Abstract:
Modular flexible panels for mounting lighting strands. In certain embodiments, each individual panel is an integral unit comprised of cables and node holders that combine to create a flexible, scalable and modular lighting surface. One or more of the panel edges can connect to an edge of another panel (either directly or indirectly) to tile multiple panels together to form a modular multi-panel assembly. Each panel provides a surface to which strands of LEDs can be mounted, such as in a uniform pattern. The panel design allows for easy replacement and serviceability of individual lighting strands, and ensures that all of the LEDs face in the same direction. The resulting robust and flexible system can provide full-motion video, graphics and messaging in a transparent single or multi-panel design.

Description:
This application claims priority of Provisional Application Ser. No. 60/987,522, filed on Nov. 13, 2007, the disclosure of which is hereby incorporated by reference. 
    
    
     BACKGROUND 
     Disclosed herein are illuminating systems and devices, such as light emitting diode devices. More particularly, various embodiments relate to indoor/outdoor illumination systems and devices in modular form capable of providing flexible lighting displays. 
     Conventional lighting systems have been used to provide customized lighting effects, such as color-changing LED lighting systems. Some such systems are arranged in network configurations and generate coordinated lighting effects. They are typically used in various venues, including concerts, meetings, exhibitions, theater, etc. 
     However, conventional systems are difficult to transport, erect and service. LED lighting strands are available, but lack structure or a surface for providing them in a flexible, modular and scalable format. It therefore would be desirable to provide a flexible, lightweight and scalable lighting assembly that is easily serviceable, such as by allowing for single strand replacement. 
     SUMMARY 
     The embodiments disclosed herein relate generally to lighting systems and methods. In certain embodiments, two or more lighting elements are arranged to form a lighting system. In one aspect of this embodiment, each lighting element includes a group of LEDs (light-emitting diodes) arranged on one or more flexible panels so as to be capable of forming various shapes. In certain embodiments, the panels are scalable and modular. In certain embodiments, each lighting element may include elements to generate the same color light, and/or elements to generate light of different colors. Two or more elements of the system may be configured as addressable lighting elements to facilitate coordination of the elements as a networked lighting system. The result of the foregoing is the ability to deploy large format video through lights in a wide variety of applications. 
     More specifically, commercially available lighting strands, such as iColor Flex stands available from Color Kinetics, which are arrays of nodes (each node comprising, for example, an LED emitting radiation of various spectrums, such as a red/green/blue tri-color LED and a control chip), or strands available from Colourweb, are mounted on flexible members at predetermined spacing to form a modular and scalable lighting surface or panel. In certain embodiments, each individual panel is an integral unit comprised of cables and node holders that combine to create a flexible, scalable and modular lighting surface that can, for example, wrap around existing structures to conform to the shape of the existing structure in three dimensions, can hang flush against existing structure horizontally or vertically, can hang freely, or can be draped or scalloped. In certain embodiments, one or more of the panel edges connects to an edge of another panel (either directly or indirectly) to tile multiple panels together to form a modular multi-panel assembly. Each panel provides a surface to which strands of LEDs can be mounted, such as in a uniform pattern, or to which individual lighting elements or sources can be mounted. The panel design allows for easy replacement and serviceability of individual lighting strands or elements, and ensures that all of the elements face in the same direction. In certain embodiments, the lighting elements are arranged in interconnecting linear arrays on the panel. The resulting robust and flexible system can provide full-motion video, graphics, color light shows and messaging in a transparent single or multi-panel design. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partial perspective view of a lighting panel in accordance with certain embodiments; 
         FIG. 2  is a perspective view of a bottom portion of a node holder in accordance with certain embodiments; 
         FIG. 3  is a perspective view of a top portion of a node holder in accordance with certain embodiments; 
         FIG. 4  is a perspective view of a portion of a node holder shown holding with a cable, the cable terminating with a buckle, in a partially assembled condition in accordance with certain embodiments; 
         FIG. 5  is a perspective view of a portion of a node holder shown holding cable, the cable terminating in a buckle, in a partially assembled condition in accordance with certain embodiments; 
         FIG. 6  is a perspective view of a portion of a node holder shown holding cable, the cable terminating in a buckle, in a partially assembled condition in accordance with certain embodiments; 
         FIG. 7  is a perspective view of a node holder shown holding cable, the cable terminating in a buckle, in an assembled condition in accordance with certain embodiments; 
         FIG. 8  is a perspective view of a cable holder in accordance with certain embodiments; 
         FIG. 9  is a perspective view of a female buckle in accordance with certain embodiments; 
         FIG. 10  is a perspective view of a male buckle in accordance with certain embodiments; 
         FIG. 10A  is a perspective view of the male buckle of  FIG. 10  with a cable shown therethrough; 
         FIG. 11  is a perspective view of a portion of a panel holding LED nodes in accordance with certain embodiments; 
         FIG. 12  is a perspective view of a panel jumper assembly in accordance with certain embodiments; 
         FIG. 13  is a top, view of two panels positioned for connection in accordance with certain embodiments; 
         FIG. 14  is a top view of two panels connected in accordance with certain embodiments; 
         FIG. 15  is a perspective view of a bracket for attachment to a panel in accordance with certain embodiments; and 
         FIG. 16  is a perspective view of a panel in a rolled-up configuration. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a portion of a panel  10  in accordance with certain embodiments. The panel  10  includes a plurality of node holders  12 , preferably positioned in a symmetrical array to form a grid pattern as shown. Each node holder  12  is joined to an adjacent node holder by a flexible string, wire rope or cable  13 ,  13 ′. Alternative configurations are within the scope of the disclosure; equal spacing between node holders in any given row or column is not necessary, although preferably the nodes  12  are equally spaced from each other, both in the longitudinal and horizontal directions. Preferably the cable  13 ,  13 ′ is aircraft cable formed of multiple strands of wires, which optionally can be covered in a plastic sheath. Preferably the node holders interconnect to form linear arrays of node holders. 
