Adjustable LED lighting system, kit and method of using same

A light emitting diode lighting system and kit includes a plurality of matched pairs of breakaway light emitting diode assemblies adapted to be mounted in a primary lamp holder where each individual matched pair assembly includes: (1) a light emitting diode coupled to a printed circuit board; (2) a break away housing adapted to be pressed fit over the light emitting diode; and (3) a breakaway lens adapted to be pressed fit into the housing to facilitate controlling the spread of light emitted by said light emitting diode from a wide range angle Ø to a narrow range angle β at a user selected breakaway angle θ of between about A degrees to about B degrees.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This application relates to adjustable lighting systems, lighting system kits, and methods for using the same. More particularly, this invention relates a to a light emitting diode lighting system, kit and method of using the kit to enable a user to customize light spread and distribution to illuminate an object within a field of view.

2. Background of Prior Art

Off road vehicles, military vehicles and similar vehicles and equipment need to illuminate large land areas with high intensity light in a fast and convenient manner. Therefore there is a need for a new and improved adjustable lighting system and lighting system kit for customizing a light spread and light distribution pattern across a desired field of view.

SUMMARY OF THE INVENTION

In a first preferred embodiment of the invention, an adjustable and customizable light emitting diode lighting system generally includes a primary holder for holding a plurality of matched pairs of breakaway light emitting diode assemblies to facilitate controlling a spread of light from a wide range angle Ø beam to a narrow range angle β beam and to further facilitate angling said spread of light from longitudinally straight forward or angled from longitudinally straight forward at a deviation angle θ of between about A degrees to about B degrees.

In a second preferred embodiment of the invention, a light emitting diode light system includes: 1. a heat sink assembly; 2. a lens assembly; and 3. a printed circuit board assembly which is sandwiched between the heat sink assembly and the lens assembly, where the lens assembly is mounted for both rectilinear movement toward and away from the printed circuit board assembly for light pattern focusing purposes and radial movement relative to the printed circuit board assembly for specific lens selection purposes.

In a third preferred embodiment of the invention, a light emitting diode lighting system includes: 1. a primary holder of a plurality of light emitting diode assemblies; 2. a secondary holder for mounting a plurality of break away lenses, wherein each individual lens is mounted for angular alignment with a corresponding individual one of the plurality of light emitting diode assemblies; and 3. wherein the secondary holder is adjustable to be spaced closer to or further away from said primary holder to facilitate controlling the spread of light emitted by the plurality of light emitting diode assemblies from a wide range angle Ø to a narrow range angle β and at individually user selected angles of inclination θ of between about A degrees to about B degrees.

In a fourth preferred embodiment of the invention, a light emitting diode lighting system includes: 1. a heat sink; 2. a printed circuit board which is coupled to the heat sink; 3. light emitting diode means which is coupled to the printed circuit board; 4. a housing platform which is mounted for rectilinear movement toward and away from the heat sink to facilitate controlling the spread of light emitted by the light emitting diode means from a wide range angle Ø to a narrow range angle β; 5. matched break away housing means which is coupled to said housing platform and mounted over the light emitting diode means; and 5. matched break away lens means which is pressed fit into the matched break away housing means to further facilitate controlling the spread of light emitted by the light emitting diode means from the wide range angle Ø to the narrow range angle β at a user selected breakaway angle θ of between about A degrees to about B degrees.

In a fifth preferred embodiment of the invention, a light emitting diode lighting system kit includes a plurality of matched pairs of breakaway light emitting diode assemblies adapted to be mounted in a primary lamp holder, and a set of assembly instructions. Each individual matched pair assembly includes: (1) a light emitting diode coupled to a printed circuit board; (2) a break away housing adapted to be pressed fit over the light emitting diode; and (3) a breakaway lens adapted to be pressed fit into the housing to facilitate controlling the spread of light emitted by said light emitting diode from a wide range angle Ø to a narrow range angle β at a user selected breakaway angle θ of inclination between about A degrees to about B degrees. The break away housing snaps apart into two portions which are rotatable 180 degrees relative to one another and then press fit together to form an angled housing having an inclined angle θ of between about 5 degrees to about 60 degrees. The break away lens includes a break away stem which when snapped apart results in a stem portion having an inclined angle θ of between about 5 degrees to about 60 degrees where its inclined angle θ is matched to the inclined angle θ of the break away housing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings and more particularly toFIG. 1, there is illustrated an adjustable and customizable light emitting diode lighting system10, which is constructed in accordance with the present invention. As best seen inFIG. 1, the lighting system10is mounted to a vehicle12which enables a vehicle driver (not shown) to customize and adjust the light pattern produced to by the lighting system10so that it illuminates large land areas with high intensity light in a fast and convenient manner. The lighting system10may be customizable to provide a lighting pattern having a wide spread angle Ø to a narrow spread angle β. In this regard, as best seen inFIGS. 11A-11E, the wide spread angle Ø can be varied between about 80 degrees to about 40 degrees, while the narrow spread angle β may be varied between about 8 degrees and about 20 degrees. The manner in which the light spread angle is varied will be described hereinafter in greater detail.

Before describing the light emitting diode system10in greater detail, it may be beneficial to briefly review the advantages afforded by this new and unique lighting system. To begin, the system10provides an inexpensive design for adjusting the light distribution pattern from the individual light emitting diode assemblies that are incorporated into the lighting system10. In this regard, the system10enables a user, via a moveable lens arrangement, to adjust the light distribution pattern from a narrow light spread angle β to a wide spread angle Ø in a fast and convenient manner. The design functions by having customizable light emitting diode assemblies with individual light emitting diodes and lenses which may be disposed in various arrays, such as a linear array in a light bar arrangement14or in a spreading spot light array as provided by a wide angle flood lamp16as best seen inFIG. 1. Moreover, the direction angle of the light pattern may be customized at an inclination angle θ as will be described in greater detail.

