Patent Publication Number: US-2016223151-A1

Title: Light emitting diode rail and light curing apparatus comprising same

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     Korean Patent Application No. 10-2015-0017561, filed on Feb. 4, 2015, and entitled, “Light Emitting Diode Rail and Light Curing Apparatus Comprising Same,” is incorporated by reference herein in its entirety. 
     BACKGROUND 
     1. Field 
     One or more embodiments described herein relate to a light emitting diode rail and a light curing apparatus including a light emitting diode rail. 
     2. Description of the Related Art 
     Light emitting diodes (LEDs) consume less power and are smaller and lighter than other types of light generating devices. Also, LEDs may emit light in a specific wavelength range. For example, one type of LED emits light having an ultra short wavelength in the ultraviolet range beyond short wavelength blue light. 
     SUMMARY 
     In accordance with one or more embodiments, a light emitting diode (LED) rail includes a rail body; a first electrode and a second electrode within the rail body; and a plurality of LEDs in the rail body and electrically connected to the first electrode and the second electrode, wherein the LEDs include a first lead frame and a second lead frame and wherein the first lead frame and the second lead frame slidably contact the first electrode and the second electrode, respectively. 
     The rail body may include a lower plate, and upper lids extending toward a center position above the lower plate, the upper lids extending from respective ends of the lower plate, the upper lids spaced to form a slit substantially at the center position above the lower plate. The LEDs may be supported by the lower plate and the upper lids of the rail body and are guided by the rail body, and the LEDs may move in a lengthwise direction of the LED rail. The LEDs may move in the lengthwise direction of the LED rail while maintaining an electrical connection between the first electrode and the first lead frame and an electrical connection between the second electrode and the second lead frame. The LEDs may emit light in an ultraviolet range. 
     The first electrode and the second electrode may be at respective sides of the rail body in a width direction of the rail body and may extend in a lengthwise direction of the rail body. The LEDs may be electrically connected to the first electrode and the second electrode in parallel with each other. 
     In accordance with one or more other embodiments, a light emitting device (LED) rail includes a rail body; a first electrode and a second electrode within the rail body; a plurality of LED supports in the rail body and electrically connected to the first electrode and the second electrode: and a plurality of LEDs on respective ones of the LED supports and inserted in the rail body, wherein the LEDs include a first lead frame and a second lead frame, wherein the LED supports include a first connecting conductive wire and a second connecting conductive wire, and wherein the first lead frame slidably contacts the first electrode through the first connecting conductive wire and the second lead frame slidably contacts the second electrode through the second connecting conductive wire. 
     The rail body may include a lower plate, side walls at respective ends of the lower plate, and upper lids extending from respective ones of the sidewalls toward a center position above the lower plate, the upper lids spaced to form a slit substantially at the center position above the lower plate. The LEDs and the LED supports may be guided by the rail body and wherein the LEDs and the LED supports are to move in a lengthwise direction of the LED rail. 
     The LEDs and the LED supports may move in the lengthwise direction of the LED rail while an electrical connection is maintained between the first electrode and the first connecting conductive wire and an electrical connection is maintained between the second electrode and the second connecting conductive wire. 
     The first connecting conductive wire and the second connecting conductive wire may protrude outwardly after penetrating through respective side walls of a support body, and each of the first connecting conductive wire and the second connecting conductive wire may be curved to have a bent shape. The first electrode and the second electrode may be at respective side walls of the rail body facing each other and may extend in a lengthwise direction of the rail body. The LEDs may emit light in an ultraviolet range. 
     In accordance with one or more other embodiments, a light curing apparatus includes a plurality of light emitting devices (LEDs); and one or more LED rails, wherein the one or more LED rails include the LEDs and wherein the LEDs are to move in a lengthwise direction of the LED rails. The one or more LEDs may be removably mounted in each of the one or more LED rails. The one or more LEDs in each of the LED rails may change position to accommodate an additional LED. The LED rails may move to a position adjacent to at least one side of an object to be light-cured, and the position may be based on a size of the object to be light-cured. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Features will become apparent to those of skill in the art by describing in detail exemplary embodiments with reference to the attached drawings in which: 
         FIG. 1  illustrates an embodiment of a light curing apparatus; 
         FIG. 2  illustrates an embodiment of an LED rail in  FIG. 1 ; 
         FIG. 3  illustrates a view of the LED rail along section line in  FIG. 2 ; 
         FIG. 4  illustrates another view of the light curing apparatus; 
         FIG. 5  illustrates another view of the light curing apparatus; 
         FIG. 6  illustrates the light curing apparatus with a different arrangement of LED rails; 
         FIG. 7  illustrates the light curing apparatus with a different spacing between LEDs; 
         FIG. 8  illustrates another embodiment of an LED rail; and 
         FIG. 9  illustrates another embodiment of an LED rail. 
