LED lighting system

An LED lighting system is provided for connection to a variable power source providing input power, the LED lighting system having at least one power analyzing and processing circuitry connecting to the variable power source, and being configured to identify one or more characteristics of the input power, where the characteristics are selected from amplitude, frequency and pulse width of the input power, compare one or more of the characteristics of the input power to preset control criteria either in hardware or software or both to yield a comparison result, and then control the current control circuitry according to the comparison result.

TECHNICAL FIELD

LED lighting control.

BACKGROUND

Traditionally to control LED lights a control signal has to be provided to the lights either through a separated control pin or wire, or wireless technology, or technologies like signal carrier, or the LED lights operate in a master-slave mode. When the LED lights work in master-slave mode the LED arrays are controlled by the power source directly. For example the power source's voltage is applied to the LEDs directly, so the LEDs are lit up when the voltage goes up and dim down when the voltage goes down. An example LED Lighting System is shown in published international application WO200709092.

SUMMARY

An LED lighting system is provided for connection to a variable power source providing input power, the LED lighting system having at least one power analyzing and processing circuitry connecting to the variable power source, and being configured to identify one or more characteristics of the input power, where the characteristics are selected from amplitude, frequency and pulse width of the input power, compare one or more of the characteristics of the input power to preset control criteria either in hardware or software or both to yield a comparison result, and then control the current control circuitry according to the comparison result.

An LED lighting system for connection to a variable power source providing input power, comprising: a support structure spanning between a first end and a second end, the support structure made of rigid material, the support structure being sufficiently heat conductive to provide heat dissipation for the LEDs; an electrical connector for connection to the variable power source at least at the first end or between the first end and second end; at least one LED array extending along the support structure; power control circuitry for the at least one LED array, the power control circuitry being carried by the support structure and being in electrical communication with the electrical connector; a circuit board supporting the at least one LED array, the corresponding power control circuitry being provided on the circuit board or on a separate board; the at least one LED array being divided into sets of LEDs; the power control circuitry being formed of one or multiple current controllers, each of the one or multiple current controllers providing current control for a corresponding set of LEDs in the LED array; and at least one power analyzing and processing circuitry connecting to the variable power source, and being configured to identify one or more characteristics of the input power, where the characteristics are selected from amplitude, frequency and pulse width of the input power, compare one or more of the characteristics of the input power to preset control criteria either in hardware or software or both to yield a comparison result, and then control the current control circuitry according to the comparison result.

An LED lighting system for connection to a variable power source providing input power, comprising: a support structure; an electrical connector for connection to the variable power source; at least one LED array in the support structure; power control circuitry for the at least one LED array, the power control circuitry being carried by the support structure and being in electrical communication with the electrical connector; a circuit board supporting the at least one LED array, the corresponding power control circuitry being provided on the circuit board or on a separate board; the at least one LED array being divided into sets of LEDs of same or different colors; the power control circuitry being formed of one or multiple current controllers, each of the one or multiple current controllers providing current control for a corresponding set of LEDs in the LED array; and at least one power analyzing and processing circuitry connecting to the variable power source, and being configured to identify one or more characteristics of the input power, where the characteristics are selected from amplitude, frequency and pulse width of the input power, compare one or more of the characteristics of the input power to preset control criteria either in hardware or software or both to yield a comparison result, and then control the current control circuitry providing same or different current control for a corresponding set of LEDs in the LED array according to the comparison result.

An LED lighting system is provided for connection to a variable power source providing input power, the LED lighting system having power control circuitry that in operation connects to the variable power source, and the power control circuitry being configured to compare input power to one or more pre-set conditions to yield a comparison result and output a control signal according to the comparison result.

An LED lighting system for connection to a variable power source providing input power, comprising: a support structure spanning between a first end and a second end; at least one LED array extending along the support structure; power control circuitry for the at least one LED array, the power control circuitry being carried by the support structure and being in electrical communication with at least an electrical connector for connection to the variable power source; and the power control circuitry being configured to compare input power to one or more pre-set conditions to yield a comparison result and output a control signal according to the comparison result.

A method of controlling an LED lighting system, comprising: comparing input power to one or more pre-set conditions using power control circuitry to yield a comparison result; and the power control circuitry outputting a control signal according to the comparison result.

Controllers connecting to an LED lighting system, the controllers being configured to: provide the output with controllable characteristics, the characteristics being selected from the group comprising voltage amplitude, power frequency and pulse width; and detect the characteristics change, such as a current change, to identify the working status of the system to synchronize the control status of the multiple controllers in the system.

An LED lighting system comprising: a support structure; at least one LED array in the support structure; power control circuitry for the at least one LED array; at least one power analyzing and processing circuitry connecting to the variable power source, and being configured to: identify one or more characteristics of the input power, where the characteristics are selected from amplitude, frequency, and pulse width of the input power, compare one or more of the characteristics of the input power to preset control criteria either in hardware or software or both to yield a comparison result, and control the current control circuitry providing same or different current control for a corresponding set of LEDs in the at least one LED array according to the comparison result.

An LED lighting system comprising: a support structure; at least one LED array in the support structure; power control circuitry for the at least one LED array; at least one power analyzing and processing circuitry connecting to a variable power source, and being configured to: identify one or more characteristics of the input power, where the characteristics are selected from amplitude, frequency, and pulse width of the input power, compare one or more of the characteristics of the input power to preset control criteria either in hardware or software or both to yield a comparison result, and control the current control circuitry providing same or different current control for a corresponding set of LEDs in the at least one LED array according to the comparison result.

In various embodiments, there may be included any one or more of the following features.