To effect a distribution pattern adjustment, the user can adjust the spread of light by moving the orientation of the individual light emitting diodes and their corresponding lens from straight forward light pattern emissions to angled light pattern emission, where the angled light pattern emission can be selected to be between about 5 degrees to about 60 degrees relative to the mounting plane of the each base portion of the individual light emitting diode assemblies. In other words, as will be explained hereinafter in greater detail, this enhancement permits individual lenses to be torn away at a stem portion and then press fit into a housing which has a matched tear away configuration so that the housing and the lens can be customized for a specific angle to focus light from an associated light emitting diode at the specific formed breakaway angle θ.

In summary then, the advantages of the new and improved light emitting diode system include:

1. a compact design which takes little space;

2. a multi-lens arrangement inclusive of one or more lenses for pattern adjustments;

3. An adaptable system that works in both linear and circular arrays;

4. Adjustments or customization steps which are simple and easy to make;

5. A spread that can be changed at any time if the need for lighting changes;

6. A low cost system; and

7. A plurality of different types of light emitting diode assemblies for achieving different light patterns and light intensity outputs.

The above-mentioned advantages are achieved by a light emitting diode system where a light source in the form of light emitting diodes are mounted in a radial pattern on a printed circuit board and disposed below a lens array or lens assembly which generally includes one or more lens sets. The lens arrangement is mounted for rotational movement above the light emitting diodes so that multiple sets of lenses can be positioned above the light emitting diodes and thus, create multiple light output patterns. One of the primary innovation is a lens arrangement which generally includes a lens array positioned in radial patterns such that as the lens arrangement is rotated first one pattern is positioned over the light emitting diodes mounted within the system, and then a second array is positioned over the light emitting diodes to provide a second lighting pattern. This lens arrangement therefore allows a user to change from a narrow focus light pattern to a wide focus light pattern without having to purchase separate types of light systems. This arrangement also allows adjustment of the light output multiple times during use of the lighting system. The ability of a user to adjust the light output patterns after the light is installed in a key and important feature of the present invention.

From the foregoing, It should be understood by those skilled in the art that lenses can be easily replaced to provide lens arrays with different radial patterns, and then adjusted by mechanical means, such as a screwdriver blade, or electro-mechanical means, to achieve different light spreads in a fast and convenient manner.

Considering now the lighting system10in greater detail with reference toFIGS. 1-7, the lighting system10generally includes a plurality of individually adjustable light emitting diode printed circuit board assemblies, such a light emitting diode printed circuit board assembly110(FIG. 2) or a light emitting diode printed circuit board assembly610(FIG. 6) and one or more primary holders, such as a primary holder20, for mounting the light emitting diode printed circuit board assemblies110,610in a linear array via the light bar arrangement14, or in a circular or round array via the wide angle flood lamp16, or a high intensity flood lamp18. The light bar arrangement14, the wide angle flood lamp16and the high intensity flood lamp18are each adapted to be mounted, on a stationary mounting surface, such as a wall, a roof, a upright stand, or on a vehicle, such as the vehicle12, either individually or in combination with one another by mounting means (not shown). It is contemplated that expected embodiments of the lighting system10could be applied, without limitation, to recessed task lighting, work space lighting, under cabinet lighting, case lighting for consumer goods, sign lighting, museum lighting, indirect lighting of display items, artwork lighting, general room illumination, industrial task lighting for assembly work, warehousing, library cases, office cubicles, vehicle lighting, aircraft lighting, and any specialized light installation where the user needs to position the light in a compact and flexible way at the installation site.

Although the preferred embodiment of the present invention is described as having a particular light emitting diode printed circuit board assembly110, it will become apparent to those skilled in the art, that other types of light emitting diode printed circuit board assemblies may also be employed within the system10. In this regard, such other light emitting diode assemblies include a light emitting diode printed circuit board assembly610(FIG. 6), a light emitting diode printed circuit board assembly810(FIG. 8), a light emitting diode printed circuit board assembly1010(FIG. 10), a light emitting diode printed circuit board assembly1110(FIGS. 11A-G), a light emitting diode printed circuit board assembly1510(FIG. 15), a light emitting diode printed circuit board assembly1910(FIG. 19), and a light emitting diode printed circuit board assembly2010(FIG. 20), each of which will be described hereinafter in greater detail. Each of these light emitting diode printed circuit board assemblies have the ability to have not only their light output pattern ranges be adjusted between a wide angle output and a narrow angle output, but each also has the ability to have the direction of their light output patterns to be customized over a wide range of output angles in a fast and convenient manner which adjustment and customization abilities are important features of the present invention.

Considering now the light emitting diode printed circuit board assembly110in greater detail with reference toFIGS. 2-5, the light emitting diode printed circuit board assembly110generally includes a printed circuit assembly board112, which includes a printed circuit board113having mounted thereon one or more light emitting diode assemblies, such as a light emitting diode assembly114. Each individual light emitting diode assembly114is adapted to have its light output pattern direction customized from a light direction perpendicular to the printed circuit board113or at about an angle of θ degrees from perpendicular to the printed circuit board113as will be explained hereinafter in greater detail. For the moment it will suffice to mention that the angle θ is between about 5 degrees and about 60 degrees and is more preferable between about 30 degrees and about 50 degrees. The angle θ is most preferably at about 45 degrees.

Considering now the light emitting diode assembly114in greater detail with reference toFIGS. 2-5, the light emitting diode assembly114generally includes an electrical heat sink mount116, a light emitting diode118, a donut shaped housing mount120, a break away or tear away housing122having a break away angle of about θ degrees, and a break away or tear away lens124having a corresponding break away or tear away angle of about θ degrees.

As will be explained hereinafter in greater detail, the break away angle θ of housing and the break away angle θ of the lens are matched and correspond to one another so the that the lens124can be press fit into the housing122and over the light emitting diode118. More specifically as best seen inFIGS. 6 and 7, an angled light emitting diode assembly114A can be easily and quickly configured when the housing122and lens124are torn away to provide an angle θ configuration. In this regard, the housing and lens combination can be customized to facilitate angling a spread of light from longitudinally straight forward or angled from longitudinally straight forward at a deviation angle θ of between about A degrees to about B degrees, where A degrees is about 5 degrees and where B is about 60 degrees.

