LED module and interconnection system

A LED module and interconnection system is disclosed. The LED module includes a lens, a housing, and a printed circuit board PCB having at least on LED disposed within the housing. The housing includes a plurality of openings providing physical and electrical access to the PCB. The interconnection system includes at least one LED module and a cable assembly. The cable assembly is configured to provide electrical connectivity to the LED module through an opening in the LED module housing.

FIELD OF THE INVENTION

The present invention relates generally to the field of lighting systems. More specifically, the present invention relates to an LED module and interconnection system for assembling LED modules into an array. The invention utilizes a module design that is flexible in mounting method, electrical connection method, LED array arrangements, and optical designs.

BACKGROUND OF THE INVENTION

Advances in the development and improvements of the luminous flux of light emitting diodes (LEDs) have made these devices suitable for use in general illumination applications, including architectural, entertainment, and outdoor lighting. As such, LEDs are becoming increasingly competitive with light sources such as incandescent, fluorescent, and high-intensity discharge lamps.

LEDs offer a number of advantages and are generally chosen for their ruggedness, long lifetime, high efficiency, low voltage requirements, and the possibility to control the color and intensity of the emitted light independently. LEDs provide an improvement over delicate gas discharge lamp, incandescent bulb, and fluorescent lighting systems. Solid state lighting sources, such as LEDs, have the capability to create the same lighting impressions, but outweigh the drawbacks associated with the other lighting technologies.

Prior art LED module systems have primarily been directed to string systems having limited interconnection flexibility. The modules or housings containing the LED's in these systems have often been inflexible with respect to modification. It would be desirable to develop a lighting technology that would be flexible in application by building a lighting system with simple modifiable modular elements having flexible interconnectivity.

Thus, an objective of the present invention is to provide an LED module and interconnection system that can be easily installed in various applications, including outdoor applications, and is flexible in the method of interconnection and arrangement of the LED's.

SUMMARY OF THE INVENTION

An LED module is disclosed that includes a housing, a printed circuit board disposed within the housing, the printed circuit board comprising connector sections having electrical contacts that provide electrical connectivity to electrical components supported by the printed circuit board, and a lens attached to the housing. The housing includes an opening for receiving a connector for providing electrical connectivity to the printed circuit board, and the electrical components include at least one LED.

The LED module further includes a gasket disposed between the lens and the housing. The LED module may further include an attachment film for attaching the LED module to a support surface.

The LED module housing includes a PCB support and alignment post for attaching the PCB within the housing in a predetermined orientation. The LED module housing may have four openings for receiving a connector for providing electrical connectivity to the printed circuit board. The LED module housing includes an opening housing generally surrounding the opening, and the opening housing is configured to receive a connector in only one predetermined orientation. The opening housing comprises tabs for releasably engaging the connector.

An LED module and interconnection system is also disclosed that includes an LED module and a cable assembly. The LED module includes a housing, a printed circuit board disposed within the housing, the printed circuit board comprising connector sections having electrical contacts that provide electrical connectivity to electrical components supported by the printed circuit board, and a lens attached to the housing.

The housing includes an opening for receiving a connector for providing electrical connectivity to the printed circuit board. The housing may include one, four or more openings. The electrical components include at least one LED.

The cable assembly includes a cable having two ends and a connector disposed at either end thereof. The connectors are configured to be received in an opening of the housing and engage the connector portion of the printed circuit board to form an electrical connection with electrical contacts of the printed circuit board. The cable assembly may include a connector disposed at both ends of the cable.

The system further includes a gasket disposed between the lens and the housing. The system may further include an attachment film for attaching the LED module to a support surface.

The LED housing of the system includes a PCB support and alignment post for attaching the PCB within the housing in a predetermined orientation. The LED housing may have four openings for receiving a connector for providing electrical connectivity to the printed circuit board. The housing further includes an opening housing generally surrounding the opening, the opening housing configured to receive the cable assembly in only one predetermined orientation.

The opening housing includes tabs for releasably engaging the cable assembly. The opening and cable assembly are configured so the cable assembly can be received in the opening in only one predetermined orientation. The connectors include resilient latches configured to releasably engage tabs on an opening housing generally surrounding the opening.

The connectors further include a housing insertion section comprising spring contacts configured to form an electrical connection with the electrical contacts of the printed circuit board when the connector is received in the opening of the housing. The housing insertion section further includes sealing features configured to environmentally seal the opening when the insertion section is inserted.

