HK1180757B - Card edge led strip connector and led assembly - Google Patents

Description

Card edge LED strip connector and LED assembly

The application is a divisional application of an invention patent application with the filing date of "2009, 12 and 08", the filing number of "200910254020.0", the invention name of "card edge light emitting diode light bar connector and light emitting diode assembly".

Technical Field

The invention relates to the technical field of light emitting diodes, in particular to a card edge light emitting diode connector and a light emitting diode assembly.

Background

LED (light emitting diode) lamps are increasingly popular for use in a wide variety of lighting applications. Significant advances in LED lighting technology have resulted in LED lamp usage that is more affordable and desirable in a variety of industrial, household, and other environments requiring an expanded lighting system.

LED lamps offer significant advantages over conventional incandescent lighting systems. In the case of incandescent bulbs, the expense is not only the expense of replacing the bulb, but also the labor and cost associated with frequent replacement of the bulb. Where a large number of bulbs are installed, such expense can be substantial, for example, in large office buildings, mass transit vehicles and systems thereof, and the like, where maintenance costs required to replace the bulbs can be high. These problems are significantly reduced by the LED lighting system.

The operating life of a conventional white LED lamp is about 100,000 hours, which is equivalent to about 11 years of continuous operation, or about 50% of 22 years of operation. This is in strong contrast to the average life of an incandescent light bulb of about 5000 hours, and thus the use of LED lamps is readily perceived to virtually eliminate the need for daily bulb replacement. This advantage is even more important when the lighting device is embedded in a place that is difficult to access.

It is generally recognized that in a properly designed system, LED lamps consume significantly less energy than incandescent light bulbs. The LED circuit has an efficiency of about 80%, which means that 80% of the electrical energy is converted into light energy, while the remaining 20% is lost as thermal energy. In large lighting systems, this cost savings is enormous.

Unfortunately, due in part to the relatively high cost of LED lamps, the prior art has instead sought fluorescent bulbs and systems as a replacement for incandescent lamps. Fluorescent lighting devices are approximately 66% less expensive than incandescent lighting devices, while providing substantially the same brightness. Fluorescent lighting devices also last longer than conventional incandescent lighting devices, and on average, fluorescent tubes have a service life five times longer than ordinary incandescent bulbs. Most commercial and industrial buildings are fitted with conventional fluorescent tube lighting, as are more recent residential buildings. Fluorescent lighting devices are also widely used in mass transit systems and vehicles, trains, subway cars, airplanes, etc.

However, fluorescent lamps have significant disadvantages. Fluorescent lighting circuits are more complex than incandescent lighting and typically require specialized installations and expensive components. Fluorescent lighting is generally less comfortable than incandescent lighting, and can be perceived as flickering and produce uneven light that can be annoying to some users. Mercury is an essential component in the manufacture of fluorescent tubes and is considered harmful by the united states environmental protection agency due to the biological concentration in the environment. Fluorescent light tubes are problematic to many municipalities and in many locations a movement is being undertaken to phase out the use of fluorescent lighting.

Increasing the reliance on LED illumination is thus a natural advance. However, replacing existing fluorescent tube devices and circuits in existing buildings, vehicles, systems, etc. is cost prohibitive. Thus, there is a need for a lighting system that can easily and economically install LED lighting devices in conventional lighting fixtures. The present invention provides a unique solution to this need.

Disclosure of Invention

Objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

According to one aspect of the invention, an LED lamp assembly is provided that includes a plurality of LED Printed Circuit Boards (PCBs), each PCB having at least one LED bulb and electrical connector pads disposed at each opposing end of the PCB. An electrical connector is arranged to electrically connect one end of a first LED PCB to one end of an adjacent second LED PCB.

The connector between the adjacent two LED PCBs may take various configurations. In a particularly unique embodiment, the electrical connector includes a dielectric body having oppositely aligned open ends. For example, the body may have an open-ended box or tunnel housing structure. At least two electrical contacts are held in the insulative body and spaced apart a distance corresponding to a separation distance of the connector pads at the ends of the LED PCB. It should be appreciated that any number of contacts may be configured in the body, depending on the desired contact leg (footprint). Each contact may be a blade-like member having a central beam and receiving channels extending in opposite directions from the central beam to respective open ends of the insulative body. The receiving channel is defined between a pair of contact arms extending transversely from the central beam and configured to electrically engage a connector pad against an end of the LED PCB inserted at the open end of the insulative body.