     Each node holder  12  includes a bottom portion  14  as shown in  FIG. 2 . The bottom portion  14  is preferably made of plastic, such as a polyolefin, particularly polypropylene, polycarbonate, or acetyl polyoxomethylene (POM). and includes a flat bottom surface. The top surface includes a plurality of projecting members  15 , preferably spaced about the perimeter, which receive the top portion  16  of the node holder  12  ( FIG. 3 ), such as by a snapping fit. The top surface of the bottom portion  14  also includes an arcuate groove  11  shaped and of sufficient depth to receive the cable  13  (see  FIG. 4 ) when in the assembled condition. The groove  11  can be formed in the bottom portion  14  by routing. 
     Turning now to  FIG. 3 , the top portion  16  of the node holder  12  is configured to be received by the bottom portion  14  to form an integral unit. The top portion  16  is also preferably made of plastic, such as a polyolefin, particularly polypropylene, or polycarbonate. The bottom surface of the top portion  16  includes an arcuate groove  11 A, shaped and of sufficient depth to receive the cable  13 ′ when in the assembled condition. The groove  11 A in the top portion  16  is positioned such that it runs perpendicularly with respect to the groove  11  in the bottom portion  14  when the top portion  16  and bottom portion  14  are adjoined in the assembled condition, such that both longitudinally running cables  13  and horizontally running cables  13 ′ can be received by the node, one above the other. The groove  11 A can be formed in the top portion  16  during an injection molding process or by routing. Preferably the top and bottom portions of the node holder  12  are assembled together, about the cables  13 ,  13 ′ properly positioned in the grooves  11 ,  11 A, and can optionally be adhered together such as with glue. More specifically, each projection  15  on the bottom portion  14  receives a shoulder  18 A of wall  18  of the top portion, with the flange  15 A of each projection  15  extending over the shoulder  18 A. The projections  15  and shoulders  18 A thus cooperate to form an integral node holder unit. 
     The top portion  16  also includes two oppositely facing side walls  17 A,  17 B projecting upwardly to define between them a space configured to removably receive an LED node or other illuminating device, as described below. Preferably each of the side walls  17 A,  17 B includes a top flange portion that extends inwardly towards the other. Opposite shorter walls  19 A,  19 B provide further stability to the LED node or illuminating device when mounted thereto. 
       FIGS. 4 through 7  illustrate one method of constructing the panel  10  comprised of node holders  12 . The bottom portions  14  are positioned as desired, and cables  13  are aligned in rows and positioned in the grooves  11  to form a plurality of columns as shown. Next, as shown in  FIG. 5 , cables  13 ′ are placed over and transversely across cables  13  to form a plurality of rows. An end cables  13 ″ also can be placed across buckles  30  as shown in  FIG. 6 . Then, as shown in  FIG. 7 , the top portion  16  of the node holder  12  is adjoined to the bottom portion  14 , to secure both the longitudinal cables  13  and the transverse cables  13 ′ in place, as well as to secure the end cables  13 ″. An adhesive can be used to secure the node holder. 
