Abstract:
A showcase member of a glass showcase, the showcase member including a first portion having a plurality of apertures, a light emitting diode (LED) module positioned at one or more of the plurality of apertures and mounted to the showcase member, and a wiring harness electrically connected to the LED module, and configured to electrically connect the LED module to an LED driver circuit. The showcase member can include a second portion integral to the first portion and having tapers forming light shields protruding from the showcase member.

Description:
CLAIM OF PRIORITY 
       [0001]    This patent application claims the benefit of priority, under 35 U.S.C. §119(e), of U.S. Provisional Patent Application Ser. No. 61/876,533, filed Sep. 11, 2013, titled “DIRECT MOUNTED LED LIGHT SOURCE” the entire disclosure of which is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    To enhance the visual appeal of products displayed in glass showcases, including refrigerated display cases, light sources are added to one or more of the showcase&#39;s mullions. In some implementations, a light bar can include a fluorescent fixture holding a fluorescent tube. The light bar is mounted along the face of a mullion inside the showcase. Other implementations mount a light emitting diode (LED) light bar on the mullion(s). 
         [0003]      FIG. 1A  is a perspective view of a conventional light bar  100 . Light bar  100  includes lens  110  and housing  120 . A light source is located within the light bar (e.g., fluorescent lamp(s) or LED light modules).  FIG. 1B  is a perspective view of a typical mounting arrangement for light bar  100  having LED modules inside the light bar. The light bar is mounted to mullion  130  by first attaching mounting clips  140  spaced along the surface of the mullion. These mounting clips have protrusions which snap into extruded grooves on the external surface of light bar  100 . Electrical connection is made to the light sources by attaching power leads  150  from the light bar to power supply wires  152  located within mullion  130  then, optionally, pieces can be added as finishing trim. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]      FIG. 1A  is a perspective view of a conventional light bar; 
           [0005]      FIG. 1B  is a perspective view of a typical mounting arrangement for the conventional light bar of  FIG. 1 ; 
           [0006]      FIG. 2  depicts an LED module mounted in a showcase member in accordance with an embodiment; 
           [0007]      FIG. 3  depicts an LED module mounted in a showcase member in accordance with another embodiment; 
           [0008]      FIG. 4  depicts an LED module mounted in a showcase member in accordance with another embodiment; 
           [0009]      FIG. 5  depicts an LED module mounted in a showcase member in accordance with another embodiment; 
           [0010]      FIG. 6  depicts an LED module mounted in a showcase member in accordance with another embodiment; 
           [0011]      FIG. 7  depicts an LED module mounted in a showcase member in accordance with another embodiment; 
           [0012]      FIG. 8  depicts a showcase member plan view having apertures in accordance with embodiments; 
           [0013]      FIG. 9  depicts a perspective view of a portion of a showcase member in accordance with embodiments; and 
           [0014]      FIG. 10  depicts a perspective view of a bezel in accordance with embodiments. 
       
    
    
     DESCRIPTION 
       [0015]    In accordance with embodiments, one or more LED modules are mounted directly to a member of a glass showcase. The showcase member can be a mullion, a frame or structural piece, a trim piece, a finishing piece, top, side, and/or bottom plate. The showcase member can be vertically, horizontally, or diagonally orientated. The number of LED modules mounted to the showcase member is dependent on such factors as the length of the showcase member; the LED light intensity; the desired illumination affect; and other factors. When mounted to the showcase member, the LED module and the member form a complete device that can be used in constructing a showcase. 
         [0016]    The LED module includes an LED light engine (e.g., a LED chip array, LED wafer, etc.) as a light source, an optical element (e.g., lens, reflector, etc.), and a printed circuit board (PCB). The PCB can include etched circuitry and/or wiring which connects to terminals on the LED light engine. The body of the LED module can be overmolded with a coating (e.g., plasticized) to provide environmental protection and electrical isolation. 
         [0017]    Individual LED modules are inserted through, or positioned at, apertures in a first portion of the showcase member surface. A wiring harness can connect the LED modules to an LED driver circuit/power supply. The wiring harness itself can be located within the showcase member and connect to the LED modules&#39; PCB. In another implementation the wiring harness can be located on an external showcase member surface and dressed/concealed with wiremold or some other encasement. In accordance with some embodiments, the wiring harness can be configured to connect the LED modules to a LED driver circuit/power supply by providing an electrical connector that can be connected to the LED driver circuit/power supply at a location remote from the showcase member. 