     
    
    
     DETAILED DESCRIPTION 
     Example embodiments are described more fully hereinafter with reference to the accompanying drawings; however, they may be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey exemplary implementations to those skilled in the art. The embodiments may be combined to form additional embodiments. 
     It will also be understood that when a layer or element is referred to as being “on” another layer or substrate, it can be directly on the other layer or substrate, or intervening layers may also be present. Further, it will be understood that when a layer is referred to as being “under” another layer, it can be directly under, and one or more intervening layers may also be present. In addition, it will also be understood that when a layer is referred to as being “between” two layers, it can be the only layer between the two layers, or one or more intervening layers may also be present. Like reference numerals refer to like elements throughout. 
       FIG. 1  illustrates an embodiment of a light curing apparatus which includes a first LED rail  210 , a second LED rail  220 , a third LED rail  230  and a fourth LED rail  240 . A window panel  100  is an example of an object to be light-cured. The window panel  100  may be, for example, a transparent glass substrate exposed outwardly from a display device to display an image. The object to be light-cured may be different in another embodiment. Each of the first to fourth LED rails  210 ,  220 ,  230  and  240  includes one or more LEDs, and may be arranged in outer peripheral regions adjacent to respective sides of the window panel  100  to provide light to the window panel  100 . 
       FIG. 2  is a three-dimensional view of an embodiment of the third LED rail  230  in  FIG. 1 , and  FIG. 3  is a cross-sectional view of the LED rail  230  taken along the line of  FIG. 2 . 
     Referring to  FIGS. 2 and 3 , the LED rail  230  includes a rail body  235 , a first electrode  236  and a second electrode  238  within the rail body, and a plurality of LEDs  300  in the rail body. The rail body includes a lower plate  234 , and upper lids  232  extending toward a center directly above the lower plate  234  from respective ends of the lower plate  234 . The upper lids  232  may form a slit, for example, at a center position directly above the lower plate  234 . 
     The third LED rail  230  includes a first electrode  236  and a second electrode  238  within the sides of the rail body in a width direction of the rail body. The first electrode  236  and the second electrode  238  may be extended in a lengthwise direction of the rail body, and may be connected to LEDs  300 _ 2  to  300 _ 6  of the third LED rail  230  in parallel with each other. The first electrode  236  and the second electrode  238  may extend outwardly in the lengthwise direction of the rail body and connected to the respective positive (+) and negative (−) direct current voltage sources. 
     The LEDs  300  in each LED rail may be substantially the same. To discriminate among the LEDs in the third LED rail  230  and a single LED in the first LED rail  210  in  FIG. 2 , and later in  FIG. 4 , the LEDs in the third LED rail  230  are denoted as reference numerals “ 300 _ 2 ”, “ 300 _ 3 ”, “ 300 _ 4 ”, “ 300 _ 5 ” and “ 300 _ 6 ” and the single LED in the first LEI) rail  210  is denoted as a reference numeral “ 300 _ 1 ”. 
       FIG. 3  illustrates an embodiment of a surface mounted LED which may correspond to the LEDs  300 . Referring to  FIG. 3 , the LED  300  includes an LED body  320 , a lens  310  arranged on the LED body  320 , and a first lead frame  330  and a second lead frame  340  extending outwardly from the LED body  320 . 
     The LED body  320  may be supported by the lower plate  234  and the upper lids  232  of the rail body, and may be guided by the rail body such that the LED body  320  is movable in the lengthwise direction of the LED rail  230 . 