The system may further include a module plug configured to environmentally seal an opening of the housing. The module plug may be made from a soft polymer such as a thermoplastic elostomer.

Further aspects of the method and system are disclosed herein. The features as discussed above, as well as other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings.

DETAILED DESCRIPTION OF THE INVENTION

With reference toFIG. 1, an exemplary embodiment of a light emitting diode (LED) module10having a lens12and housing14is disclosed. Lens12includes a top surface portion16and a rearward portion18. Top surface portion16may have any practical geometry as known in the art to project and/or diffuse light. Rearward portion18has serrations20to assist in attaching the lens12to the housing14. Alternatively, rearward portion18may have other grip assisting features or tool slots, such as corners and sides, or may be a smooth cylindrical surface. Lens12may be formed of any lens material known in the art, including, but not limited to glasses and plastics.

As shown inFIG. 1, the housing14has a generally circular cross section, however, other cross sectional geometries including square, hexagonal, triangular, octagonal or other polygon, as well as curved profiles may be used for applications having different assembled system geometries. Housing14includes a plurality of openings22, opening housings24, and attachment points26. In this exemplary embodiment, the housing14is shown with four openings, although in alternative embodiments, one, two, three or more than four openings may be present. Opening housings24generally surround openings22. Opening housings24include tabs25. Openings22and opening housings24are shown having a generally rectangular geometry, but other alternative geometries including square, triangular, round and combinations thereof may be used for either or both the access openings22and opening housings24. Attachment points26are configured to secure the housing14to a support surface (not shown). The attachment points26may be omitted in applications where the module10is intended to stand freely or when the module10is affixed by an external element. Housing14is preferably formed of a plastic housing material, but may be formed of any housing material known in the art.

An exploded view of LED module10is shown inFIG. 2. As can be seen inFIG. 2, the LED module10further includes a gasket30, a populated printed circuit board (PCB) assembly32, fasteners33such as screws, and an attachment film34. The gasket30may be a flat gasket, an O-ring gasket, or other similar gasket configured to form an environment seal between the lens12and the housing14. The PCB assembly32includes a substantially circular PCB36supporting LEDs38. The LEDs38may be attached to the PCB36by surface mount soldering or through hole soldering. Although the PCB assembly32is shown including four LEDs, the number of LEDs supported by the PCB assembly32may vary.

The PCB36includes connector sections41. The connector sections41are disposed between connector slots42as shown inFIG. 2. The connector sections41include contact pads40. The contact pads40are conductively connected by traces (not shown) to the LEDs38and/or to any additional electrical components (not shown), such as resistors and capacitors, supported on the PCB36. Thus, the contact pads40are configured to provide electrical connectivity to the LEDs38and/or any additional electrical components (not shown). The contact pads40, traces (not shown), and any additional electrical components (not shown) may be mounted on a top surface44of the PCB36, a bottom surface (not shown), or both. Although the PCB36is shown having contact pads40located on four connector sections41, contact pads40may be omitted from some of the connector sections41as required by design.

The PCB36additionally includes holes46and an alignment notch48. Holes46allow fasteners33to releasably attach the PCB36within the housing14, and the alignment notch48assures a predetermined orientation of the PCB36when attached within the housing14. Although the PCB36is shown with two holes46and one alignment notch48, the PCB36may be provided with any number of screw holes46and alignment notches48to facilitate installing and securing the PCB36to the housing14.

Attachment film34may be a two-sided adhesive tape or other similar adhesive, which is intended to attach a bottom surface (not shown) of the housing14to a support surface (not shown). The attachment points26may be omitted when the attachment film is used to attach the housing14to a support surface (not shown). Alternatively, attachment film34may be omitted and the housing attached by the attachment points26, or both the attachment points and the attachment film may be omitted.

As can further be seen inFIG. 2, the housing14includes external threads50configured to engage internal threads (not shown) on an internal surface (not shown) on the rearward portion18of lens12.

A cross-sectional view of the LED module10ofFIG. 1taken along line3-3is shown inFIG. 3. As can be seen inFIG. 3, the housing14further includes PCB supports52for supporting the PCB32in the housing14. PCB supports52have internal channel (not shown) for receiving fasteners33in attaching the PCB32to the housing14. In this exemplary embodiment, the housing14includes two PCB supports52, one positioned on each side of the cross-section, positioned to correspondingly receive the fasteners33as shown inFIG. 2. The housing14further includes alignment post54configured to be received in alignment notch48(FIG. 2). Alternatively, the housing14may include more than one alignment post54and corresponding alignment notch48(FIG. 2). As can be further seen inFIG. 3, the openings22provide access to the PCB connector sections41.