         [0018]    The optical element is positioned over the LED light engine. The optical element directs (e.g., diffracts or otherwise shapes and/or redirects) light emitted by the LED towards the products placed in the showcase to help enhance their appearance and desirability. In accordance with embodiments, the optical element can be a total internal reflection (TIR) lens, a Fresnel lens, a reflector, and/or the like. The optical element can direct the emitted light towards the left and right, typically with less light being directed forward. Because the showcase member may block the product view from outside the showcase, there may be less need for light directly in front of the showcase member. 
         [0019]    The LED module may be mounted to the showcase member providing a minimal protrusion above the surface of the showcase member. The combined thickness of the direct mounted LED source in combination with the showcase member may have a thinner profile than conventional light bars in combination with the showcase mullion. Thus, the light source may be further from the displayed product than with a conventional light bar. This added distance may reduce the light beam pattern diffraction angle needed to illuminate the displayed product. Commensurate with the reduced diffraction angle is a more efficient and uniform lighting affect. 
         [0020]    Combining the LED module with the showcase member may remove the need of an independent housing which is a necessary part of the prior art light bar. In accordance with embodiments, the LED module can be mounted to the showcase member without a separate housing by several modes. In accordance with implementations shown and described herein are several implementations. However, any number of other configurations may be provided in accordance with embodiments. 
         [0021]      FIG. 2  depicts LED module  200  mounted in an aperture formed on showcase member  210  in accordance with an embodiment. The LED module includes optical element  220  and body  230 . Body  230  includes first cross-sectional width  232  and second cross-sectional width  234 . The second cross-sectional width is wider than the first cross-sectional width. The portion of body  230  where the two cross-sectional widths meet forms seat  238 . 
         [0022]    The LED module is inserted into the showcase member aperture until seat  238  rests against an underside of the showcase member. Bezel  240  can be inserted between the LED module and the showcase member and pressed-fit against first cross-sectional width  232  to hold the LED module in the aperture. 
         [0023]    In one implementation, the bezel can include a recess along its lower leg. This recess can snap-fit into a protrusion on the aperture&#39;s edge, or a protrusion located on the LED module. Conversely, the recess can be located on the showcase member or LED module, and the protrusion on the bezel lower leg. 
         [0024]      FIG. 3  depicts LED module  300  mounted in an aperture formed on showcase member  210  in accordance with an embodiment. In accordance with this implementation, the LED module itself can include snap-fit features, which provide for the LED module to snap into the showcase member aperture. 
         [0025]    LED module  300  includes additional material  310  extending from the first cross-sectional width. This extended, additional material forms notch  330  in the profile of the LED module. Insertion of the LED module into the showcase member aperture causes the edge of the showcase member aperture to snap into the notch The outer edge of the additional material can be include taper  320 . As the LED module is inserted into the showcase member aperture, the tapered edge can ease the LED module through the aperture and then prevent it from reversing back out of the aperture. In one implementation, at least a portion of the showcase member aperture edge can include a complementary taper. In accordance with implementations, the material used to form at least taper  320  can be pliable so that the LED module can be removed by applying a reverse force. 
         [0026]      FIG. 4  depicts LED module  200  mounted in an aperture formed on showcase member  200  in accordance with an embodiment. In accordance with an embodiment, bezel  440  can be held into place with screws or rivets. The bezel can include flange  444 . The flange can include through holes/slots to accept rivets and/or screws. The rivets or screws can secure the bezel to the showcase member so as to provide secure placement of the LED module. 
         [0027]      FIG. 5  depicts LED module  200  mounted in an aperture formed on showcase member  210  (numbering as in  FIG. 2 ) in accordance with an embodiment. In accordance with an embodiment, bezel  540  can be welded to the showcase member, or ultrasonically welded to the module&#39;s overmolding material. 
         [0028]      FIG. 6  depicts LED module  200  mounted in an aperture formed on showcase member  210  in accordance with an embodiment. In accordance with an embodiment, the bezel can magnetically adhere to the LED module. Impregnating the overmold material with magnetic material before the overmold is formed can result in enough magnetic attraction to hold the bezel in place. This magnetic attraction can secure the LED module in the aperture. In another implementation, opposing magnets  610  can be placed on the underside of the showcase member to hold the bezel in position 
         [0029]      FIG. 7  depicts LED module  200  mounted in an aperture formed on showcase member  210  in accordance with an embodiment. In accordance with an embodiment, adhesive material  700  (e.g., tape, glue, etc.) can be positioned between an underside of the showcase member and LED module seat  238 . In one implementation, the two-sided tape can be die cut to fit around seat  238 . In another implementation, an ultra-high bond adhesive can be placed on the seat. 