     The LED lens  310  may be exposed outwardly from the rail body through the slit formed by the upper lids  232  of the rail body, and may emit light outwardly having a wavelength corresponding to unique features of LEDs. 
     The first lead frame  330  and the second lead frame  340  may penetrate into the LED body  320  and electrically connected to the respective light emitting bodies within the LED body  320 . Furthermore, the first lead frame  330  and the second lead frame  340  may extend outwardly from the LED body  320  and connected to the respective first electrode  236  and second electrode  238 . For example, the LED may be electrically connected to the first electrode  236  and the second electrode  238  through the first lead frame  330  and the second lead frame  340 . 
     The first lead frame  330  and the second lead frame  340  may slidably contact the first electrode  236  and the second electrode  238 , respectively. This allows an electrical connection to be formed and maintained between the first electrode  236  and the first lead frame  330  and an electrical connection to be formed and maintained between the second electrode  238  and the second lead frame  340 , even when the LED  300  moves in the lengthwise direction of the rail body within the rail body. 
     The expression “slidably contact” as used herein may include a state where the positions of at least two components vary by external force when the two components are in contact with each other, and/or may include a contact state not fixed by an adhesive, external fixing means, or the like. 
     In one embodiment, since the LED  300  in the rail body moves in the lengthwise direction of the rail body while maintaining electrical connection with the first electrode  236  and the second electrode  238 , a spacing between the plurality of LEDs  300  in the LED rail may be adjusted. For example, when an object to be light-cured requires a greater quantity of light for curing, additional LEDs may be inserted into the rail body to increase the number of LEDs in the LED rail  230 , and spacing between LEDs may be narrowed. Thus, the spacing between LEDs is narrowed to increase the quantity of light per unit area or per unit length incident on the object to be light-cured. 
     As another example of providing a greater quantity of light to an object to be light-cured, LEDs of a relatively lower capacity may be removed from the rail body of the LED rail and high capacity LEDs may be inserted into the rail body. Thus, the quantity of light per unit area or per unit length incident on the object to be light-cured may be increased. 
     In another embodiment, the spacing between the LEDs in the LED rail may be widened or the LEDs may be replaced by LEDs of a relatively lower capacity, so as to reduce the quantity of light incident on the object to be light-cured. 
     In one embodiment, when the object to be light-cured includes an ultraviolet curable agent, the LEDs  300  may be ultraviolet LEDs which emit light of an ultraviolet wavelength region. If a material of the object to be light-cured is changed, the LEDs  300  may be replaced by LEDs which emit light having a corresponding (e.g., different) wavelength. Also, an LED which is damaged or deteriorated may be replaced by another LED, thereby lengthening the useful life of the LED rail as an LED light source. 
       FIG. 4  is a left side embodiment of the light curing apparatus in  FIG. 1 . This view shows the window panel  100 , a display panel  120 , and a light curable agent  110  between the display panel  120  and the window panel  100 . In  FIG. 4 , an ultraviolet curable material is provided as an example of the light curable agent  110 . The ultraviolet curable material may serve to maintain adhesion between, and thus seal a gap between, the window panel  100  and the display panel  120 . Such an arrangement may prevent air from permeating into the gap. 
     Referring to  FIG. 4 , part of the first LED rail  210  and the third LED rail  230  may be arranged in the vicinity of one side of the window panel  100  which has a tetragonal shape overall. 
     One single LED  300 _ 1  of the first LED rail  210  and the LEDs  300 _ 2  to  300 _ 6  of the third LED rail  230  may provide ultraviolet rays to the ultraviolet curable material between the window panel  100  and the display panel  120 . Distances L 1  to L 5  between LEDs  300 _ 1  to  300 _ 6  may be adjusted to control the quantity of ultraviolet light per unit area or per unit length provided to the ultraviolet curable material, and to make the distribution of the quantity of ultraviolet light provided to the ultraviolet curable material to be uniform. If each of LEDs  300 _ 1  to  300 _ 6  emits the same quantity of light, distances L 1  to L 5  between LEDs  300 _ 1  to  300 _ 6  may also be the same. In another embodiment, the distances may be different. 