Each LED of the at least one LED array has a power rating of no less than 0.01 watts. The support structure is generally elongated in a first direction; the at least one LED array having a first illumination field directed perpendicularly to the first direction; and at least one other LED array carried by the support structure, the at least one other LED array having a second illumination field directed perpendicularly to the first direction, the second illumination field being oriented at a non-zero angle to the first illumination field. The first illumination field and the second illumination field are oriented at 180 degrees to each other. The support structure being generally elongated in a first direction; and plural other LED arrays carried by the support structure, the plural other LED arrays being oriented to provide an illumination field that extends 360 degrees around the support structure at a given distance outward from the support structure. The support structure has a front side on which the at least one LED array is carried and a rear side on which the power control circuitry is carried. An electrical connector at a second end of the support structure. The electrical connectors at each of the first end and the second end of the support structure are compatible with fluorescent light receptacle attachment pins. The onboard current control circuitry is configured to provide constant current to the LEDs of the LED array. The support structure is made of a unitary piece of material that is both heat conductive and rigid. An optically transparent or translucent cover secured to the support structure over the at least one LED array. The support structure is hollow. The at least one LED array is provided on a front side of the support structure and the support structure has a domed shaped rear side. The combination of support structure and optically transparent cover has an egg shaped cross-section. Multiple LED lighting systems installed in a vehicle. The vehicle is a watercraft, aircraft or land vehicle. Multiple LED lighting systems installed in a building or in signage.

The LED lighting system has one or more of a support structure spanning between a first end and a second end, the support structure made of rigid material, the support structure being sufficiently heat conductive to provide heat dissipation for the LEDs; an electrical connector for connection to the variable power source at least at the first end or between the first end and second end; at least one LED array extending along the support structure; power control circuitry for the at least one LED array, the power control circuitry being carried by the support structure and being in electrical communication with the electrical connector; and a circuit board supporting the at least one LED array, the corresponding power control circuitry being provided on the circuit board; the at least one LED array being divided into sets of LEDs; the power control circuitry being formed of one or multiple current controllers, each of the one or multiple current controllers providing current control for a corresponding set of LEDs in the LED array. In some embodiments, sets of LEDs may be of the same or different colors, and the current control circuitry may provide same or different current control for a corresponding set of LEDs in the LED array according to the comparison result.

There may for example be a support structure forming a channel and being heat conductive and rigid, with one or both ends of the support structure having electrical connectors for connection to a power source. An LED array in some embodiments extends along the support structure for example within the channel, and in some embodiments supported in slots, each LED in the LED array may have in some embodiments a power rating of greater than 0.1 watt. The power supply circuitry in some embodiments is provided by current control circuitry, for example onboard circuitry, carried by the support structure, in some embodiments within the channel, and may provide current control for individual sets of LEDs. The current control allows careful control of the forward current passing through the LED array so that it controls the brightness and heat production by the LEDs. Devices with full 360 degree illumination are disclosed, along with devices with LEDs having differently angled illumination fields. Various electrical power supplies, structural support configurations and shapes, lens configurations, and overall structural configurations are also disclosed.

The output signal may be applied to a control circuit to control power provided to the at least one LED array according to the comparison result. The pre-set conditions may be selected from amplitude, frequency and pulse width of the input power. In a further embodiment, there is provided a method of controlling an LED lighting system, comprising comparing input power to one or more pre-set conditions using power control circuitry to yield a comparison result; and the power control circuitry outputting a control signal according to the comparison result. The output signal may be applied to a control circuit to control power provided to an array of LEDs according to the comparison result.

Controlling the power provided to the LEDs comprises adjusting brightness, such as brightening or dimming, and different LEDs may be adjusted differently, so that for example some LEDs may be brightened and some dimmed.

The output signal is applied to a control circuit to control power provided to the at least one LED array according to the comparison result. A circuit board supporting the at least one LED array; the at least one LED array being divided into one or more sets of LEDs; and the power control circuitry being formed of one or more current controllers, each of the one or multiple current controllers providing current control for a corresponding set of LEDs in the LED array. The power control circuitry is configured to change state upon a positive comparison result and output the control signal upon occurrence of the change of state. The pre-set conditions are selected from amplitude, frequency and pulse width of the input power. Upon the occurrence of the comparison result, the power control circuitry is configured to send a dim signal to the at least one LED array. The control signal is configured to instruct LEDs in the at least one LED array to flash. The control signal comprises a check code. The output signal is applied to a control circuit to control power provided to an array of LEDs according to the comparison result. The pre-set conditions are selected from amplitude, frequency and pulse width of the input power. The power control circuitry changing state upon a positive comparison result and outputting a control signal upon occurrence of the change of state. Controlling current provided to the array of LEDs comprises controlling brightness of the LEDs. Controlling current provided to the array of LEDs comprises dimming the LEDs. The control signal instructs LEDs in the at least one LED array to flash. The control signal comprises a check code.

One or more controllers, the controllers can control the LED lighting system synchronously. At least one controller in the group controllers, the group of controllers can control at least one LED lighting system. The group of controllers can be connected in series or parallel. The controller can be remotely controlled by other controlling systems through networks. The networks can be wired or wireless. The controller can be installed in the LED system. The controller in the lighting system can be mounted at same PCB of the LED lighting system or mounted at another PCB separately. The controller in the lighting system can be communicated with the LED lighting system by the methods of wired or wireless. The LED lighting system with or without the controller can be made in different shapes. One or more controllers, the controllers being configured to control the LED lighting system synchronously. A group of controllers, the group of controllers being configured to control at least one LED lighting system. The group of controllers are connected in series or parallel. The controller is configured to be remotely controlled by one or more other controlling systems through one or more networks. The one or more networks are wired or wireless. The controller is configured to be installed in the LED system. The controller in the lighting system is configured to be mounted to the same PCB of the LED lighting system or mounted to another PCB separately. The controller in the lighting system is configured to be communicated with by wired or wireless methods. The LED lighting system made in different shapes.