As best seen inFIGS. 2 and 3, the electric mount116has a general circular shape having a centrally disposed circular cutout which is dimensioned for receiving therein the light emitting diode118. In turn the electrical mount116and the light emitting diode118are coupled mechanically and electrically to the printed circuit board113in such a manner that the light emitting diode118is supported in an orientation that is perpendicular to the printed circuit board113. Surrounding the circular cutout is the donut shaped housing mount120. The housing mount120is dimensioned to receive thereon in a friction tight fit a mounting portion or cutout121of the housing122that will be described hereinafter in greater detail.

Considering now the housing122in greater detail with reference toFIGS. 2-5, the housing122has a cylinder like shape and includes a tear line L1that permits the housing122to be easily and quickly snapped or torn apart into to two separate pieces as will be described hereinafter in greater detail. The housing122has a reflective coating123disposed on its inner surface to allow light from the light emitting diode118to be reflected off its inner wall surface into the lens124. The bottom of the housing is closed except for a cutout121which is dimensioned to receive therein the light emitting diode118and to be pressed fit onto the donut shaped housing mount120in a friction tight fit for securing the housing to the printed circuit board113. When the housing122in a non tear away form is mounted to the printed circuit board113, light from the light emitting diode118is reflected from within the housing122and into the lens124for directing light perpendicular to the printed circuit board113as best seen inFIG. 2.

Considering now the a break away or tear away lens124in greater detail with reference toFIGS. 3 and 5, the lens124has an elongated shape which includes a circular cup shaped upper lens portion130and a conically shaped lower lens stem portion132where the upper lens portion130and the lower lens stem portion132are integrally attached to one another. The upper lens portion130is adapted to be pressed fit into the upper lens receiving portion126of the housing122while the lower lens portion132is adapted to be pressed fit onto the ball shaped light emitting diode118a best seen inFIG. 5.

Considering now the light emitting diode printed circuit board assembly610, with reference toFIG. 6, the light emitting diode printed circuit board assembly610is substantially identical to light emitting diode printed circuit board assembly110except that the tear away housing and tear away lens are arranged in a tear away configuration. As the light emitting diode printed circuit board assembly610is substantially similar to assembly110, only the tear away differences will be described hereinafter in greater detail.

Considering now the breakaway or tear away housing122in greater detail, the breakaway housing122is generally cylindrical in shape having an angled tear away line L1which effectively enables the housing122to be broken or snapped into two parts, into an upper lens receiving portion126and a lower mounting portion128as best seen inFIG. 7. In this regard, when the housing122is broken into two parts and the two portions126and128are rotated 180 degrees relative to one another along their respective longitudinal axis, the two portions126and128may then be pressed fit together to form an angled housing122A (FIG. 7) having an inclined angle θ of between at about 5 degrees and at about 60 degrees. A more preferable angle θ is between at about 30 degrees and about 50 degrees, while the most preferred angle θ is at about 45 degrees.FIG. 2illustrates the housing122mounted to the printed circuit board113in an unbroken state, whereasFIG. 6illustrates the angled housing122A in a broken and rotated state mounted to the printed circuit board113.

It should be understood from the foregoing that if a user does not desire to break the housing122and reassembly the housing into an angled housing122A, the user may mount the whole housing122onto the housing mount120. In the regard, the housing122can be easily assembled to the housing mount120and the printed circuit board113in a fast and convenient manner. In a similar manner, the angled housing122A may also be easily assembled to the housing mount120and the printed circuit board113. Thus customization of the output light pattern direction from the light system10can be accomplished in a very fast and very convenient manner.

Considering now the a break away or tear away lens124in greater detail, the conically shaped lower lens portion132includes an angled tear away line L2which effectively enables the lens124to be broken into two parts which includes a modified upper lens portion134and a throw away piece136which was previously part of the lower lens portion132. The angled tear way line L2is selected to have a matching angle to the tear away line L1so that a resulting angled lens124A with a modified lens portion134will be press fit and received in a friction tight fit within the upper housing portion126and angled to be received onto the light emitting diode118as best seen inFIGS. 6-7.

From the foregoing those skilled in the art should understand that the light stream emitting from the light emitting diode118may be directed in one of several different angles from a linear array of assemblies or from a circular array of assemblies. In order to change the angle of any one of the light emitting diode assemblies, a user need only snap off the housing and to replace the housing and lens with one having a desired angle of inclination, such as an angle θ, which can be selected to be anywhere between at about 5 degrees and at about 60 degrees. In this manner, the light array from the primary holder20can be customized over a wide range of different angles thereby giving the lighting system10the ability to illuminate a large field of view or a very narrow field of view at various inclination angles. This is an important feature of the present invention.

Considering now the wide angle flood lamp16in greater detail with reference toFIGS. 1, and12, the wide angle flood lamp16generally includes a primary housing or holder20which is adapted to have mounted therein a plurality of high intensity light emitting diode printed circuit board assemblies, such as the light emitting diode printed circuit board assembly810as best seen inFIG. 8. The wide angle flood lamp16is configured so that its light output pattern can be customized or adjusted so that it illuminates large land areas with high intensity light in a fast and convenient manner. The wide angle flood lamp16may be customizable to provide a lighting pattern having a wide spread angle Ø to a narrow spread angle β. In this regard, as best seen inFIGS. 11A-11E, the wide spread angle Ø can be varied between about 80 degrees to about 40 degrees, while the narrow spread angle β may be varied between about 8 degrees and about 20 degrees. The manner in which the light spread angle is varied will be described hereinafter in greater detail.

Although the preferred embodiment of the present invention is described as having a particular light pattern as created by the light emitting diode printed circuit board assembly810, other light patterns and ranges are possible, For example, the patterns generated by the light emitting diode printed circuit board assembly1010(FIG. 10), the light emitting diode printed circuit board assembly1110(FIGS. 11A-11G), the light emitting diode printed circuit board assembly1510(FIG. 15), the light emitting diode printed circuit board assembly1910(FIG. 19) and the light emitting diode printed circuit board assembly2010(FIG. 20), each of which will be described hereinafter in greater detail.