       FIG. 5  to  FIG. 7  illustrates an embodiment of a method for changing the positions of the first to fourth LED rails  210 ,  220 ,  230  and  240  and for adjusting the spacing between the LEDs  300  in the light curing apparatus. This embodiment may be applied, for example, when the size of the object to be light-cured is reduced or under other circumstances. 
       FIG. 5  is a top view illustrating both the light curing apparatus including the first to fourth LED rails and an object to be light-cured having a relatively smaller size than the object to be light-cured in  FIG. 1 .  FIG. 6  is a top view illustrating an embodiment of the light curing apparatus in which the position of each LED rail in  FIG. 5  is changed according to the size of an object to be light-cured.  FIG. 7  is a top view of the light curing apparatus in which the spacing between adjacent LEDs of each LED rail in  FIG. 6  is adjusted. 
     Referring to  FIG. 5 , a window panel  100 _ 1  is provided having a relatively smaller size than the window panel in  FIG. 1 . The first to fourth LED rails  210 ,  220 ,  230 , and  240  may be arranged at the respective four sides of the smaller window panel  100 _ 1 , such that the first to fourth LED rails  210 ,  220 ,  230 , and  240  are spaced apart from the four sides of the window panel  100 _ 1 . 
     The first LED rail  210  may move in a first direction M 1 , the second LED rail  220  may move in a second direction M 2 , the third LED rail  230  may move in a third direction M 3 , and the fourth LED rail  240  may move in a fourth direction M 4  in correspondence to the size of the smaller window panel  100 _ 1 , which is the object to be light-cured. 
     For example, the distance between the first LED rail  210  and an upper side of the smaller window panel  100 _ 1  is first spacing d 1 , the distance between the fourth LED rail  240  and a lower side of the smaller window panel  100 _ 1  is second spacing d 2 , the distance between the third LED rail  230  and a left side of the smaller window panel  100 _ 1  is third spacing d 3 , and the distance between the second LED rail  220  and a right side of the smaller window panel  100 _ 1  is fourth spacing d 4 . In this case, the first LED rail  210  may have one end movable downwardly in a vertical direction by the first spacing d 1  and movable left in parallel in a horizontal direction by the fourth spacing d 4 . 
     Furthermore, the second LED rail  220  may move upwardly in a vertical direction by the second spacing d 2 , and move left in parallel in a horizontal direction by the fourth spacing d 4 . 
     Furthermore, the third LED rail  230  may move downwardly in a vertical direction by the first spacing d 1 , and move right in parallel in a horizontal direction by the third spacing d 3 . 
     Furthermore, the fourth LED rail  240  may move upwardly in a vertical direction by the second spacing d 2 , and move right in parallel in a horizontal direction by the third spacing d 3 . 
       FIG. 6  illustrates an example in which the first to fourth LED rails  210 ,  220 ,  230 , and  240  are moved and located such that the LEDs  300  are arranged along the four sides of the smaller window panel  100 _ 1 . Referring to  FIG. 6 , the LEDs  300  are arranged adjacent to the four sides of the smaller window panel  100 _ 1  with movement of the first to fourth LED rails  210 ,  220 ,  230 , and  240 . However, since the spacing between the adjacent ones of LEDs  300  in each LED rail  210 ,  220 ,  230 , and  240  may not move, the arrangement relationship between the LEDs adjacent to each side of the smaller window panel  100 _ 1  and each side of the smaller window panel  100 _ 1  may differ, among the four sides of the smaller window panel  100 _ 1 . 
     For example, the number of and distance between LEDs provided adjacent to each corner C 1  to C 4  of the smaller window panel  100 _ 1  may differ among the corners C 1  to C 4 . Accordingly, the distribution of the quantity of light incident on the smaller window panel  100 _ 1  to be light-cured or on a curable material may differ among the four sides of the smaller window panel  100 _ 1 . Thus, the quantity of light provided to a portion of the four corners C 1  to C 4  may not be sufficient for light curing. 
     The above-described difficulties may result from fixing the spacing between the LEDs that are used as a light source for the light curing apparatus. For example, when an LED bar-shaped light source is used having the LEDs  300  fixed on a printed circuit board in the light curing apparatus, the LED bar-shaped light source may not emit a sufficient quantity of light, when the size of the window panel  100  to be light-cured is changed, at least at the corners of the window panel  100  having the changed size. 