DETAILED DESCRIPTION

In this patent document, “comprising’ means ‘including”. In addition, a reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present. Each one of the individual features described here may be used in one or more embodiments and is not, by virtue only of being described here, to be construed as essential to all embodiments as defined by the claims.

InFIGS. 1-3, 7-12, there is shown an exemplary LED lighting system10that includes a plurality of LEDs100, each LED100being supplied power from a circuit board101supported by support structure102. Support structure102in one embodiment forms a channel and is made of a heat conductive and rigid material, such as aluminum, ceramic or any thermally conductive formable material. In one embodiment, the support structure102is both heat conductive and rigid and is made of a unitary piece of material. The support structure102is rigid and extends from end to end of the LED lighting system10. The heat sink capability may be continuous from end to end or may be semi-continuous. In the case of being semi-continuous, the material providing the heat sink function may have breaks, in which case additional connector material is required to provide the channel with sufficient rigidity so that the lighting system10does not collapse or sag under its own weight. The circuitry20or30provide current control for the LED lighting system10and are attached to the support structure102permanently such as by fasteners108(FIG. 3), which may be rivets or screws, so they do not allow for vibration to loosen the connection between the circuit board101and the support structure102over time. The support structure102does not require adhesive, or thermally conductive substance to connect to the circuit board101. The support structure102provides a rigid backbone structure to the LED lighting system10, and is sufficiently rigid to prevent the LED lighting system10to resist or prevent breakage during normal use, or bending, unless the product design requires it. The support structure102may be provided with a cover107secured in a groove109that runs along the inside edge of the support structure walls. The cover107is transparent or translucent and may be formed as a lens.

At one or both ends of the support structure102there are provided electrical connectors103,105, and106for connection of the lighting system10to a power source. When LED lighting system10is configured as a bulb, rather than as tube, it will typically have connectors only at one end. In the embodiment ofFIGS. 1, 4, 7 and 8, a single connector105of Pin Type 1 is formed in end caps of the support structure102. In the embodiment ofFIGS. 2, 5, 6, and 9-12double connectors106of Pin Type 2, either in the bi-pin format (FIGS. 6, 11 and 12) or the recessed double contact type (FIGS. 5, 9 and 10) are formed in end caps104of the support structure102. These connectors105,106are of conventional design. The end caps104may be any suitable material such as plastic, Lexan™, polycarbonate, acrylic, ABS, metal such as aluminum, copper, brass, stainless steel, metal alloy, combination of metal and plastic, or fiberglass. The end caps104may be manufactured in different shapes and sizes, all able to connect to the circuit boards101within the support structure102. The end caps104encase the channel, are secured against movement and do not break with vibration. The end caps104also secure and prevent movement of the lens107,118-127. As with the other components of the lighting system10, the end caps104should be made to withstand high ambient temperatures (up to 125° C.+) and low ambient temperatures (as low as −40° C.). In the case of use of the LED lighting system10as a fluorescent light fixture replacement, the connectors105,106are conventional pins for attached to fluorescent light fixture receptacles. In other embodiments, such as when the LED lighting system10is used in a single socket fixture, the connectors106may be provided at one end only of the support structure102.

An LED array formed of LEDs100extends along the support structure within the channel formed by the support structure102. To provide sufficient power to provide light, particularly in an industrial or commercial environment, each LED100in the LED array should have a power rating sufficient to provide the desired degree of light, including in the case of vehicles used for transportation a sufficient degree of light to meet regulatory requirements. For example, such requirements may be met by LEDs having a power rating of greater than 0.1 watt, depending on the efficiency of the LED in converting power to light energy. The LEDs may also be organic LEDs or any other suitable LED now known or later developed.

The circuit boards101provide in one embodiment onboard current control circuitry for the LED array. The circuit boards101are carried by the support structure102and are in electrical communication with the electrical connectors103.105,106. The LEDs100are preferably organized in groups of LEDs, either in series, or parallel. The LEDs may be surface mounted (SMT) or through hole mounted (TH). The color of the LEDs can be any available color such as white, blue, green, red, yellow, amber, purple, pink, or orange.

FIGS. 13 and 14show circuit diagrams with an example circuit20for onboard current control. The circuits ofFIGS. 13, 14, 35, 36may all be placed on the circuit board or boards101.FIG. 13illustrates a single circuit20connected to a conventional power source208, whileFIG. 14shows multiple circuits20in parallel connected to a conventional power source208. The circuit boards101for the circuits20may be made of fiberglass based printed circuit board (PCB) or metal based (for example Aluminum) PCB or any other suitable PCB material now known or later developed. The circuit boards101may be TH type or SMT type. Preferably, the surface of the circuit boards101have a white solder mask and exposed areas of tinned plane so as to efficiently reflect the majority of LED light. The circuit boards101may be flexible to accommodate mounting channels and lighting fixtures in different shapes and curves. As shown inFIGS. 13 and 14, the LED array is divided into sets209of LEDs, with for example five LEDs per set. As shown inFIG. 14, the onboard current control circuitry is formed of multiple circuits20. Each circuit20provides current control for a corresponding set209of LEDs in the LED array.