Considering now the light emitting diode printed circuit board assembly810in greater detail with reference toFIGS. 8-9, the light emitting diode printed circuit board assembly810generally includes a printed circuit board812having a plurality of light emitting diodes mounted thereon, such as a light emitting diode818, a lens assembly822, and a heat sink assembly840. The plurality of light emitting diodes is mounted in a radial pattern array on the printed circuit board812with the lens assembly mounted directly above the printed circuit board812.

As will be described hereinafter in greater detail, the assembly810is constructed for adjusting the light patterns produced by the assembly810in a fast and convenient manner. That is the light pattern can be angled from a straight perpendicular direction to the positive or the negative from perpendicular. The light spread pattern can also be adjusted from a narrow focus range to a wide focus range in a quick and easy manner.FIGS. 11A-11Gillustrate the adjustment range of a light emitting diode printed circuit board assembly1110which is constructed similar to assembly810except that it employs a different light emitting diode array and corresponding lens array. Since the construction is similar except for the array layouts the printed circuit board assembly1110will not be described hereinafter in greater detail except as follows: it has a narrow focus range of between about 8 degrees and about 20 degrees and a wide focus range of between about 40 degrees and about 80 degrees. It also has an incline range of between about 1 degree and about 10 degrees. As noted earlier, the manner of adjusting the light pattern spread can be accomplished by hand with a screwdriver blade or with electromechanical means (not shown).

Considering now the heat sink assembly840in greater detail with reference toFIG. 8, the heat sink assembly840generally includes a heat sink mount842, and a heat sink844having a centrally disposed hole846. The heat sink mount842generally includes a mounting plate848, having a centrally disposed upright spindle850integrally attached thereto. The spindle850is cylindrical in shape and is dimensioned to be received within the hole846. A set of spaced apart threaded holes are disposed near the outer peripheral edge of the mounting plate848where the holes are dimensioned for receiving therein adjustment screws, such as an adjustment screw852. Each adjustment screw, such as the adjustment screw852has a sufficient length to be extended upwardly a sufficient distance to engage the lens assembly822. In this regard, a user by adjusting the individual screws852can set the lens assembly822on an inclined angle φ, where the angle φ is between about 1 degree and about 8 degrees. A more preferred angle φ is between about 2 degrees and about 7 degrees, and the most preferred angle φ is about 5 degrees.

As best seen inFIG. 8, the lens assembly822generally includes a mounting ring824, and a lens mounting surface826having disposed thereon a plurality of lenses, such as a narrow focus lens828and a wide focus lens830. The mounting ring824is mounted for rotational movement relative to the printed circuit board812so that the individual ones of the lens828and830can be rotated into vertical alignment with individual ones of the light emitting diodes. In this regard, as the lens assembly822is rotates above the light emitting diodes818multiple sets of lens are positioned above the light emitting diodes creating multiple light output patterns.

The primary innovation is a lens assembly that generally includes a minimum of two lens arrays positioned in a radial pattern such that as the mounting ring824is rotated to a first or narrow light focus pattern, such as the light focus pattern produced by the individual narrow focus lenses828, positioning the first set of lens over the light emitting diodes on the printed circuit board812, and then another light focus pattern, such as the wide focus pattern produced by the individual wide focus lens830, is positioned over the light emitting diodes on the printed circuit board812. In this manner, a user is allowed to change from a narrow focus light output pattern to a wide focus light output pattern without having to purchase separate types of light system. Moreover, this fast and convenient manner of changing the light output pattern can be accomplished as many times as may be needed by the user. This ability of the user to adjust the light output pattern after the assembly810has been installed is an important feature of the present invention.

From the foregoing, those skilled in the art will understand that by changing the mounting pattern for the individual ones of the light emitting diodes disposed on the printed circuit board812in combination with changing the mounting pattern for the individual ones of the lens disposed on the lens assembly822, a variety of different types of lighting patterns can be easily and quickly achieved with the present invention. For example, with reference toFIG. 8and the lens assembly822, there is illustrated a lens layout that is configured to work with a light emitting diode array comprised of four light emitting diodes arranged in a circular pattern. In this regard, the lens assembly822has two sets of lens, a narrow focus set828S and a wide focus set838S. The first set828S with a narrow light-spreading pattern can be positioned over the four light emitting diodes. Rotating the lens assembly822by 45 degrees positions the second set838S with a wide light-spreading pattern can be positioned over the light emitting diodes.

Considering now the light emitting diode printed circuit board assembly1010in greater detail with reference toFIG. 10, the light emitting diode printed circuit board assembly1010generally includes a printed circuit board1012having a plurality of light emitting diodes mounted thereon, such as a light emitting diode1018, a lens assembly1022, and a heat sink assembly1040. The plurality of light emitting diodes are mounted in a radial pattern array on the printed circuit board1012with the lens assembly1022mounted directly above the printed circuit board1012. The heat sink assembly1040is constructed substantially the same as heat sink assembly840. Therefore heat sink assembly1040will not be described hereinafter in greater detail.

Considering now the light emitting diode printed circuit board1012in greater detail with reference toFIG. 10, the light emitting diode printed circuit board1012is constructed substantially the same as printed circuit board812except that printed circuit board1012has a diode array layout that is different so that the diode arrangement corresponds with the lens arrangement on the lens assembly1022as will be explained hereinafter in greater detail.

As best seen inFIG. 10, the lens assembly1022includes a mounting ring1024, and a lens mounting surface1026having disposed thereon a plurality of lens arranged in two concentric circles. This arrangement can be employed with a light emitting diode array of 2, 4, 6, or 8 individual light emitting diodes. On an inner portion of the mounting circle1026there is a first ring set of lens1027S including a first set of narrow focus lenses, such as a narrow focus lens1028and a first set of wide focus lens, such as a wide focus lens1030. On an outer portion of the mounting circle1026, there is a second ring set of lens1031S including a second set of narrow focus lens, such as a narrow focus lens1032and a second set of wide focus lens, such as a wide focus lens1034.