The contacts may be retained in the connector housing in a variety of ways. For example, in a unique embodiment, slots may be formed in the inner surfaces of the top and bottom sides of the dielectric body, the slots having a width that substantially corresponds to the thickness of the contacts. The slots are open at one of the ends of the body so that the contacts can slide into the slots at the respective ends. The slot may be blind at the opposite end so that the contact is not pushed out of the slot. This embodiment contemplates the inclusion of an identifying indicia on the exterior surface of the body shell that provides an identification of the respective longitudinal ends of the open slots. When connecting adjacent LED PCBs, the first PCB should be inserted into one end of the connector having the open slot before inserting the PCBs into the opposite end of the connector. First inserting the PCB into the opposite end of the connector may cause the contacts to be pushed out of the housing through the open end face of the slot.

The contacts may take any desired shape and configuration that ensures reliable electrical contact with the contact pads on the LED PCB. In one embodiment, the electrical contacts include barbs on the contact arms that are configured to slide against the connector pads. The contact arms may be biased into the receiving channels, and the barbs also serve to allow the contact arms to deflect after the ends of the LED PCB are inserted into the receiving channels.

It will be appreciated that the contacts may be retained in the insulative body by other suitable means, for example, the electrical contacts may be molded into the body.

The electrical connectors between the LED PCBs allow for minimal spacing between the boards and thus allow for uniform spacing between the LED bulbs of adjacent boards. The center beam of the electrical contact substantially defines a separation distance between ends of adjacent LED PCBs. In a particular embodiment, the central beam has a longitudinal length of between 1mm and 5mm such that adjacent ends of the LED PCB are spaced apart by a minimum distance equal to between about 1mm and 5mm in an assembled state.

The invention also encompasses an LED tube assembly configured for receipt in a lighting fixture, the tube assembly comprising a tube having end cap connectors at respective opposite longitudinal ends thereof. In this manner, the LED tube assembly may resemble a conventional fluorescent lighting tube. A plurality of LED PCBs are connected within the tube in an end-to-end configuration, wherein each LED PCB has at least one LED bulb and electrical connector pads disposed at respective opposite ends of the board. The electrical connector pads on the distal-most opposing ends of the connected boards are in electrical mating contact with the end cap connectors. As described above, the electrical connectors connect the connector pads of the aligned ends of adjacent LED PCBs within the tube such that an end of a first LED PCB is electrically contacted to an end of a second LED PCB. In this manner, any predetermined number of LED PCBs may be connected in an end-to-end manner within the tube. Accordingly, tubes of various sizes and power ratings can be easily manufactured and assembled with standard sized LED PCBs, end cap connectors, and board connectors. Only the length of the tube needs to be varied to accommodate the desired number of LED PCBs.

The LED tube assembly is unique in that it can be easily configured for reception in existing fluorescent lighting fixtures. The end cap connector may include pin contacts shaped to be received within a receptacle in a fluorescent lighting fixture. Thus, the LED tube may be a replacement bulb for existing fluorescent lighting fixtures.

The electrical connectors between the LED PCBs in the tube assembly may be configured as described above.

The invention also includes an electrical connector configured for connecting adjacent ends of an LED PCB within a light pipe, wherein the LED PCB has at least one LED bulb and a plurality of electrical contact pads at each end of the board. The connector may have a unique structure and advantages as described above and is described in more detail herein.

Various aspects of the invention are presented below with reference to specific embodiments shown in the figures.

Drawings

FIG. 1A is a detail view of one embodiment of an LED tube assembly;

FIG. 1B is a partially assembled view of the LED tube assembly of FIG. 1A;

FIG. 2A is a part view of one embodiment of an electrical connector and LED PCB assembly according to aspects of the present invention;

FIG. 2B is an assembled view of the components of FIG. 2A;

FIG. 3 is a cross-sectional side view of the assembled components of FIG. 2B;

FIG. 4 is an end view of an embodiment of an LED PCB connector;

FIG. 5 is a top view of the insulative body member of the LED PCB connector of FIG. 4;

FIG. 6 is a side view of the insulative body member of the LED PCB connector of FIG. 4; and

FIG. 7 is a top view of an end of an LED PCB showing connector pads.