     Referring to  FIG. 7 , in accordance with one embodiment, the LEDs  300  may move in the lengthwise direction of the first to fourth LED rails  210 ,  220 ,  230 , and  240 . As a result, the LEDs  300  may be arranged to emit a uniform quantity of light to the regions adjacent to the four sides of the smaller window panel  100 _ 1  and to the regions adjacent to the four corners of the smaller window panel  100 _ 1 . 
     For example, a single LED may be arranged at each corner C 1  to C 4  of the smaller window panel  100 _ 1 , and the spacing between the LEDs  300  in the first to fourth LED rails  210 ,  220 ,  230 , and  240  may be adjusted to be the same. 
     Furthermore, surplus LEDs which are not used in light-curing the smaller window panel  100 _ 1  may be removed from the first to fourth LED rails  210 ,  220 ,  230 , and  240 , thereby reducing waste of power caused by operation of unnecessary LEDs. Furthermore, the removed LEDs may be re-used later, thereby lengthening the useful life of the LED rails and the light curing apparatus. 
     If the size of the window panel  100  to be light-cured is increased, the first to fourth LED rails  210 ,  220 ,  230 , and  240  may move to correspond to four sides of the larger window panel  100 , and additional LEDs may be inserted into each of the first to fourth rails to provide a sufficient quantity of light. 
       FIG. 8  is illustrates a cross-sectional view of another embodiment of an LED rail  500 . Referring to  FIG. 8 , the LED rail  500  includes a rail body  505 , a first electrode  540  and a second electrode  550  arranged within the rail body, an LED support unit  400  inserted into the rail body and electrically connected to the first electrode  540  and the second electrode  550 , and an LED  300  mounted on the LED support unit  400  and inserted in the rail body. 
     The rail body  505  includes a lower plate  520 , side walls  530  formed at respective ends of the lower plate  520 , and upper lids  510  extending from the side walls  530  toward a center directly above the lower plate  520 . The upper lids  510  may form a slit in the center directly above the lower plate  520 . 
     The first electrode  540  and the second electrode  550  are arranged on respective sidewalls  530  of the rail body  505  facing each other, and extend in the lengthwise direction of the LED rail  500 . 
     The LED support unit  400  includes a support body  410 , a first connecting conductive wire  420 , and a second connecting conductive wire  430 . The first connecting conductive wire  420  and the second connecting conductive wire  430  penetrate through respective side walls  412  and  411  of the support body  410 , which face the respective side walls  530  of the rail body  505 . The first connecting conductive wire  420  and the second connecting conductive wire  430  pass through the support body  410  and penetrate through an upper surface of the support body  410  to protrude outwardly. 
     The LED  300  may be mounted on the upper surface of the support body  410  of the LED support unit  400 , supported by the upper surface of the support body  410  and the upper lids  510 , and guided by the LED support unit  400  and the upper lids  510 . As a result, the LED  300  is movable in the lengthwise direction of the LED rail. 
     The first lead frame  330  and the second lead frame  340  of the LED  300  may be electrically connected to the first connecting conductive wire  420  and the second connecting conductive wire  430 , respectively. The first connecting conductive wire  420  and the second connecting conductive wire  430  may be in tight contact with the first lead frame  330  and the second lead frame  340 , respectively, to restrict movement of the LED on the support body  410 . 
     The first connecting conductive wire  420  and the second connecting conductive wire  430  protrude outwardly after penetrating through the respective side walls  412  and  411  of the support body  410 , and are electrically connected to respective ones of first electrode  540  and second electrode  550 . The first connecting conductive wire  420  and the second connecting conductive wire  430  slidably contact the first electrode  540  and the second electrode  550 , respectively. As a result, electrical connection between the first electrode  540  and the first connecting conductive wire  420  and electrical connection between the second electrode  550  and the second connecting conductive wire  430  may be maintained even when the LED  300  and the LED support unit  400  move in the lengthwise direction of the rail body  505  within the rail body  505 . 
     Furthermore, the first connecting conductive wire  420  and the second connecting conductive wire  430 , which protrude outwardly after penetrating through the respective side walls  412  and  411  of the support body  410 , may be curved into a predetermined (e.g., U-shape), and may function, for example, as a U-shaped spring for supporting horizontal movement of the support body  410  between the first electrode  540  and the second electrode  550 . 