The onboard current control circuitry20is configured to provide constant current to the LEDs100of the LED array209. A polarity protection circuit201of conventional design safeguards against the user installing the product in the wrong polarity. Current control is provided by current control circuit202, also of conventional design. As an example, the current control circuit202may be use pulse width modulation (PWM) to control the current supplied to the LEDs. The circuit202supplies constant, controlled, current to unit for the entire LED set209with information from voltage sensor203. The voltage sensor203receives current information from LEDs209and feeds back information to the current control circuitry202. For example, in the use of PWM, the voltage sensor203converts the current of LED array209to voltage signal and supplies the voltage signal to the current control circuit202. The current control circuit202senses how much the detected voltage varies from the desired level, and by varying the pulse width or frequency, changes the current supplied to the LEDs towards the desired level. The power supply208may be AC or DC, although in the example shown it is DC. Current control provides constant brightness and prevents overheating. A typical pulse frequency for the current control may be 200 kHz to 4 MHz. This low voltage application shown here provides voltage for applications below about 72 volts.

The organization of the circuit boards101is shown inFIGS. 15 and 16.FIG. 15shows a single set of five LEDs100with circuit components201,202and203.FIG. 16shows an exploded side view of an LED lighting system10, with support structure102, cover107and with LEDs100, which LEDs may be for example secured or joined to a circuit board101by any suitable means as for example soldering or heat sink compound117.

FIG. 17is an example of an LED lighting system or tube10in a mass transit application. A transit vehicle has a body or hull303with a windshield300. The break away shows floor304, with seating306and partitions305. Lighting tubes10may be installed in pre-existing fluorescent light sockets or receptacles309, with bypassing or removal of the fluorescent light ballasts308.FIG. 26is another view of the mass transit application, showing also passengers310and a reading plane311and floor plane313, which acts as a test zone for establishing whether the LEDs are providing sufficient illumination.FIGS. 18, 19 and 20illustrate an application in which the LED lighting system10is used as part of an advertising sign401for a taxi400.FIGS. 21, 22 and 23illustrate an application in which the LED lighting system10is used as part of an on duty sign404for a taxi400.FIGS. 24 and 25illustrate installation of the LED lighting system10in new or pre-existing fluorescent light fixtures of an aircraft with a fuselage500, seating501, windows502, upper luggage compartment503, cargo area504and floor505.

InFIGS. 27A-27K, various shapes of cover lens107are shown including moderate convex124, straight107, straight raised118, asymmetrically peaked119and120, symmetrically peaked121, raised dome122, low dome123, convex124, depressed low dome125raised convex126, and low dome with channel enclosing127.FIG. 28shows a fluorescent lamp fixture600with power receptacles or sockets601, conventional ballast602for lamp603, replacement LED lighting tube10, ballast cover604and diffuser panel605. While the lens107is not required for the final assembly it can be added to act as a guard against vandalism, as a dust/dirt guard, as a light enhancing device, as a light directing/focusing device, as a moisture/waterproofing device (sealing unit completely with the addition of sealant) or as a light diffuser. InFIG. 28, only the lighting tube10is new.FIG. 37shows replacement of a fluorescent lamp603in a display sign application with an LED lighting tube10that fits between power receptacles601. The ballast602may be removed or bypassed.

InFIGS. 29-31, powered end of an LED lighting tube for a vehicle application includes LED100(one of several in the array), support structure102, connecting wires103that connect to the circuit board101and rivets108for securing the circuit board101on the support structure102. The connecting wires103pass through the holes114in O-rings110that are secured to the upstanding flange of an inner mounting bracket116. The mounting bracket116is secured to the support structure102by a bolt113secured with nuts112and washer111. Bolt113and nuts112also secure outer mounting bracket115to the support structure102. Rivets108also secure the side walls of the mounting bracket116to the channel walls of the support structure102. Mounting bracket115is used to connect the LED lighting tube of this embodiment to a structural portion of a vehicle.FIGS. 32-34show the non-powered end of the LED lighting system for a vehicle, which is the same as the powered end except that there are no power connections.

FIG. 35shows electrical circuitry30of an current circuit, andFIG. 36shows several such boards connected in parallel between respective power buses.FIGS. 35 and 36show circuitry for a high voltage power source, above 72 volts, for example 120 volts to 240 volts, either AC or DC. The example shown here is for AC power supply. Fuse215protects the circuitry of the board from power surges. The fuse can be permanent or be a resettable fuse. Bi-directional filter circuit204filters out noise. Full wave rectifier205transforms AC current from the power bus (left side of figure) to DC current. The DC current from the full wave rectifier205is supplied to voltage regulator207to step the voltage down to a low level, for example 5 volts, to power switching power supply control IC210. The switching power supply control IC210provides a modulated signal at about 250 kHz or more that determines the switching frequency or pulse width of a high voltage switching power driver circuit211. The switching signal from driver211drives a primary coil of transformer216, and causes DC voltage supplied by the full wave rectifier205to switch at the switching frequency or pulse width determined by the control IC210. Transformer216couples this switching voltage through half-wave rectifier206which also filters the high frequency signal from the transformer216to the LED array209on the right side ofFIG. 35. The half-wave rectifier206provides the switching frequency or pulse width of the current from the secondary of the transformer216and supplies a isolated feedback signal through a signal feedback circuit212to control IC210. Depending on whether the sensed signal is above or below the desired current level, the control IC210varies the pulse width or pulse frequency of the signal driven by the driver circuit211to ensure a constant average current supplied to the LEDs. The transformer216both isolates input from the output, which drives the LEDs, and provides a voltage step down from high voltage above 72 volts, to low voltage required by the LED array209. The control IC210may also be configured to vary the average current supplied to the LEDs, by suitable controlling the pulse width or frequency of the drive signal to the circuit211, and thus provide a dimmable controller that can be used to control the brightness of the lighting devices. The switching power supply circuit30may be mounted on each circuit board101, or shared by each of several circuit boards101and located at one end of the lighting device10.