Although two different printed circuit board and lens arrangements have been described in the preferred embodiment of the present invention, it should be understood by those skilled in the art that other board layout and lens layout arrangement are possible.FIGS. 11A-11Gfor example illustrate another lens layout that would function with the diode layout illustrated on printed circuit board812. Other board layouts and diode layouts are contemplated as well. For example a board layout and lens layout where the diodes and lens are arranged in two concentric circles, a first wide angle circle of lens, and a second wide angle circle of lens, where both circles of lens are disposed around a centrally disposed single narrow focus lens. This arrangement can be employed with an outer light emitting diode circle array of 12 light emitting diodes and an inner light emitting diode circle array of 6 light emitting diode where each circle of light emitting diodes are disposed around a centrally disposed single high intensity light emitting diode. Based on the foregoing, there is no intention of limitations to the exact lens and light emitting diode layouts as disclosed herein this detailed description.

Considering now the high intensity flood lamp18in greater detail with reference toFIGS. 1,13-14, the high intensity flood lamp18generally includes a primary housing22, a printed circuit board assembly24, and a lens plate assembly26(FIG. 14). The high intensity flood lamp18is configured so that its light output pattern can be customized or adjusted to illuminate large land areas with high intensity light in a fast and convenient manner. As will be explained hereinafter in greater detail, the high intensity flood lamp18may be customizable to provide a lighting pattern having a wide spread angle Ø to a narrow spread angle β. In this regard, the wide spread angle Ø can be varied between about 30 degrees to about 45 degrees, while the narrow spread angle β may be varied between about 5 degrees and about 20 degrees. The manner in which the light spread angle is varied will be described hereinafter in greater detail.

As best seen inFIG. 13, the primary housing22of the high intensity flood lamp18has generally a tear drop shape with a flat front open face area indicated generally at28. The printed circuit board assembly24which is mounted in the front open face area28has mounted thereon a plurality of light emitting diodes, such as a light emitting diode30. The light emitting diodes30are arranged in a predetermined pattern on the printed circuit board, so that the diodes mounted thereon will be arranged for alignment with a plurality of light directing lens which are disposed on the lens plate assembly26. As will be explained hereinafter in greater detail, individual ones of the plurality of light directing lens, such as a light directing lens32, and a light directing lens34, are mounted in a customized arrangement that facilitates spreading light in a customized lighting pattern.

It should be understood by those skilled in the art, that with the ability to provide light emitting diodes arranged in a predetermined pattern on the printed circuit board, it is possible to customize the light pattern output using different lens arrangements. For example FIGS.1and13-14illustrate at least two different lens arrangements for providing customized light output patterns. Therefore, there is no intention of limitations to the exact lens and light emitting diode layouts as disclosed herein this detailed description.

The primary housing22includes a set of mounting screws, indicated generally at S, which are utilized to align and hang the lens plate assembly26to the primary housing22. In this regard, the mounting screws S are loosely received within mounting or alignment holes, such as alignment hole50, which are disposed about the periphery on the lens plate assembly26as will be described hereinafter in greater detail.

The primary housing22also includes a lens plate assembly alignment screw36, which help secure the lens plate assembly26to the primary housing22and simultaneously enables the lens plate assembly26to be moved slight toward and slightly away from the printed circuit board assembly24in order to facilitate fine lens adjustments as needed. In this regard, the lens plate assembly26includes a centrally disposed mounting hole38which is dimensioned to receive therein the alignment screw36.

Considering now the lens plate assembly26in greater detail with reference toFIG. 14, the lens plate assembly26generally includes a mounting plate40having mounted thereon a plurality of upstanding break away mounts, such as a breakaway lens mount42and a breakaway lens mount44. Each breakaway mount, such as the mount44, includes at least three upstanding break away legs46,47, and48respectively. Each break away leg is a graduated leg with a series of indicia marker, such as an indicia marker M that help facilitate configuring an associated mount so that it can receive and support therein in a friction tight fit manner a individual light directing lens at a precise incline of about a mounting angle θ. The mounting angle θ can be customized for each mount to be between about 5 degrees and about 60 degrees from the horizontal plane of the mounting plate40. In this regard, the graduation indicia markers M on each leg are arrange for about a 5 degree adjustment for each segment torn away from an upstanding leg member. If none of the legs are broken away in a given mount, such as the mount42, the lens mounted therein will be disposed parallel to the mounting plate40so the lens will mount directly onto its associated light emitting diode and light will be directed at 90 degrees to the plane of the mounting plate40. Stated otherwise, the light beam will spread longitudinally straight forward.

Considering now the light directing lens32and34in greater detail with reference toFIG. 14, the lenses32and34are tear away lenses, where lens32is illustrated in a non tear away form and lens34is illustrated in a tear away form. As the lenses32and34are substantially similar to lens124and124A previously described, the lenses32and34will not be described hereinafter in greater detail.

Referring now to the drawings and more particularly toFIG. 21there is illustrated a customizing light emitting diode kit2110, which is constructed in accordance with the following invention. The kit2110is for use with a primary housing or holder, such as the primary housings20and22for example, which are adapted to receive and have mounted therein various ones of the components found in the kit2110as will be explained hereinafter in greater detail. The kit2110also permits a user to customize and adjust the light pattern produced to by a lighting system which utilizes one or more of the same or different types of primary housings. In this regard for example, the kit2110when installed in the primary housing22will create a light output pattern that illuminates large land areas with high intensity light in a fast and convenient manner. The light output pattern may be customizable to provide a lighting pattern having a wide spread angle Ø to a narrow spread angle β. In this regard, the wide spread angle Ø can be varied between about 80 degrees to about 40 degrees, while the narrow spread angle β may be varied between about 8 degrees and about 20 degrees. The manner in which the light spread angle is varied will be described hereinafter in greater detail.