     For example, the first connecting conductive wire  420  and the second connecting conductive wire  430 , which protrude outwardly after penetrating through the respective side walls  412  and  411  of the support body  410 , may have a U-plate spring shape and may be slidably connected to the respective first electrode  540  and second electrode  550 , to support horizontal movement of the support body  410  and to maintain electrical connection with the first electrode  540  and the second electrode  550  in the LED rail  500 . 
       FIG. 9  is a cross-sectional view of another embodiment of a LED rail  600  which includes a rail body  605 , a first electrode  640  and a second electrode  650  arranged within the rail body  605 , an LED support unit  800  in the rail body  605  and electrically connected to the first electrode  640  and the second electrode  650 , and an LED  700  mounted on the LED support unit  800  and inserted in the rail body  605 . 
     The rail body  605  includes a lower plate  620 , side walls  630  formed at respective ends of the lower plate  620 , and upper lids  610  extending from the side walls  630  toward a center directly above the lower plate  620 . The upper lids  610  may form a slit in the center directly above the lower plate  620 . Furthermore, the first electrode  640  and the second electrode  650  may be arranged on the two sidewalls  630  of the rail body  605  facing each other, respectively. 
     The LED support unit  800  includes a support body  810 , a first connecting conductive wire  820 , and a second connecting conductive wire  830 . The first connecting conductive wire  820  and the second connecting conductive wire  830  penetrate through respective side walls  811  and  812  of the support body  810 , which face respective side walls  630  of the rail body. The first and second connecting conductive wires  820  and  830  pass into the support body  810  and are electrically connected to the first lead frame  720  and the second lead frame  730 , respectively, of the through-type LED  700  in support body  810 . 
     The LED includes an LED lamp  710 , a first lead frame  720 , and a second lead frame  730 . The LED lamp  710  is exposed outwardly through the slit in the rail body  605 . The first lead frame  720  and the second lead frame  730  penetrate through respective holes in an upper surface of the support body  810 , and are inserted into the support body  810  and electrically connected to the respective ones of the first connecting conductive wire  820  and second connecting conductive wire  830 . 
     The first connecting conductive wire  820  and the second connecting conductive wire  830  protrude outwardly after penetrating through the respective side walls  811  and  812  of the support body  810 , and are electrically connected to the respective ones of first electrode  640  and second electrode  650 . In this case, the first connecting conductive wire  820  and the second connecting conductive wire  830  may slidably contact the first electrode  640  and the second electrode  650 , respectively, so that electrical connection between the first electrode  640  and the first connecting conductive wire  820  and electrical connection between the second electrode  650  and the second connecting conductive wire  830  is maintained, even when the LED  700  and the LED support unit  800  move in the lengthwise direction of the rail body  605  within the rail body  605 . 
     Furthermore, the first connecting conductive wire  820  and the second connecting conductive wire  830  which are protruded outwardly after penetrating through the respective side walls  811  and  812  of the support body  810  may be curved into a U-shape, and may function as a U-shaped spring for supporting the horizontal movement of the support body  810  between the first electrode  640  and the second electrode  650 . 
     For example, the first connecting conductive wire  820  and the second connecting conductive wire  830 , which protrude outwardly after penetrating through respective side walls  811  and  812  of the support body  810 , may have a predetermined (e.g., U-plate spring) shape, and may be slidably connected to respective ones of the first electrode  640  and second electrode  650  to support the horizontal movement of the support body  810  and to maintain electrical connection with the first electrode  640  and the second electrode  650  within the LED rail  600 . 
     Example embodiments have been disclosed herein, and although specific terms are employed, they are used and are to be interpreted in a generic and descriptive sense only and not for purpose of limitation. In some instances, as would be apparent to one of skill in the art as of the filing of the present application, features, characteristics, and/or elements described in connection with a particular embodiment may be used singly or in combination with features, characteristics, and/or elements described in connection with other embodiments unless otherwise indicated. Accordingly, it will be understood by those of skill in the art that various changes in form and details may be made without departing from the spirit and scope of the invention as set forth in the following claims.