Patent Publication Number: US-11378261-B2

Title: Linear light apparatus

Description:
FIELD 
     The present invention is related to a linear light apparatus, and more particularly related to a linear light apparatus with compact design. 
     BACKGROUND 
     The time when the darkness is being lighten up by the light, human have noticed the need of lighting up this planet. Light has become one of the necessities we live with through the day and the night. During the darkness after sunset, there is no natural light, and human have been finding ways to light up the darkness with artificial light. From a torch, candles to the light we have nowadays, the use of light have been changed through decades and the development of lighting continues on. 
     Early human found the control of fire which is a turning point of the human history. Fire provides light to bright up the darkness that have allowed human activities to continue into the darker and colder hour of the hour after sunset. Fire gives human beings the first form of light and heat to cook food, make tools, have heat to live through cold winter and lighting to see in the dark. 
     Lighting is now not to be limited just for providing the light we need, but it is also for setting up the mood and atmosphere being created for an area. Proper lighting for an area needs a good combination of daylight conditions and artificial lights. There are many ways to improve lighting in a better cost and energy saving. LED lighting, a solid-state lamp that uses light-emitting diodes as the source of light, is a solution when it comes to energy-efficient lighting. LED lighting provides lower cost, energy saving and longer life span. 
     The major use of the light emitting diodes is for illumination. The light emitting diodes is recently used in light bulb, light strip or light tube for a longer lifetime and a lower energy consumption of the light. The light emitting diodes shows a new type of illumination which brings more convenience to our lives. Nowadays, light emitting diode light may be often seen in the market with various forms and affordable prices. 
     After the invention of LEDs, the neon indicator and incandescent lamps are gradually replaced. However, the cost of initial commercial LEDs was extremely high, making them rare to be applied for practical use. Also, LEDs only illuminated red light at early stage. The brightness of the light only could be used as indicator for it was too dark to illuminate an area. Unlike modern LEDs which are bound in transparent plastic cases, LEDs in early stage were packed in metal cases. 
     In 1878, Thomas Edison tried to make a usable light bulb after experimenting different materials. In November 1879, Edison filed a patent for an electric lamp with a carbon filament and keep testing to find the perfect filament for his light bulb. The highest melting point of any chemical element, tungsten, was known by Edison to be an excellent material for light bulb filaments, but the machinery needed to produce super-fine tungsten wire was not available in the late 19th century. Tungsten is still the primary material used in incandescent bulb filaments today. 
     Early candles were made in China in about 200 BC from whale fat and rice paper wick. They were made from other materials through time, like tallow, spermaceti, colza oil and beeswax until the discovery of paraffin wax which made production of candles cheap and affordable to everyone. Wick was also improved over time that made from paper, cotton, hemp and flax with different times and ways of burning. Although not a major light source now, candles are still here as decorative items and a light source in emergency situations. They are used for celebrations such as birthdays, religious rituals, for making atmosphere and as a decor. 
     Illumination has been improved throughout the times. Even now, the lighting device we used today are still being improved. From the illumination of the sun to the time when human can control fire for providing illumination which changed human history, we have been improving the lighting source for a better efficiency and sense. From the invention of candle, gas lamp, electric carbon arc lamp, kerosene lamp, light bulb, fluorescent lamp to LED lamp, the improvement of illumination shows the necessity of light in human lives. 
     There are various types of lighting apparatuses. When cost and light efficiency of LED have shown great effect compared with traditional lighting devices, people look for even better light output. It is important to recognize factors that can bring more satisfaction and light quality and flexibility. 
     It is important to design light devices with low cost while easily to be assembled. Security issues are very important. Sometimes, when certain factors occur, the light device may cause serious damages like fires. 
     It is therefore important to consider safety design like grounding. Usually, it takes effort to particularly add a ground wire and connect the ground wire to a ground, but it needs some effort. 
     Therefore, it is beneficial if a better design is provided to ensure safety factors are considered while the assembling is still simple. 
     SUMMARY 
     In some embodiments, a linear light apparatus includes a light strip, a light passing cover, a main bracket, a bottom holder and a metal clip. 
     The light strip having an elongated substrate mounted with LED modules. 
     The main bracket holds the light strip for the LED modules emitting a light passing through the light passing cover. 
     The main bracket has a first metal part. 
     A first insulation layer covers at least a portion of the first metal part. 
     The bottom holder has two side walls for respectively attaching to two lateral walls of the main bracket. 
     The bottom holder has a second metal part. 
     A second insulation layer covers at least a portion of the second metal part. 
     The metal clip has a first thorn and a second thorn. The metal clip is pressed to one side wall for the first thorn to stab the second insulation layer to electrically connect the bottom holder and the metal clip. 
     The second thorn stabs the first insulation layer for the metal clip to be electrically connect to the first metal part of the main bracket. 
     In some embodiments, the metal clip is a U-shape structure with a top portion and two wings. 
     The two wings define a clip opening for clipping said side wall of the bottom holder. 
     In some embodiments, the second thorn has two second thron units protruding from the two wings toward the clip opening. 
     In some embodiments, the first thorn has two first thorn units protruding over the top portion of the U-shape structure toward the main bracket. 
     In some embodiments, a positioning hole is placed on the wing of the U-shape structure. 
     In some embodiments, a ground wire is fixed to the positioning hole. 
     In some embodiments, the first thorn and the second thorn have sharp edges to remove the second insulation layer and the first insulation layer. 
     In some embodiments, the first thorn is defomred when stabbing to the main bracket. 
     In some embodiments, a ground path is connected to the metal clip for connecting to a ground. 
     In some embodiments, the main bracket has a ladder groove between the two lateral walls. 
     The ladder groove has a central surface and two tilt surfaces. 
     The two tilt surfaces respected extends from top edges of the two lateral walls to lower the central surface. 
     The central surface is used for mounting the light strip. 
     In some embodiments, the two tilt surfaces define a spreading angle with respect to the central surface. 
     The spreading angle is larger than a main light angle of the light strip. 
     In some embodiments, the tilt surfaces have reflective layers facing to the light strip. 
     In some embodiments, a driver is placed between the bottom holder and the main bracket. 
     In some embodiments, the metal clip is not electrically connected to the driver. 
     In some embodiments, the linear light apparatus may also include two end covers on two sides of the main bracket. 
     The two end covers are respectively clipped between block plates of the bottom holder and the main bracket. 
     In some embodiments, the block plate has a socket for connecting to a power source and a ground. 
     The metal clip is electrically connected to the ground via the socket. 
     In some embodiments, the main bracket is formed completely by the first metal part and the first insulation layer. 
     In some embodiments, the bottom holder is formed completely by the second metal part and the second insulation layer. 
     In some embodiments, the metal clip is clipped by the side wall of the bottom holder and the lateral wall of the main bracket. 
     In some embodiments, the side wall has a first buckle unit and the lateral wall has a second buckle unit. 
     The main bracket and the bottom holder are attached by buckling the first buckle unit to the second buckle unit. 
     When the first buckle unit and the second buckle unit are buckled, the second thorn stabs the main bracket. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  illustrates an embodiment of a linear light apparatus. 
         FIG. 2  illustrates an exploded view of the embodiment in  FIG. 1 . 
         FIG. 3  illustrates a metal clip example. 
         FIG. 4A  illustrates a first view of the metal clip example. 
         FIG. 4B  illustrates a side view of the metal clip example. 
         FIG. 5  illustrates the metal clip clipping the side wall. 
         FIG. 6  illustrates another view of the example in  FIG. 5 . 
         FIG. 7  illustrates a cross-sectional view of the metal clip and other components. 
         FIG. 8  illustrates an exploded view of components. 
         FIG. 9  illustrates another exploded view of components. 
         FIG. 10  illustrates a main light angle of a light strip in a first structure. 
         FIG. 11  illustrates a main light angle of a light strip in another structure. 
         FIG. 12  illustrates another metal clip example. 
         FIG. 13  illustrates another metal clip example. 
         FIG. 14  shows another embodiment of a linear light apparatus. 
         FIG. 15  shows another view of the example in  FIG. 14 . 
     