The switching power supply circuit30is integrated with the LEDs100on each section of printed circuit board101, so that any defect of each power supply circuits or LEDs100would not affect the lighting device10as a whole. The other circuit boards101of the lighting device are still active. The LED lighting device10can be installed in polarity or no polarity, and may have any required length. The LED lighting device10may use voltages from 1.5V˜240V in both DC and AC, and may fit retroactively into existing fluorescent lighting fixtures after removing or bypassing the ballast. This LED lighting device10can be a replacement or retrofit for all existing fluorescent lighting tubes larger than the size of T5.

FIG. 38andFIG. 39show two different views of an embodiment of an LED lighting system in which the LEDs100lie on flat PCB heat sinks134. The LED arrays are attached to the flat PCB heat sinks with each of the LED arrays facing in a different direction. Each LED array contains a series of LEDs, each with a conical beam, that together create an illumination field. The orientation of the illumination fields of the LED arrays shown inFIGS. 38 and 39are angularly offset from each other by 90 degrees. In other embodiments, this angle may change, and/or individual LEDs may have conical beams that are angularly offset from each other. Additional LED arrays may also be provided, with each LED array having a differently oriented illumination field. In one embodiment, the illumination fields of three or more LED arrays may together make up a 360 degree pattern. In the embodiment ofFIGS. 38 and 39, an 180 degree lens133with guides is attached to the support structure136in channel109, and may slide into place along the channel109. InFIG. 39, two PCB heat sink slots135are formed in the support structure136. The heat sinks134fit in the slots135. Heat from the heat sinks134is in part conducted to the support structure136to assist in heat dissipation. A suitable heat conductive material such as aluminum may be used for the heat sinks134and support structure136.

FIGS. 40 and 41show a further embodiment of an LED lighting system with 360 degree coverage in which the support structure137defines two channels and the LEDs100of two LED arrays on circuit boards101have illumination fields at 180 degrees to each other. A double sided lens130is received in channel109in the support structure137. Grooves131on the outside of the support structure are provided for receiving a mounting clip such as mounting clip115shown inFIG. 51. Mounting clip115has arms138with hooks139that insert into the grooves131. The clip115may be secured by any suitable means to the structure137such as a part of the surface to which it is mounted.

FIGS. 42 and 45show a further embodiment of an LED lighting system with 360 degree coverage similar to the design ofFIG. 66, but the lens covers129are omitted, and the locking elements128are also omitted, the cylindrical lens127being used to secure the elements together.

FIGS. 43 and 44shows an end socket for use with an LED lighting system10which uses two pins106secured within an inner mounting channel116inside an end cap channel132. This end socket may be used with the designs of hollow support structures (or at least partially hollow) such as those ofFIGS. 42, 45, 66 and 67with the channel116protruding into the hollow support structure140or147.

FIGS. 46-50show how various configurations of LED arrays may be carried by a support structure141. In these figures, the support structure141is the same in each case, and may be provided with one or two semi-cylindrical lenses133received in slots109running along the length of the support structure141. Mounting clip grooves131are provided on the outer sides of the support structure141. There may be one (FIG. 46), two (FIG. 47), three (FIG. 48) or four (FIG. 49) circuit boards101carrying LEDs100in linear arrays that may be directly secured to the support structure141or placed on flat PCB heat sinks134that are received in angled slots135running along the length of the support structure141. In this way, the orientation and number of the LED arrays can be selected according to the application.

FIGS. 52-55show a variety of LED lighting systems with a domed support structure142and144. A 180 degree lens143has guides that are received in grooves109in the support structure142and144. An LED array formed of LEDs100on circuit boards101in one 180 degree embodiment (FIG. 52) is received in slots135on the front side of the support structure, and on the opposite rear side a power supply30may be secured by any suitable means within the domed portion of the support structure142and144. In another embodiment (FIG. 54), the LEDs of respective circuit boards101have illumination fields that are oriented at different angles, though both illumination fields are perpendicular to the direction of elongation of the support structure. The direction of the illumination field is the direction perpendicular to the light emitting surface of the LEDs100. The embodiments ofFIGS. 52-55may be connected to fixtures by end cap channels132as for example shown inFIGS. 59-61.

FIGS. 56 and 57show further embodiments of an LED lighting system with differently angled LED arrays. In this embodiment, the support structure145may be mounted by clips with lips that are received in grooves131. The embodiment ofFIG. 58is an example of an LED lighting system with 360 degree illumination field generated by four LED arrays at angles to each other, with semi-cylindrical lenses133, and also that may be mounted on a mounting clip.

FIGS. 62-65show a variety of end sockets for use with LED lighting systems, showing support structure102, end cap104, pin connector Type 1105, and end cap channel132.

FIGS. 66 and 67show an embodiment of an LED lighting system with 360 degree coverage. In this embodiment, there are four LED arrays each secured to one piece of a two piece hollow support structure147. In this example, the support structure147forms four channels at the base of which circuit boards101holding the LEDs100are fixed by any suitable means. The four channels are defined by four arms of the support structure147. Lens covers129are received in slots running the length of the arms and are provided with openings for the LEDs. The LEDs protrude into the openings. A cylindrical lens127surrounds the support structure147. The two pieces of the support structure147are held together by locking elements128.

