrical conductor. In one embodiment, the LED electrically contacts the electrical conductor and is mechanically secured to the insulating covering. Alternatively, the LED electrically contacts the electrical conductor and is mechanically secured to the insulating covering via the connector.

Claims

1. An LED light engine, comprising:

an electrical conductor;

a flexible, electrically insulating covering surrounding the electrical conductor; and

an LED, which electrically contacts the electrical conductor and is mechanically secured to the insulating covering.

2. The LED light engine as set forth in claim 1, wherein the electrical conductor includes a plurality of conductive elements.

3. The LED light engine as set forth in claim 2, wherein each of the conductive elements includes a plurality of strands and is about 14 gauge.

4. The LED light engine as set forth in claim 2, wherein the flexible covering surrounds and electrically insulates each of the conductive elements.

5. The LED light engine as set forth in claim 4, wherein:

the LED includes a plurality of electrical leads; and

a pair of the leads displaces the insulating covering and contacts respective ones of the conductive elements.

6. The LED light engine as set forth in claim 5, wherein each of the electrical leads is wedge-shaped.

7. The LED light engine as set forth in claim 5, wherein the flexible covering includes a plurality of dips positioned for aligning the leads with the conductive elements.

8. The LED light engine as set forth in claim 1, further including:

a connector mechanically secured to the flexible insulating covering and electrically contacting the electrical conductor, the LED electrically contacting the electrical conductor and being mechanically secured to the insulating covering via the connector.

9. The LED light engine as set forth in claim 8, wherein:

the conductor includes a plurality of conductive elements, each of which is electrically insulated by the flexible covering from the other conductive elements; and

the connector includes a plurality of electrical contacts that extend through the flexible covering and electrically contact respective ones of the conductive elements, the LED being electrically connected to the electrical contacts.

10. The LED light engine as set forth in claim 9, wherein:

each of the electrical contacts is V-shaped; and

each of the conductive elements is positioned within an opening defined by the respective V-shaped electrical contact.

11. The LED light engine as set forth in claim 10, wherein the connector includes a locking tab for securing the connector in a locked position, the conductive elements being positioned within the respective V-shaped electrical contacts when the connector is in the locked position.

13. The method of manufacturing an LED light engine as set forth in claim 12, wherein the securing step includes:

displacing an insulating covering over one of the conductive elements;

inserting one of the LED leads into the displaced covering.

14. The method of manufacturing an LED light engine as set forth in claim 12, wherein the conductive elements include a plurality of conductive strands, the contacting step including:

passing one of the LED leads through an insulating covering over one of the conductive elements; and

inserting the LED lead between the conductive strands of the conductive element.

15. The method of manufacturing an LED light engine as set forth in claim 14, wherein the insulating covering includes a groove, further including, before the passing step:

aligning the LED lead with the conductive element via the groove.

16. The method of manufacturing an LED light engine as set forth in claim 12, wherein:

the securing step includes;

mechanically attaching a connector to an insulating covering on the conductor; and

the contacting step includes;

passing an electrical contact, secured to the connector, through the insulating covering so that an electrical connection is made between the contact and a respective one of the conductive elements.

17. The method of manufacturing an LED light engine as set forth in claim 16, wherein the electrical contact is V-shaped, the passing step including:

securing the conductive element within the V-shaped contact.

19. The LED strip as set forth in claim 18, wherein:

the conductor and the electrically insulating material are flexible in a first direction where a plurality of the connectors are mechanically secured to the electrically insulating material; and

the conductor and the electrically insulating material are flexible in a second direction where a plurality of the LEDs are mechanically secured directly to the electrically insulating material.

20. The LED strip as set forth in claim 18, wherein:

the connector electrically contacts the conductors via a V-shaped contact;

the conductive elements include a plurality of electrically conductive strands; and

the LED which directly electrically contacts the conductive elements include leads which are inserted between the strands.

21. The LED strip as set forth in claim 18, wherein the conductor, the electrically insulating material, and the at least one of the a) connector mechanically secured to the electrically insulating material and the b) LED mechanically secured directly to the electrically insulating material are capable of being spooled.

12. A method of manufacturing an LED light engine, the method comprising:

insulating a plurality of conductive elements to form a flexible electrically insulating conductor;

mechanically securing an LED to the insulated conductive elements; and

electrically contacting a plurality of leads of the LED to respective ones of the conductive elements.

18. An LED strip, comprising:

a conductor including a plurality of substantially parallel conductive elements;

an electrically insulating material which electrically insulates each of the conductive elements; and

at least one of a) a connector mechanically secured to the electrically insulating material and electrically contacting the conductive elements, an LED mechanically and electrically secured by the connector electrically contacting the conductive elements via the connector, and b) an LED mechanically secured directly to the electrically insulating material and directly electrically contacting the conductive elements.