Detailed Description

Reference will now be made to specific embodiments of the invention, examples of which are illustrated in the accompanying drawings, wherein the various embodiments illustrated herein are for the purpose of explaining various aspects of the invention, and should not be construed as limiting the invention, e.g., features illustrated or described with respect to one embodiment may be applied to another embodiment to yield a still further embodiment. It is intended that the present invention include these and other modifications and variations as come within the scope and spirit of the invention.

FIGS. 1A and 1B illustrate one particular embodiment embodying various aspects of the present invention. In fig. 1A, an LED lamp assembly 10 is shown, the assembly 10 including a plurality of individual LED Printed Circuit Boards (PCBs) 12. Each of these panels 12 includes at least one LED light bulb 14. In the illustrated embodiment, each plate 12 includes four light bulbs 14. The plate 12 may be machined to have a standard length, number of bulbs, and other standard dimensions. In this manner, the manufacturer does not have to manufacture and stock different sizes of LED PCBs 12, which is a significant cost and manufacturing advantage.

Each board 12 includes a first end 16 and an opposite second end 18, each end 16, 18 including a connector pad leg embodied as a plurality of connector pads 22. These pads 22 may be defined on an extension 20 of the main portion of the board 12, said extension 20 defining the extreme end of the board 12. In an alternative embodiment, the connector pads 22 may be shaped across the entire dimension of the main portion of the board 12 without the extensions 20. The connector pads 22 are used to electrically connect and supply power to the light bulbs 14 mounted on the board 12.

A more detailed view of the end of the board 12 is given in fig. 7, in which the extension 20 is embodied as two separate connector pads 22, which may be made of any conventional and suitable electrically conductive material, for example, in a particular embodiment, the pads are tinned. As shown in fig. 7, dimensions are specified in some of the figures for illustrative purposes only. It should be readily appreciated that size and dimensions are not limiting factors of the present invention, and that the present invention may be configured to have different dimensions and sizes depending on the particular end product in which the component is used.

Referring again to FIG. 1A, a connector 24 is disposed between adjacent LED PCBs 12, which connector 24 may take on a variety of configurations and is used to interconnect adjacent boards 12 in an end-to-end configuration. In the particular embodiment shown in the figures, the electrical connector 24 includes a dielectric body 26, the dielectric body 26 being formed of any suitable dielectric material, such as nylon 46. Other materials are well known to those skilled in the art and may be used for the connector 24 of the present invention. The body 26 has oppositely aligned open ends 38 as shown in fig. 4. In this manner, the body 26 may have an open-ended box-like or tunnel-like housing structure 28 with a channel formed completely through the housing 28.

The plurality of electrical contacts 40 held in the body 26 of the connector 24 may be made of any suitable material, such as a tin-plated copper alloy. The contacts 40 are spaced apart a distance corresponding to the separation distance of the connector pads 22 at the ends of the LED PCB12, as particularly shown in fig. 2A. Each contact 40 electrically engages and abuts a single connector pad 22 of one LED PCB and electrically connects the respective pad 22 to an aligned pad 22 of an adjacent LED PCB, as particularly shown in fig. 2A and 2B. It should be appreciated that any number of contacts may be configured in the body 26 depending on the contact and solder pad fillets on the respective LED PCB 12. For example, in fig. 2A and 2B, the connector 24 includes five contacts 40 that electrically engage with respective five connector pads 22 on each board 12. Such a configuration may be referred to in the art as a five-way connector. In the embodiment shown in fig. 4, two contacts 40 are held in the body 26 of the two-way connector 24. In the embodiment shown in fig. 1A, the connector 24 may be a four-channel connector having four individual contacts 40 to mate with corresponding four connector pads at the end of the board 12. It should thus be appreciated that the connector 24 is not limited by the number of contact elements or the end use configuration.

The contacts 40 retained in the connector body 26 may take on different shapes and configurations. In the particular embodiment shown particularly in fig. 3, for example, each contact element 40 is a blade-like member and includes a central beam or strut member 42. A pair of contact arms 46 extend in opposite longitudinal directions from the central beam, with each pair of arms 46 defining a receiving channel 44 for receiving an extension 20 of board 12 with a connector pad 22 on the extension 20, as particularly shown in fig. 3. Each arm 46 may include a barb 50 having an angled front face, as particularly shown in fig. 3. Each arm 46 may be biased into the receiving channel 44 to provide a more rigid and secure engagement against the connector pad 22. With this construction, the angled front faces of the barbs 58 assist in inserting the end 20 of the plate 12 into the receiving channel 44.