FIG. 68illustrates the main structure of a LED lighting system connected to a 2-wire power source217.

A polarity protection circuit201of conventional design safeguards against the user installing the product in the wrong polarity.

The power source217may be AC or DC. The characteristics of the power source217, such as voltage amplitude, power frequency and pulse width, can be adjusted.

The power analyzer and processor218connects to the power source217and analyze the characteristics of power source217such as the voltage amplitude, power frequency and pulse width. Then the power analyzer and processor218compares one or all of these characteristics to the preset control criteria, which could be realized by hardware or software or both. According to the comparison results, the power analyzer and processor218controls the current control circuit202to adjust the function of LED arrays209.

This method is different from the common ways used for the LED lighting control. Traditionally to control the LED lights a control signal has to be provided to the lights either through a separated control pin or wire, or wireless technology, or technologies like signal carrier, or the technology in a master-slave mode. When the LED lights work in master-slave mode the LED arrays are controlled by the power source directly. For example the power source's voltage is applied to the LEDs directly, so the LEDs are lit up when the voltage goes up and dim down when the voltage goes down. In our invention the power source is not applied to the LEDs directly. The power source's characteristics, such as voltage amplitude, will be compared to the preset value. The light is controlled according to the comparison results. It is possible the light is lit up when the input voltage goes down, which is totally different from the traditional way. In this way the LED lights can be more conveniently controlled by controlling the characteristics of the power source.

As shown inFIG. 68, the LED array is divided into sets209of LEDs, for example five LEDs per set. The current control circuitry202is configured to provide constant current to the LEDs100of the LED array209. As an example, the current control circuit202may use pulse width modulation (PWM) to control the current supplied to the LEDs. The circuit202supplies constant, controlled, current to unit for the entire LED set209with information from voltage sensor203. The voltage sensor203receives current information from LEDs209and feeds back information to the current control circuitry202. For example, in the use of PWM, the voltage sensor203converts the current of LED array209to voltage signal and supplies the voltage signal to the current control circuit202. The current control circuit202senses how much the detected voltage varies from the desire varying the pulse width or frequency, changes the current supplied to the LEDs towards the desired level.

FIG. 69shows an embodiment of an LED lighting system10with two handles701. Handles701are made of metal and/or plastic materials to help the heat dissipation and reduce the shock and vibration. The circuit boards101are installed on the housing102. The Housing102is made of heat conductive and rigid material. Cover lens107is mounted on the housing102. It can be transparent or translucent. External lens702is a tube made of various materials such as Polycarbonate. Mostly the external lens702is clear. It is used to provide water proof and/or anti-explosion features. In this embodiment three rows of LEDs100are installed at different angles to provide wider viewing angle. Each row of the LEDs100might have different colors, which can be turned on at the same time or individually to provide desired features. In another embodiment, shown inFIG. 70, the shape of the housing102can be changed to hold one or two rows of LEDs100to provide different angles and functions.

FIG. 71shows a tube embodiment of an LED lighting system10. The housing102is made of heat conductive material. The cross section of the housing102is a closed half circle. The circuit boards101with LEDs100are installed on the housing102. The housing102helps to dissipate the heat from the circuit board101. The cover lens107is in a shape of half circle to be mounted on the housing102. The whole assembly forms a tube like traditional fluorescent light.

FIG. 72shows another tube embodiment of the LED lighting system10. The housing102in this embodiment has a tube shape with an unclosed half circle section, so a double-sided circuit board101can be installed on the housing102. The cover lens107has same features as inFIG. 71.

FIG. 73shows a rectangle embodiment of LED lighting system10. The housing102is made of heat conductive and rigid materials. The circuit boards101with LEDs100are installed on the housing102. Three rows of LEDs100are installed at different angles to provide wider viewing angle. The cover lens107is flat and installed on the housing102. The whole assembly forms a rectangle. This lighting system can be applied in the recessed lighting applications.

FIG. 74shows an embodiment of an LED lighting system10, with housing102, cover lens107and with LEDs100secured to a circuit board101. This system has low profile to fit into desired applications.

FIG. 75illustrates the main structure of a LED lighting system connected to a 2-wire power source217. A polarity protection circuit201of conventional design safeguards against the user installing the product in the wrong polarity. The power source217may be AC or DC, and may be a variable or adjustable power source. The characteristics of the power source217, such as voltage amplitude, power frequency and pulse width, can be adjusted (varied), such as by operation of a switch (not shown) operating on the power source217. The power analyzer and processor218, current control202, polarity protection201(if present) and voltage sensor203together comprise power control circuitry for the LEDs100. A single power control circuitry may control one or more arrays209, through one or more current controls202or there may be provided multiple power control circuits and multiple LED arrays, each power control circuit being supplied for a corresponding LED array.

A power analyzer and processor218connects to the power source217and analyzes the characteristics of power source217such as the voltage amplitude, power frequency and pulse width. Then the power analyzer and processor218compares one or all of these characteristics to preset control criteria, which may be realized by hardware or software or both. According to the comparison results, the power analyzer and processor218controls the current control circuit202to adjust the function of LED arrays209.