       FIG. 8  illustrates a cable holder  22  that is used to hold end cable  13 ″ in place along panel edges where nodes are not used, such as at every other space between nodes as shown in  FIG. 7 . The cable holder  22  includes an arcuate groove  11 B of sufficient shape and depth to receive cable  13 ″, and is preferably secured to buckle  20  such as by gluing. The buckles  30  also can have projections  15 ′, similar to projections  15  on the bottom portions  14 , to assist in securing the cable holders  22 . 
     As can be seen in  FIGS. 4-7 , the ends of cable  13  and  13 ′ are affixed to female buckles  30  which define a panel edge and to allow for expansion of the panel, i.e., to create a modular design. Although side release buckles are shown, those skilled in the art will appreciate that any suitable buckle, latch, clip or other mechanism can be used to adjoin the edge of one panel to the edge of another panel, either directly or via an intermediate attachment mechanism (e.g., one that itself attaches, as a bridge or jumper, to edges of first and second panels). Each buckle  30  can have an aperture (not shown) in which the cable  13  or  13 ′ is inserted and secured within the buckle, such as by crimping at or near the end of a cable a metal cylinder  71  or the like that acts as a wedging stop when inserted into the aperture (see  FIGS. 10A and 12 ), and can be further secured therein by gluing. The stop ensures that the buckles do not slide along the cable. Other means to secure the cable to the buckle are within the scope of the present disclosure. A suitable female buckle  30  is illustrated in detail in  FIG. 9 . The top surface of each buckle  30  preferably includes the spaced upwardly extending projections  15 ′, which are similar to projections  15  on node holder portion  14 . The projections  15 ′ are spaced and configured to hold a node holder  12  or cable holder  22  in snapping relation with the buckle  30 , as seen in  FIG. 7 . Although four such projections  15 ′ are shown, the disclosure is not limited to any particular number. 
     The female buckle  30  includes a front slot  31  preferably extending the substantial width of the front face of the buckle, and opposite side apertures  32 ,  32 A spaced inwardly from the front face of the buckle  30 . The side apertures are shaped and position to receive respective flexible male prongs of a male buckle to cooperatively form a side release buckle assembly. Thus, as seen in  FIG. 10 , the male buckle  35  includes opposite prongs  36 A,  36 B, each of which can be flexed inwardly towards one another, enabling insertion into the front slot  31  of female buckle  30 . Further insertion followed by release of the prongs causes the prongs to return to their unflexed state, thereby extending through slots  32 A,  32 B and locking the buckles together. To release the buckle, the portion of the prongs protruding through the slots are pushed inwardly while the male member is pulled out of the female buckle  30 . 
     Certain male buckles  35  can have an aperture  37  in which cable  13  or  13 ′ is inserted and secured within the buckle, such as by gluing. In certain embodiments, as shown in  FIG. 12 , such cable is attached at its other end to an identical, oppositely facing, male buckle  35 ′, which secures to a different female buckle attached to a different panel, to secure the two panels together, creating a modular, scalable panel assembly. The length of the cable separating the two male buckles  35 ,  25 ′ is chosen so that the distance between an end row or column of node holders on the first panel is appropriately spaced from an end row or column of node holders on the second panel. For example, the assembly of two male buckles with a cable therebetween, termed a panel jumper assembly  60 , can be of a two inch length, a four inch length, or the two buckles  35 ,  35 ′ can abut, depending upon the desired distance between rows or columns of nodes. Each end node holder can have such a slide buckle assembly or panel jumper assembly  60 , to adequately secure the two panels together. 
     For example, turning back to  FIG. 1 , column A defines an end column of the left side panel, and column B is the end column of the right side panel. The two panels are secured together in a tiled assembly by side release buckle assemblies at each node holder  12  of column A. It will be readily appreciated by the skilled artisan that any number of columns and/or rows can make up a panel, including a single column or row, so that modular panel assemblies of any shape and size (e.g., any number of rows and columns) of node holders can be fabricated, simply by attaching rows and/or columns to each other using side buckle assemblies or other suitable attachment means. 
     Those skilled in the art will appreciate that the location of the male buckles and female buckles could be reversed (e.g., the male buckles could define an edge of a panel, and the panel jumpers could be female buckles). 
     The node holders  12  provide lightweight, preferably plastic surfaces to which strands of LED nodes can be simply attached or connected and detached or released. Such strands typically include an array of nodes, each node containing, for example, a red/green/blue tri-color LED and control chip, pre-mounted on flat flexible wire at a fixed spacing. Suitable strands are commercially available as iColor Flex strands available from Color Kinetics, and comprise a plurality of LED lights along three common conductor wires. Similar lighting elements are available from Lighting Science Group Corporation. 