Each contact 40 may be retained in the body 26 of the connector 24 in a variety of ways-in the illustrated embodiment, a groove 48 is machined or otherwise formed in the interior surfaces of the top 30 and bottom 32 of the body 26, as particularly shown in fig. 2A. The slots 48 are open at one end of the body 26 for insertion of the contact 40 into the body 26. The open front face of the slot 48 is readily visible in fig. 2A. The slot 48, which has a width generally corresponding to the thickness of the blade contact 40, may be blind at the other end of the body 26 so that the contact 40 cannot be pushed completely through the body 26.

Due to the slot configuration discussed above, preferably, the board 12 is first inserted into the longitudinal end of the connector 24 having the open end of the slot 48. By inserting the plate 12 first into this end portion, each contact 40 is pushed completely into the body 26 to rest against the blind end of the slot 48 at the other end of the body 26 and thus cannot be displaced from the connector body 26. After the board 12 is inserted into this end, another board 12 may then be inserted into the other end of the connector 24. Here, it is contemplated that a marking or other indicia 52 may be provided on the top 30 and bottom 32 of the connector body 26, the marking 52 providing a positive indication to the first end of the connector 24 for insertion of the LED PCB12 during a subsequent assembly process. The indicia may be any manner of engraving, stamping, indentation, and the like.

It should be appreciated that the individual contacts may be retained in the dielectric body 26 of the connector 24 by any other suitable means, for example, the contacts 40 may be molded directly into the body 26 or retained by other mechanical means.

Referring to fig. 2B, it can be seen that the electrical connectors 24 between adjacent LED PCBs 12 enable the spacing between the boards to be minimized and thus a well-defined uniform spacing between the LED bulbs 14 of adjacent boards 12. The center beam member 42 of each contact 40 substantially defines a separation distance between the ends of adjacent LED PCBs 12. In a particular embodiment, the center beam has a longitudinal length between 1mm and 5mm such that adjacent ends of the LED PCB12 are spaced apart equal to a minimum distance between about 1mm and 5mm in an assembled state.

Fig. 5 and 6 are top and side views of the body 26 in the illustrated connector 24, as depicted in these and other figures, the body 26 may have a box or tunnel-like housing structure 28 defining an internal passage therethrough, as particularly shown in fig. 4.

The present invention also includes an LED tube assembly 60, as particularly shown in FIGS. 1A and 1B. The assembly 60 includes a light tube 62, which light tube 62 may be, for example, glass, plastic, or any other type of suitable clear or transparent material. The assembly 60 includes end cap connectors 64 at opposite ends of the light pipe 62, each of these connectors 64 including any form of external electrical connector means, such as pins 66, which pins 66 engage into electrical supply sockets in a conventional lighting fixture, such as any form of conventional fluorescent lighting fixture. A plurality of LED PCBs 12 are connected in an end-to-end configuration within the tube 62, as shown conceptually in fig. 1A, which shows two plates 12. The connector pads 22 on the extreme ends of the connected boards 12 engage in corresponding receptacles or other connector members in the end cap connectors 64. Thus, in this manner, a complete circuit board is defined from one end cap connector 64 through the interconnected panels 12 to the opposing end cap connector 64.

Referring again to fig. 1A, it should be appreciated that lamp assemblies 60 of various sizes and power ratings can be easily manufactured and assembled with standard sized LED PCBs, end cap connectors 64, and board connectors 24. Only the length of the tube 62 needs to be changed to accommodate the increased or decreased number of LED PCBs 12. The light tube assembly 60, particularly shown in fig. 1A, is unique in that it resembles a conventional fluorescent lighting bulb and can be easily configured to be received in existing fluorescent lighting fixtures. Thus, the LED light tube assembly 60 can serve as a replacement light bulb for existing fluorescent lighting fixtures.

It should also be readily appreciated that the present invention also encompasses an electrical connector 24, as described above, that is configured for connection to an adjacent end of the LED PCB12 within the tube 62 or other type of lighting fixture.

It should also be readily appreciated by those skilled in the art that various modifications and changes may be made thereto without departing from the scope and spirit of the invention as set forth in the claims and their equivalents.