Referring toFIG. 75A, an example of the functions carried out by the processor218or power control circuitry is shown. The processor218may be a semiconductor circuit configured by software or firmware or may be hardwired. It is preferred that the processor218be programmable for maximum flexibility. Input power217is supplied to a filter220. The filter220smoothes the incoming power. The incoming power may be AC or DC and may have irregularities imposed on the signal that may be removed by a low pass filter. The processor218is provided with one or more pre-set conditions that are stored in memory, not necessarily in memory integrated with the processor218but on some accessible storage. The conditions may be for example in the case of an incoming sine wave, a loss of signal or zero signal for a defined period, such as 200 milliseconds. In another example, a change in DC voltage level may be a pre-set condition. In another example, a change in frequency may be a pre-set condition. In another example, a change in pulse width may be a pre-set condition. Any detectable power change may be used as a pre-set condition. After filtering in step220, the processor218reads the pre-set conditions at221and compares the pre-set conditions at step222with the filtered input. If the filtered input satisfies the conditions (for example a zero signal for 200 ms), then the processor218changes state such as from a passive state to an active state in step224and outputs a control signal at step226to the current control circuit202. The control signal may instruct the current control circuit202for example to increase power supplied to the LEDs100(brighten) or decrease the power (dim) the LEDs, or carry out other functions such as turn off or on some but not others of the LEDs or cause a change of color of the LEDs by turning on or off different colored LEDs. The processor218preferably may take as input a signal of any frequency, for example 50 Hz, 60 Hz or 100 Hz to provide greatest flexibility in application. Various methods of controlling current may be used and the current control may take various forms, such as disclosed in international publication number WO200709092 published Aug. 16, 2007. The LED lighting system may be constructed in various ways, such as shown inFIGS. 76-81, other embodiments of this document, or in some embodiments as constructed in international publication number WO200709092, the disclosure of which is hereby incorporated by reference where permitted by law.

This method is different from the common ways used for the LED lighting control. Traditionally to control the LED lights a control signal has to be provided to the lights either through a separated control pin or wire, or wireless technology, or technologies like signal carrier, or the technology in a master-slave mode. When the LED lights work in master-slave mode the LED arrays are controlled by the power source directly. For example the power source's voltage is applied to the LEDs directly, so the LEDs are lit up when the voltage goes up and dim down when the voltage goes down. In the disclosed embodiment, the power source is not applied to the LEDs directly. The power source's characteristics, such as voltage amplitude, will be compared to the preset value. The light is controlled according to the comparison results. It is possible the light is lit up when the input voltage goes down, which is totally different from the traditional way. In this way the LED lights can be more conveniently controlled by controlling the characteristics of the power source.

As shown inFIG. 75, the LED array is divided into multiple sets209of LEDs (only one is shown), for example five LEDs100per set. The current control circuitry202is configured to provide constant current to the LEDs100of the LED array209. As an example, the current control circuit202may use pulse width modulation (PWM) to control the current supplied to the LEDs. The circuit202supplies constant, controlled, current to unit for the entire LED set209with information from voltage sensor203. The voltage sensor203receives current information from LEDs209and feeds back information to the current control circuitry202. For example, in the use of PWM, the voltage sensor203converts the current of LED array209to voltage signal and supplies the voltage signal to the current control circuit202. The current control circuit202senses how much the detected voltage varies from the desire varying the pulse width or frequency, changes the current supplied to the LEDs towards the desired level.

FIG. 76shows an embodiment of an LED lighting system10with two handles701spanning between respective ends of a housing102. Handles701are made of metal and/or plastic materials to help heat dissipation and reduce shock and vibration. Circuit boards101carrying the LEDs100are installed on the housing102for example being received in longitudinal slots that face inward and run along the length of the housing102. The power control circuit218may be incorporated on the circuit boards101or on separate circuit boards (not shown) installed in the housing. The housing102is preferably made of heat conductive and rigid material and spans between the two handles701. The housing (support structure) or at least the relevant parts that are in contact with the LEDs is sufficiently heat conductive to provide heat dissipation for the LEDs. Cover lens107is mounted on the housing102, for example having inward directed edges that are received in outward facing slots running along the housing102. The cover lens107may be transparent or translucent. External lens702is a tube made of various materials such as Polycarbonate and may be held in place by the handles701. Mostly the external lens702is clear. It is used to provide water proof and/or anti-explosion features. In this embodiment three rows of LEDs100are installed at different angles to provide wider viewing angle. Each row of the LEDs100might have different colors, which can be turned on at the same time or individually to provide desired features. In another embodiment, shown inFIG. 77, the shape of the housing102can be changed to hold one or two rows of LEDs100to provide different angles and functions.

FIG. 78shows a tube embodiment of an LED lighting system10. The housing102is made of heat conductive material. The cross section of the housing102is a closed half circle. The circuit boards101with LEDs100are installed on the housing102. The housing102helps to dissipate the heat from the circuit board101. The cover lens107is in a shape of half circle to be mounted on the housing102with inward facing edges received in outward facing slots of the housing102. The whole assembly forms a tube like a traditional fluorescent light.

FIG. 79shows another tube embodiment of the LED lighting system10. The housing102in this embodiment has a tube shape with an unclosed half circle section, so a double-sided circuit board101can be installed on the housing102with edges of the circuit board101being received in inward facing slots of the housing102. The cover lens107has same features as inFIG. 77.

FIG. 79shows a rectangle embodiment of LED lighting system10. The housing102is made of heat conductive and rigid materials. The circuit boards101with LEDs100are installed on the housing102. Three rows of LEDs100are installed at different angles to provide wider viewing angle. The cover lens107is flat and installed on the housing102. The whole assembly forms a rectangle. This lighting system can be applied in the recessed lighting applications.