         [0030]    In accordance with embodiments, LED modules can be installed inside of, or on top of, an existing showcase member. Some embodiments pertain to mounting a light engine from the inside of a showcase member. Such mounting can be performed from either the front or the back of the showcase member. Methods of so mounting an LED module to a showcase member can be carried out in any suitable fashion, and encompasses being carried out by the original equipment manufacturer (OEM), and/or carried out as a retrofit of an existing showcase member. 
         [0031]      FIG. 8  depicts showcase member  800  having apertures  810 ,  820 ,  830  in accordance with embodiments. Apertures can be either equally spaced along the length of the showcase member, or strategically placed at different densities to put more light in areas of the case with different light level needs, such as at the top or bottom of the showcase where there could be deeper shelf areas. The apertures need not be in a single row (e.g., apertures  810 ), but can be formed as an array of apertures depending on the door, showcase geometry, and/ or lighting requirements (e.g., apertures  820 ,  830 ). In some implementations the orientation of the aperture can be rotated up to as much as 90 degrees from the orientation depicted in  FIG. 8 . 
         [0032]    In accordance with embodiments, the showcase member can have one or more apertures along its length in which can be inserted LED modules, rather than a single slot that runs the whole length of a mullion to accept a light bar. Each LED module does not have to be identical. For example, LED modules can have different optical elements, light engines, etc. depending on placement on the showcase member, the member&#39;s position in the showcase, and/or the orientation of the LED module on the showcase member. 
         [0033]      FIG. 9  depicts a perspective view of a portion of showcase member  900  having tapered sections in accordance with embodiments. The showcase member includes a first portion  910  in which aperture  912  is formed to receive an LED module  920  in accordance with embodiments. Side portions  930  of showcase member  900  are bent outward to form light shields. These light shields are angled so that when positioned in the showcase, the light shields reduce the angular propagation of light from the LED modules to reduce glare from the LED modules. This glare can cause a user to avert their eyes, thus limiting the selection of product viewed by the user. 
         [0034]    In accordance with another implementation, the LED module can be mounted in recess  940  formed in first portion  910  at the location of aperture  912 . Recess  940  can extend across about the width of the first portion adjacent to the aperture. By mounting the LED module in an aperture adjacent to the recesses, the angular glare of the LED module can be reduced. In accordance with some embodiments, showcase member can include side portions  930  and/or recesses  940  to form the light shields to reduce angular glare from the LED modules. 
         [0035]      FIG. 10  depicts a perspective view of bezel  1240  in accordance with some embodiments. Bezel  1240  can be used to hold LED module in an aperture formed in the showcase member as disclosed above with reference to  FIG. 2 . As disclosed above, an LED module can be seated against an underside of the showcase member. Bezel  1240  can be press-fit between the LED module and the showcase member to secure the LED module to the showcase member. In accordance with an embodiment, Bezel  1240  includes extended side portions  1250  which form light shields. These light shields are angled so that when positioned in the showcase, the light shields reduce the angular propagation of light from the LED modules to reduce glare from the LED modules. 
         [0036]    In accordance with embodiments, the apertures can be formed in the showcase member by being punched, stamped, or routed into the showcase member&#39;s face using standard machining processes. In some implementations (e.g. retrofit operations) the apertures can be punched in the field using standard hole-punch tools. Depending on the LED module geometry, standard punch-out dies or custom dies can be used to match the module&#39;s geometry. 
         [0037]    Embodiments of the present disclosure can include the following advantages: lower cost by utilizing standardized LED modules and reduced parts (e.g., mounting clips and associated hardware may be avoided), ease of installation, an improved aesthetic look, and an improved optical performance from having a mounting profile closer to the mullion surface. Embodiments typically do not require an independent housing and result in additional available space for product placement and deeper shelving. 
         [0038]    Although specific hardware and methods have been described herein, note that any number of other configurations may be provided in accordance with embodiments of the invention. Thus, while there have been shown, described, and pointed out fundamental novel features, it will be understood that various omissions, substitutions, and changes in the form and details of the illustrated embodiments, and in their operation, may be made by those skilled in the art without departing from the spirit and scope of the invention. Substitutions of elements from one embodiment to another are also fully intended and contemplated.