Considering now the kit2110in greater detail with reference toFIG. 21, the kit2110is packaged in a convenient container, such as a container2112which holds all of the component parts in a centralized location for easy access by a user. Within the container2112, the component parts include a plurality of tear away lens holder housings, such as a lens holder housing2114and a lens holder housing2116. The lens holders2114and2116are configured to be customized at different angles of inclination. For example, the lens holder2114is configured to be torn away and reconfigured to provide an angled housing with a first angle of inclination, while the lens holder2116is configured to be torn away and reconfigured to provide an angled housing with a second angle of inclination, where the first angle of inclination is about 5 degrees greater that the second angle of inclination. The kit2110may contain lens holders that provide angles of inclination of anywhere selected between about 5 degrees and about 60 degrees depending upon whether the kit is selected for wide angle illumination or narrow angle illumination.

As the manner of reconfiguring the individual lens holders2114and2116is substantially the same as previously described for lens holder124and124A, the manner of reconfiguring lens holders2114and2116will not be described hereinafter in greater detail. Instead for the details one should refer to the description herein as it relates to lens holder housings124and124A.

The kit2110also includes a plurality of tear away light directing lenses, such as a tear away lens2118and a tear away lens2120. The tear away lenses2118and2120are configured to be customized at different angles of inclination, for example, the tear away lens2118is configured to be torn away to provide an angled lens with a third angle of inclination, while the tear away lens2120is configured to be town away to provide an angled lens with a fourth angle of inclination, where the third angle of inclination is about 5 degrees greater that the fourth angle of inclination. The kit2110may contain tear away lenses that provide angles of inclination of anywhere between about 5 degrees and about 60 degrees depending upon whether the kit is selected for wide angle illumination or narrow angle illumination.

Considering now the light directing lens2118and2120in greater detail with reference toFIG. 21, the lenses2118and2120are tear away lenses, where each lens is illustrated in a non tear away form. In this regard each lens may be reconfigured in substantially the same manner so-only the reconfiguring of lens2118will be described hereinafter in greater detail.

Considering now the light directing lens2118in greater detail the lens2118includes a scored stem portion indicated generally at2130and an upper lens portion2134. The scored stem portion2130includes an upper stem portion2135and a stem lower portion2136which portions are separated from one another by a tear or score line indicated generally at L3. The score line L3is angled so that when a user grabs the upper stem portion2135and pulls and snaps or tears away the lower portion stem2136, the lower stem portion2136separates and may be discarded leaving the lens2118with an angled stem portion having an angle of inclination of about θ3where the angle of inclination of about θ3is selected to correspond to the angle of inclination θ1of a corresponding housing.

From the foregoing it should be understood by those skilled in the art that the kit2110includes lens holders and lens which are matched. That is the kit2110includes a first plurality of tear away lens holders with score lines having an angle of inclination θ1matched with a first plurality of tear away lens with score lines having an angle of inclination θ3, where the angles of inclination θ1and θ3are matched so they correspond with one another. The kit2110further includes a second plurality of tear away lens holders with score lines having an angle of inclination θ2matched with a second plurality of tear away lens with score lines having an angle of inclination θ4, where the angles of inclination θ2and θ4are matched so they correspond with one another. Depending upon the wide angle or narrow angle application for the kit2110, the kit2110may contained a number of other tear away housing and tear away lenses which are matched at still different angles of inclination. Therefore there is no intention of limiting the kit to the angles of inclination described herein as other angles of inclination are contemplated within the true scope of the appended claims.

The kit2110also includes a set of printed circuit boards, such as a printed circuit board2122, where each printed circuit board has mounted thereon a light emitting diode2124. Each light emitting diode2124is a high intensity light emitting diode. A set of instruction2150is also included in the kit, which provides instructions for a user so that the user understand how to mount the printed circuit boards2122within the primary housing22, and how to configure the individual one of the tear away lens housings and individual ones of the tear away lenses so they are configured for wide angle illumination or narrow angle illumination applications. In this regard, the instructions2150would typically include the following steps:

1. Mount the individual printed circuit boards2122in the primary housing22making certain there is an electrical connection made between the individual ones of the printed circuit boards2122.

2. Temporarily apply power to the electrically connected printed circuit boards2122to make certain that each of their associated light emitting diodes2124illuminate properly.

3. Replace any light emitting diodes that are not operating properly and once all the light emitting diodes2124are operating properly disconnect the electrical power.

4. Select individual ones of the lens housings which provide the greatest angle of inclination for mounting on the printed circuit board.

5. Select corresponding individual ones of the tear away lens which provide the greatest angle of inclination for mounting within the housing selected in step 4.

6. As necessary, reconfigure the individual ones of the lens housings selected in step 4.

7. As necessary, reconfigure the individual ones of the lenses selected in step 5.

8. Mount the reconfigured lens housings from step 6 to selected ones of the light emitting diode as previously described herein relative to tear away housing.

9. Mount the reconfigured lenses from step 7 to the mounted reconfigured lens housing as described in step 8.

9. Select individual ones of lens housing which provide another but lesser angle of inclination for mounting on the printed circuit board.

10. Select corresponding other individual ones of the tear away lens which provide a matched angle of inclination relative to the housings selected in the previous step.

11. Reconfigure the individual ones of the lens housing selected in step 9.

12. Reconfigure the individual ones of the lenses selected in step 10.

13 Mount the reconfigured housing from step 11 to selected ones of the light emitting diodes as previously described herein relative to tear away housing.

14. Mount the reconfigured lenses from step 12 to the mounted reconfigured lens housing as described in step 13.

15. Repeat steps 9, 10, 11, 12, 13, and 14 until all matched tear away lens housings and tear away lens have been mounted to the remaining printed circuit boards and their corresponding light emitting diodes.

Considering now the light emitting diode printed circuit board assembly1910with reference toFIG. 19, the light emitting diode printed circuit board assembly1910is adapted to be mounted in a primary MR 16 lamp holder which MR 16 lamp holder is well known to those skilled in the art. Stated otherwise, the printed circuit board assembly1910is packaged as an MR 16 lamp replacement where the term MR 16 is a coded designation in which MR stands for Multifaceted Reflector and 16 is the number of eighths of an inch the front is in diameter, in the case of MR16: 2 inches.