FIG. 80shows an embodiment of an LED lighting system10, with housing102, cover lens107and with LEDs100secured to a circuit board101. This system has low profile to fit into desired applications. InFIG. 80, the housing102has a base portion that is rectangular in section with a flat base and outer walls that are perpendicular to the flat base. A part of the housing connecting the outer walls above the flat base is recessed downward to receive the circuit boards101within the volume formed by the flat base and outer walls. The cover107in this example may be flat. In general, the configuration exemplified byFIG. 80is that in cross-section, the walls of the housing form a polygon, that is not convex and may be open on a side, and the circuit boards are located on a recessed or concave portion of the housing. In this way, a low profile of housing may be obtained. InFIG. 81, domed cover107is provided, and the housing102holds a circuit board101with LEDs100. The housings102in bothFIGS. 80 and 81each have a width and depth perpendicular to the long axis of the respective housings102, and the width (intermediate axis) in each case is more than twice the depth (short axis), for example 3 or 4 times the depth. The LEDs in the system10as a group have a mean facing direction, defined by considering each LEDs own facing direction as a vector, summing the vectors and dividing by the number of LEDs. The mean facing direction of the LEDs may be perpendicular to the intermediate and long axes of the housing102.

In various embodiments, the power control circuitry is formed on the circuit boards101that are carried by the various housings102(support structures) and are in electrical communication with the electrical connectors of the power sources217. The circuit boards102support at least one array of LEDs100. The at least one LED array may be divided into sets of LEDs. The power control circuitry may be formed of one or multiple current controllers, each of the one or multiple current controllers providing current control for a corresponding set of LEDs in the LED array. In some embodiments, sets of LEDs may be of the same or different colors, and the current control circuitry may provide same or different current control for a corresponding set of LEDs in the LED array according to the comparison result. The housings102may form channels. Each LED in the LED array may have in some embodiments a power rating of greater than 0.1 or 0.01 watt. The power control circuitry in some embodiments is provided by current control circuitry, for example onboard circuitry, carried by the support structure, in some embodiments within the channel, and may provide current control for individual sets of LEDs. The current control allows careful control of the forward current passing through the LED array so that it controls the brightness and heat production by the LEDs. Devices with a range of illumination field are disclosed, along with devices with LEDs having differently angled illumination fields. The housings102may have a front side on which the at least one LED array is carried and a rear side on which the power control circuitry is carried.

The pre-set conditions may be supplied to the power control circuitry by loading software or replacement or installation of hardware or both. The pre-set conditions may also be obtained by communication with external controllers, devices or equipment. The output control signal sent by the power control circuitry to the current control202may be used to cause the LEDs100to flash at selectable speeds. The output control signal may also comprise a code sent to an external controller (not shown) or monitoring system (not shown) for checking on the function of the power control circuitry, the input power217or response of the LEDs to control signals. That is, if the LEDs100or current control202are non-responsive to a control signal, then an error code may be sent by the power control circuitry to an external system to notify the external system of a problem. An output control signal sent to an external controller may also specify the comparison result and the nature of the instruction received from the input power, and this information may be used by external systems for control of other lighting systems in conjunction with the specific set of LEDs100being controlled by the power control circuitry.

Referring toFIG. 82, a block diagram of a controller800is shown. The switching power unit802may be used to convert the line input806to the working voltage of the CPU control unit804. The current detect unit810may be used to detect the current change in the system, and provide the detected current value to the CPU control unit804. The CPU control unit804analyses the current value and provides a control signal to the power driver unit808. The line input806connects to the power driver unit808through the current detect unit810. The power driver unit808will adjust the output characteristics, such as voltage amplitude, frequency or pulse width, according to the signal from CPU control unit804and output on line814to the LED lighting system. The line input806and line output814have voltages relative to neutral line812. The switching power unit802, CPU control unit804and power driver unit808all are connected to the neutral line812but these connections are not shown for simplicity.

With the controller design inFIG. 82, a controller800can know what other controllers800have done in the system when there are multiple controllers in the system. When one controller changes the working status of the system, the current in the system will change. When other controllers detect the current change, they will know what other controllers have done and know the current system working status and can control the lighting system synchronously without conflicts.

FIG. 84show a connection method that the controllers800connect with in parallel, whileFIG. 83shows a connection method where the controllers connect in serial. The controllers800inFIGS. 82-84can also be connected to the intranet or internet network816(FIG. 83) and receive the control information from the network and adjust the output to the LED lighting system820accordingly.

FIG. 82shows a controller800that detects the current change in the system. There are other ways to implement the desired functions, such as detecting the voltage change, frequency change or pulse width change.

The current level in the system reflects different working statuses. The table1below shows a sample of different current levels at different status. When one controller controls the LED lighting system to change from one status to another status, the current in the system will change. After other controllers detect the current change, the controllers will know the lighting system working status. When people try to control the light with a different controller, this controller knows the current working status and will know what the next status should be. This technology will help those controllers with a single button to control multiple statuses by pressing the button repeatedly.

For example, controller 1 controls the system to be ‘ON’ with 100% current level. When someone presses controller 2 once, the light changes to ‘DIM 1’ with 50% current level. Without the technology above, controller 1 would not know the status change. If someone wanted to change the status to ‘DIM 2’ using controller 1, it would change to ‘DIM 1’ after pressing the button once because it would still think the system is at ‘ON’ status. This would cause the whole system to be messed up.

This technology can be applied to different application, such as a building, a shelter, vehicles and ships. It is helpful in the applications that need multiple controllers to control the same group of lights without adding more control wires. For example, a shelter has six entrances. The controllers can be installed at every entrance. Six controllers will control the lights in the shelter synchronously.

Immaterial modifications may be made to the embodiments described here without departing from what is claimed.