Claims (12)

1. An LED light tube assembly configured for receipt in a lighting fixture, comprising:

   a lamp tube having end cap connectors at each of its opposite longitudinal ends;

   a plurality of LED printed circuit boards connected in an end-to-end configuration within the light pipe, each of the LED printed circuit boards having at least one LED bulb and electrical connector pads disposed at respective opposite ends of the LED printed circuit board, the electrical connector pads of the opposite ends of the connected ends of the LED printed circuit boards being in electrical mating contact with the end cap connector;

   an electrical connector connecting the electrical connector pads of the aligned ends of adjacent LED printed circuit boards within the light pipe such that an end of a first LED printed circuit board is electrically contacted to an end of a second LED printed circuit board, wherein the electrical connector further comprises:

   an insulative body and a plurality of electrical contacts having a closed top and a closed bottom extending to opposite open longitudinal ends of the body, the electrical contacts being retained in the insulative body and spaced apart a distance corresponding to a separation distance of the electrical connector pads at the ends of the LED printed circuit board;

   each of the electrical contacts has oppositely extending receiving channels extending in opposite directions to respective ones of the open longitudinal ends of the dielectric body, the receiving channels being defined by opposing pairs of contact arms disposed in slots in the inner surfaces of the closed top and closed bottom portions of the dielectric body, the slots extending at least to the ends of the contact arms.
2. 2. The LED tube assembly of claim 1, wherein the assembly is configured for receipt in a fluorescent lighting fixture, the end cap connector comprising pin contacts shaped for receipt in a socket in the fluorescent lighting fixture.
3. 3. The LED tube assembly of claim 1, wherein said LED printed circuit boards are of a standard uniform length, and whereby assemblies of varying lengths and powers are configured by connecting more or less of said LED printed circuit boards within said tube.
4. 4. The LED tube assembly of claim 1, wherein the slots are open at one of the longitudinal ends of the insulator body for insertion of the electrical contacts, and further comprising an identification marking on an outer surface of the insulator body, the identification marking providing an indication of the respective longitudinal end of the slot having the opening.
5. 5. The LED tube assembly of claim 1, wherein the opposing pairs of contact arms include barbs disposed to slidingly bear against and maintain electrical engagement with the electrical connector pads of the LED printed circuit board inserted into the receiving channels.
6. 6. The LED tube assembly of claim 5, wherein the contact arm is biased into the receiving channel.
7. 7. The LED tube assembly of claim 1, wherein the electrical contacts are molded into the insulative body.
8. An LED printed circuit board electrical connector configured for connection to adjacent ends of an LED printed circuit board within an LED lamp assembly, the LED printed circuit board having at least one LED bulb and a plurality of electrical connector pads at each end thereof, the connector comprising:

   a dielectric body having opposing open longitudinal ends and at least two electrical contacts retained in the dielectric body, the contacts being spaced apart by a distance corresponding to a separation distance of the electrical connector pads at the ends of the LED printed circuit board;

   each of the electrical contacts having a central beam and opposing receiving channels extending in opposite directions from the central beam to respective longitudinal ends of the opening of the insulative body, the receiving channels defined between opposing pairs of contact arms extending transversely from the central beam, the contact arms configured to electrically engage the electrical connector pads against an end of one of the LED printed circuit boards inserted at the longitudinal ends of the opening of the insulative body;

   the insulative body includes a housing having a closed top, a closed bottom, sides, and a passageway extending therethrough between the open longitudinal ends of the body, the top and bottom extending to the open longitudinal ends, each of the opposing pairs of contact arms fitting into slots in the inner surfaces of the top and bottom of the housing, the slots extending at least to the ends of the contact arms.
9. 9. The LED printed circuit board electrical connector of claim 8, wherein said slots are open at one of said longitudinal ends of said housing for insertion of said electrical contacts, and further comprising an identification mark on an outer surface of said housing, said identification mark providing an indication of the respective said longitudinal end of the slot having said opening.
10. 10. The LED printed circuit board electrical connector of claim 8, wherein the opposing pairs of contact arms are biased into the receiving channel and include barbs that are configured to slide against and maintain electrical contact with the electrical connector pads of the LED printed circuit board inserted into the receiving channel.
11. 11. The LED printed circuit board electrical connector of claim 8, wherein the electrical contacts are molded into the insulative body.
12. 12. The LED printed circuit board electrical connector of claim 8, wherein the central beam of the electrical contact has a longitudinal length between 1mm and 5mm such that adjacent ends of the LED printed circuit board are spaced apart a minimum distance equal to the length of the central beam in an assembled state.