     To assemble a panel, the following steps can be used:
         1. Individual bottom pieces  14  of a pre-routed node holder  12  for cable are laid flat and in parallel vertical and horizontal rows.   2. Coated cable  13 ,  13 ′ is then laid across the bottom portions  14  of the node holders  12 . Each bottom portion  14  holds intersecting cable in place at 90 degree angles ( FIG. 5 ).   3. A top portion  16  of the node holder  12  is placed above each bottom portion  14  and secured with adhesive or similar material, thereby securing the cables in place.   4. At the end of every horizontal row and vertical column of coated cable, a female side-release buckle  30  can be connected, finishing an edge of one panel. This female side-release buckle  30  sits across the top, bottom, and each side of the panel, creating the panel edges. Each panel is finished in the same manner, with female side-release edges.   5. Male panel jumpers, constructed of coated cable with a male buckle  35  on each, can be inserted into a female side-release buckle  30  of the panel, allowing one panel to modularly connect to another panel.       

     A guide can be used to appropriately position each bottom portion  14  of node holder  12  to ensure proper spacing and assembly. For example, a custom-rounded table can be used as a substrate to maintain accuracy of spacing and hold then node holder bottom portions  14  in place, such as by placing the bottom portions  14  in cuts in the guide at intersections where the node holder  12  will be. Cable is cut from a roll and laid into the guide with a small amount of adhesive at each node holder bottom portion  14 . Once accuracy of the grid pattern created is verified and adhesive is applied per node holder bottom portions  14 , the node holder top portions  16  are attached to respective bottom portions  14 , enveloping cable intersections. At each cable intersection around the exterior of the panel where there is no node holder, a clip  22  is assembled around the cable with adhesive. The adhesive is allowed to cure, and node holders  12  are now suitable for mounting strands of lights thereto. 
       FIG. 11  illustrates a portion of a panel with strands of nodes attached to the node holders  12 . In certain embodiments, each strand includes a plurality of LED nodes  50  mounted in small plastic housings and arrayed in increments along a three-wire conductor, such as 16 or 18 AWG cable. Preferably the nodes are individually addressable to provide color flexibility, since each node can be called upon to generate virtually any color at any specified time. The strands are connected to a central wiring harness leading to existing power/data supply units to create a large-format modular lighting and/or video surface. Because the nodes  50  are housed in node holders  12 , undesirable twisting of the strands is eliminated. Furthermore, if a single or several LEDs on a strand malfunction, the strand can be easily replaced without having to replace other strands. 
     Those skilled in the art will appreciate that the panels are not limited to holding strands of nodes; individual lighting elements can be used, and the lighting elements can be Christmas lights, incandescent lights, LED&#39;s, etc. 
       FIG. 13  illustrates two juxtaposed panels  10 ,  10 ′, with panel jumper assemblies  60  positioned between them to join the panels together. The figure shows the edges of panel  10  comprises a plurality of female buckles  30  positioned to connect, if desired, to corresponding male buckles  35  to scale the panel.  FIG. 14  illustrates the two panels  10 ,  10 ′ joined by the panel jumper assemblies  60 , each male buckle  35  of a panel jumper coupling to a female buckle  30  along one column of each panel  10 ,  10 ′ edge. 
     In certain embodiments, the panel  10  can be mounted to one or more brackets  70  ( FIG. 15 ) to assist in hanging, or to provide structure and rigidity to a tiled set of panels. Bracket  70 , which can be fabricated of extruded metal, such as metal framing commercially available from Unistrut, includes a plurality of apertures through which the wiring for the light strands can pass, such as for connection to a power source. Extending from the bracket  70  via cable are male buckles  35 , each positioned to engage a corresponding female buckle  30  of a panel edge to attach the panel  10  to the bracket  70 . One or more standard theatrical C-clamps  75  or conduit brackets (J-hooks, conduit clamps, etc.) can be used to affix the bracket to a structure such as a truss or pipe. 
     In view of the flexibility of the panels  10 , a panel  10  can be rolled-up upon itself for ease of handling, transport and storage, as illustrated in  FIG. 16 . In the embodiment shown, this result sin a cylindrical rolled-up body that is lightweight and can be easily transported manually. The rolled-up form can be comprised of a single panel, or a multiple panel modular assembly. To the extent a panel assembly has been scaled by combining multiple panels in the manner described, they can easily disassembled simply by disconnecting the buckles, which also can enhance the portability of the device. 
     Panels can be constructed in a variety of grid spacings to achieve scalability in resolution for content availability. The ability to tile panels together in vertical or horizontal fashions offer modularity and scalability to the end user. The absence of exposed metal creates a transparent, aesthetically pleasing panel, that lends itself to display on the side of a building or a glass background.