It should be noted that MR16-compatible light emitting diode lamps are known in the prior art. They are similar in shape to halogen MR16 lamps, and can be used in most fixtures designed for MR16 lamps. For example reference may be made to U.S. Pat. No. 6,986,593 by Roads et al. issued on Jan. 17, 2006. The present invention is uniquely different however, from the '593 lamp as will be explained hereinafter in greater detail. For example, the printed circuit board assembly1910, unlike the '593 lamp does not include a multifaceted reflector. In fact, the printed circuit board assembly1910does not include any type of reflector. Neither does the printed circuit board assembly1910include any special dichroic coatings that reflect particular frequencies of the visible spectrum. Yet due to the unique and novel structure of the printed circuit board assembly1910it is able to delivery different beam angles from a narrow spot of light as small as 5 degrees to a wide field flood lamp of at least 60 degrees in a highly efficient and cost effective manner.

As best seen inFIG. 19, the light emitting diode printed circuit board assembly1910generally includes a two pin electric connector mount1912coupled mechanically to a heat sink mounting plate1913for supporting thereon a heat sink1914. The heat sink1914draws heat from a printed circuit board assembly1916carrying a plurality of light emitting diodes, such as a light emitting diode1915. Mounted over the light emitting diodes is a lens assembly mount1918which supports from below a plurality of customizable or tear away lens assemblies, such as a customizable lens assembly1920and a customizable lens assembly1922. The tear away lens assemblies enable the light pattern for the assembly1910to be easily customized to a narrow beam application to a wide flood beam application as will be explained. For the moment it will suffice to mention, since the two pin electric connector mount1912is a conventional MR 16 type connector mount, it will not be described hereinafter in greater detail but to mention that it includes a set of thread holes spaced about its periphery for receiving therein elongated adjustment screws such as an adjustment screw1924. The adjustment screws1924have sufficient lengths to raise and lower the lens assembly mount1918for beam adjustment purposes.

The two pin electrical connector mount1919is coupled electrically to the printed circuit board assembly1916which is mounted to the top surface area of the heat sink1914and spaced from the lens assembly mount1918by a sufficient distance to facilitate beam focusing purposes as will be explained. The electrical connector mount1919is isolated electrically from the heat sink mounting plate1913and the heat sink1914supported thereon. In this manner, electrical current can be easily and safely transferred from the mount1919to the printed circuit board assembly1916and the light emitting diodes mounted thereon, such as the light emitting diodes1915.

Considering now the lens assembly mount1918in greater detail, the lens assembly mount1918is supported from below by the elongated adjustment screws1924so that the lens assembly mount1918may be moved closer to or further away from the printed circuit board assembly1916. This is an important feature of the present invention as this allows a focus adjustment for the assembly1910by moving the tear away lens assemblies1920and1922closer to or further away from their associated light emitting diodes1930.

The lens assembly mount1918is generally circular in configuration having a diameter that is substantially the same as the heat sink1914and the two pin electrical connector mount1919to provide the overall configuration of the light emitting diode printed circuit board assembly1910with a configuration which is compatible with the MR16 lamp configurations. The lens assembly mount1918is adapted to have mounted thereon so as to support from below at least a pair of the customizable or tear away lens assemblies, such as the lens assembly1920and the lens assembly1922.

Considering now the lens assemblies1920and1922in greater detail, the lens assemblies1920and1922are substantially identical so only lens assembly1920will be described in greater detail. Lens assembly1920generally includes a breakaway housing1960and a breakaway lens1970. The breakaway housing1960and the breakaway lens are matched to have substantially the same break away angle of inclination θ, which angle of inclination θ is between about 5 degrees and about 60 degrees. The break away housing1960is substantially similar to break away angled housing122A and therefore breakaway housing1960will not be described hereinafter in greater detail. In a similar manner, break away lens1970is substantially similar to break away lens124and therefore break away lens1970will not be described hereinafter in greater detail.

The manner in which the break away housing1960is configured into an angle housing is substantially similar to the manner in which break away angled housing122A is configured into an angle housing. Similar the manner in which the break away lens1970is configured into an angled lens is substantially similar to the manner in which break away lens124is configured into an angled lens124A. Therefore the manner in which the break away housing1960and the manner in which the break away lens1970are configured into an angled housing and an angled lens will not be described hereinafter in greater detail.

Although in the preferred embodiment only a pair of the lens assemblies1920and1922are illustrated as being mounted on the top surface of the lens assembly mount1918, it should be understood by those skilled in the art that fewer lens assemblies or a greater number of lens assemblies may be mounted within the available mounting area of the lens assembly mount1918.

Considering now the light emitting diode printed circuit board assembly1910in still greater detail, the printed circuit board assembly1916is matched to the number of lens assemblies which are disposed on the lens assembly mount1918. That is, since the lens assembly mount1918is configured to support from below two lens assemblies1920and1922, the printed circuit board assembly1916is configured with two light emitting diodes, such as a light emitting diode1930.

Considering now the method of focusing the light patterns generated by the light emitting diodes1930in greater detail with reference toFIG. 19, the lens assembly mount1918is mounted closely spaced apart from the printed circuit board assembly1916. For clarity of understanding the focusing method, the lens assembly mount1918inFIG. 19is illustrated at a maximum spaced position from the printed circuit board assembly1916, which is a first adjustment position. A user by adjusting the focus adjustment screws1924decreases the spacing distance between the lens assemblies1920and1922and the printed circuit board assembly1916so that the distance between the lens1970carried on the break away housing1960and1962is adjusted to a second adjustment position which is a focus position so that the generated light patterns are in focus. It should be understood that the travel distance between the lens assembly mount1918and the printed circuit board assembly1916and its associated light emitting diodes1930is sufficiently small that only a minor adjustment of the adjustment screws1924is required for pattern focusing purposes.

Considering now the light emitting diode printed circuit board assembly2010with reference toFIG. 20, the light emitting diode printed circuit board assembly2010generally includes a heat sink mount2012, a heat sink mounting plate2013, a heat sink2014, a printed circuit board assembly2016, a lens assembly mount2018, and a customizable lens assembly, such as a customizable lens assembly2020. Light emitting diode printed circuit board assembly2010is substantially similar in configuration to light emitting diode printed circuit board assembly1910except that it is configured with only a single light emitting diode2015on printed circuit board assembly2016and only the single customizable lens assembly2020. Therefore the light emitting diode printed circuit board assembly2010will not be described hereinafter in greater detail, except to further describe the customizable lens assembly2020.