FIG. 4illustrates an exemplary cable assembly400used to physically and electrically connect two LED modules10(FIG. 1) together or an LED module10(FIG. 1) to another electrical component (not shown). The electrical component may be a power supply, power source, LED driver or other lighting component. Cable assembly400includes a cable410and two connectors420disposed at opposite ends of the cable410. The cable410includes conductors or wires (not shown). The cable length may vary depending upon application, as would be appreciated by one of ordinary skill in the art. The wires (not shown) are terminated by terminals or contacts (not shown) in the connectors420. The wires (not shown) may be terminated to the contacts (not shown) by soldering, crimping, resistance welding, ultra sonic welding or any other similar termination method. The contacts (not shown) may be spring contacts510(seeFIG. 6).

As shown inFIG. 4, the connectors420include resilient latches422. The connectors420are shown having two resilient latches422, however, the number and configuration of resilient latches422on a single connector420may vary, and should be configured to mate to corresponding tabs25(FIG. 1) of housing14(FIG. 1). For example, in alternative embodiments, each connector420may include one, three, four or more resilient latches422. Furthermore, in an alternative embodiment, the cable assembly400may include only one connector420, with the opposite end of the cable410having wires, contacts, or similar electrical interconnection for terminating the cable assembly400to another electrical device.

Resilient latches422include a tab section424and a latching section426. The resilient latches422are configured to pivot to allow the latching section426outward movement when the connector420is inserted into an opening22in housing14so as to engage a corresponding tab25(FIG. 1) on housing14(FIG. 1). The latching section426includes an inward protrusion428. Inward pressure applied to the tab section424pivots the latching section426outward, releasing the resilient latches422once engaged to a corresponding tab25(FIG. 1).

The connectors420further include a housing insertion section430. The housing insertion section430includes an outer surface432including sealing features434. Sealing features434extend circumferentially around the outer surface432as shown inFIG. 4, however, it should be appreciated that alternative configurations of sealing features may be used to provide environmental protection. In alternative embodiments, the sealing features may be deleted. The housing insertion section430has a generally rectangular geometry that substantial corresponds with the openings22in the module housing14(FIG. 1). The housing insertion section430, including ridges434, may be formed of a soft polymer or compliant polymeric material, such as thermoplastic elastomer. For example, the thermoplastic elastomer may be Santoprene™ made by ExxonMobile Chemical Company of Houston, Tex.

An end view of connector420is shown inFIG. 5. As can be seen inFIG. 5, the connector420further includes spring contacts510supported on a contact support512. As can also be seen inFIG. 5, the housing insertion section430includes chamfered sides514that assist in aligning the connector420with a corresponding opening22(FIG. 1) and to assure that the connector420is inserted in an opening22with the correct orientation. In alternative embodiments, other contacts may be used in place of the spring contacts510to form the electrical connection between the cable assembly400(FIG. 4) and the LED module10(FIG. 1).

A partial cross-sectional view of connector420taken along line6-6ofFIG. 5is shown inFIG. 6. As can be seen inFIG. 6, spring contacts510are configured within the housing insertion section430such that when the housing insertion section430is inserted into an opening22(FIG. 3) of the housing14(FIG. 3), spring contacts510receive the connector portion41(FIG. 3) of the PCB32(FIG. 3) and form an electrical connection with corresponding contacts40(FIG. 3), thereby providing an electrical connection to the LED module10(FIG. 3).

FIG. 8shows a cross-sectional view taken along line3-3ofFIG. 1with a partial section of a housing insertion section430and a module plug700shown inserted into openings22. As shown inFIG. 8, spring contacts510are engaging contact pads40(FIG. 3) on connector sections41of PCB32to provide electrical connection to LEDs38and other electrical components supported on the PCB32, and LED module opening plug700substantially seals closed corresponding opening22. The ridges434of the housing insertion section430and the sealing features722of the module plug700are configured to form an environmental seal with the housing14. As can be further seen inFIG. 8, gasket30forms an environmental seal between housing14and lens12.

An exemplary arrangement of LED modules10and wire connectors400is shown inFIG. 9. As can be seen inFIG. 9, a module plug700has been used to seal one of the LED modules10and prevent further connectivity. As can be seen inFIG. 9, the design of the LED module10and cable assembly400permits a wide variety of lighting design configurations to be assembled.