Considering now the customizable lens assembly2020, the customizable lens assembly2020generally includes a breakaway housing2060and a breakaway lens2070. The breakaway housing2060and the breakaway lens2070are matched to have substantially the same break away angle of inclination θ, which angle of inclination θ is between about 5 degrees and about 60 degrees. The break away housing2060is substantially similar to break away housing122and therefore breakaway housing2060will not be described hereinafter in greater detail. In a similar manner, break away lens2070is substantially similar to break away lens124and therefore break away lens2070will not be described hereinafter in greater detail.

It should be understood by those skilled in the art that the various light emitting diode printed circuit board assemblies, such as assemblies1510,1910, and2010for example, have low voltage light emitting diodes. In order to convert a primary power source, whether its 110 VAC, 220 VAC or some other alternating current voltage value, a converter or voltage driver, such as a converter1930, or a converter2030can be mounted below associated heat sinks, such as heat sink2014,1914, and2014respectively. In this manner the light emitting diode printed circuit board assemblies may operate with constant current and or low voltage 12V, 24V, 48 V AC or DC low voltage as needed. Assemblies can have direct wires or pin connectors or direct screw in sockets such as one would find on a conventional light blub. Moreover, it should be understood that such converters may be mounted apart from such assemblies in a remote junction box for example. In short then, the converters1930and2030enable the assemblies to run universal power 90 volts, 120 volts, 240 volts, 277 volts or 480 as required and needed in universal power applications. As such converters or voltage drivers are well known in the prior art, the converters1930and2030will not be described hereinafter in greater detail.

While a particular embodiment of the present invention has been disclosed, it is to be understood that various different modifications are possible and are contemplated within the true spirit and scope of the appended claims. For example, it is contemplated that the lens assembly822can be configured to rotate by application of a tool or by hand requiring no tools. Detents can also be included to provide a user with feedback that the lens assembly is positioned optimally over the light emitting diode array. A pattern of one, two, three, four or any integer number of lenses is possible matched to a light emitting diode array disposed on the printed circuit board assembly. The lens assembly is free to rotate over the light emitting diode array and is free to be adjusted to be inclined at about an angle φ. As another example, the light emitting diode system10may also includes means for adjusting the intensity of the light emitted by the system10so that it may varied from a fully on state to a fully off state in a series of dimming steps. In this regard it is contemplated that the intensity of the light emitting diode may be dimmed from a fully on state to a plurality of intermediate states arranged in about 10 percent steps including about 100 percent off, 90 percent off, 80 percent off, 70 percent off, 60 percent off, 50 percent off, 40 percent off, 30 percent off, 20 percent off, and 10 percent off. As still yet another example, the lens assembly2020may be reconfigured into an angle assembly2020A as best seen inFIG. 15to provide yet another light emitting diode printed circuit board assembly1510which is adapted to be mounted in a primary MR 16 lamp holder. Therefore, there is no intention of limitations to the exact abstract or disclosure herein presented.

REFERENCE CHARACTER LISTING

M an indicia markerS mounting screw10an adjustable and customizable light emitting diode lighting system (FIG. 1)12a vehicle14a light bar arrangement16a wide angle flood lamp18a high intensity flood lamp20a primary housing22a primary housing24a printed circuit board assembly26a lens plate assembly (FIG. 14)28a flat front open face30a light emitting diode32a light directing lens34a light directing lens36a lens plate assembly alignment screw38a centrally disposed mounting hole40a mounting plate42a lens mount44a lens mount110a light emitting diode printed circuit board assembly (FIG. 2)112a printed circuit board assembly (FIG. 2)113a printed circuit board114a light emitting diode assembly (FIGS. 2-3)114A an angled light emitting diode assembly (FIGS. 6-7)116an electrical mount118a light emitting diode120a housing mount121a mounting portion or cutout122a break away or tear away housing122A an angled housing123a reflective coating124a break away or tear away lens124A a resulting angled lens124A126an upper lens receiving portion128a lower mounting portion130an upper lens portion132a lower lens portion134a modified upper lens portion136a throw away lens piece810a light emitting diode printed circuit board assembly (FIG. 8)812a printed circuit board818a light emitting diode822a lens assembly824a mounting ring826a lens mounting surface828a narrow focus lens828S a narrow focus set830a wide focus lens838S a wide focus set840a heat sink assembly842a heat sink mount844a heat sink848a mounting plate850an upright spindle852a screw1010a light emitting diode printed circuit board assembly (FIG. 10)1012a printed circuit board1018a light emitting diode1022a lens assembly1024a mounting ring1026a lens mounting surface or circle1027S a first ring set of lens1028a narrow focus lens1030a wide focus lens1031S a second ring set of lens1032a second set of narrow focus lens1034a wide focus lens1040a heat sink assembly1510a light emitting diode printed circuit board assembly (FIG. 15)1910a light emitting diode printed circuit board assembly (FIG. 19)1912a two pin electric connector mount1913a heat sink mounting plate1914a heat sink1916a printed circuit board assembly1915a light emitting diode1918a lens assembly mount1920a customizable lens assembly1922a customizable lens assembly1924an adjustment screw1930a converter or voltage driver1960a breakaway housing1970a breakaway lens2010a light emitting diode printed circuit board assembly (FIG. 20)2012a heat sink mount2013a heat sink mounting plate2014a heat sink2015a light emitting diode2016a printed circuit board assembly2018a lens assembly mount2020a customizable lens assembly2020A an angle assembly2030a converter or voltage driver2060a breakaway housing2070a breakaway lens2110a customizing light emitting diode kit2112a container2114a lens holder housing2116a lens holder housing2118a tear away lens2120a tear away lens2122a printed circuit board2124a light emitting diode2130a scored stem portion2134an upper lens portion2135an upper stem portion2136a lower stem portion2150a set of instruction