    
    
     DETAILED DESCRIPTION 
     Please refer to  FIG. 14  and  FIG. 15 , which illustrates an embodiment in two views. The same reference numerals among drawings refer to the same components and would not be repeated again for brevity. 
     In  FIG. 14 , a linear light apparatus includes a light strip  606 , a main bracket  609 , two end covers  602  and a bottom holder  610 . 
     The light strip  606  has an elongated substrate  607  mounted with LED modules  608 . 
     The light passing cover  601  has two side arc openings  615  and two lateral bottom edges  618 . 
     The two lateral bottom edges  618  of the light passing cover  601  are respectively attached to two lateral walls  619  of the main bracket  609 . 
     The ladder groove  620  has a central surface  616  and two tilt surfaces  617 . 
     The two tilt surfaces  617  respectively extend from top edges  621  of the two lateral walls  619  to lower the central surface  616  below a bottom line  622  of the side arc opening  615 . 
     The central surface  616  is used for mounting the light strip  606 . 
     The two end covers  602  respectively have a top part  631  and a bottom part  632 . 
     The top parts  631  of the two end covers respectively cover the arc openings  615  of the light passing cover  601 . The bottom parts  632  of the two end covers  602  respectively cover the lateral groove  620 . 
     The bottom holder  610  is attached to the two lateral walls  619  of the main bracket  609 . 
     The bottom holder  610  has two block plates  611  on two opposite sides of the bottom holder  610 . 
     The bottom part  632  of the end cover  602  is kept between the block plate  611  and the main bracket  609 . 
     In some embodiments, the light strip is inserted to the central surface of the main bracket via the track of the main bracket. 
     In some embodiments, a top edge  642  of the block plate  611  engages a bottom edge  641  of the top part  631  of the end cover  602 . 
     In some embodiments, one block plate has a socket  612  for connecting to an external power source  613 . 
     In some embodiments, another socket of the other block cover is used for inserting an extension module  643 . The extension module  643  has a circuit, e.g. a wireless circuit, for extending a function of a driver  611  providing a driving current of the light strip  606 . 
     In some embodiments, the block plate only engages the bottom part of the end cover, not engages the top part of the end cover, as illustrated in  FIG. 9 . 
     In  FIG. 9  and  FIG. 10 , the bottom holder has two side walls  646 . 
     The side wall  646  has a first buckle unit  648  for attaching to a second buckle unit  647  of the lateral wall  619  of the main bracket  609 . 
     In some embodiments, the main bracket  609  is made by bending a metal plate. 
     In some embodiments, the second buckle unit is a bent edge of the metal plate. 
     In  FIG. 10 , the art edge  655  defines the arc opening  615 . 
     In some embodiments, the linear light apparatus may also include a driver disposed in a driver space enclosed by the main bracket and the bottom holder. 
     In some embodiments, the block plate is a made by folding an edge part of the bottom holder. 
     In some embodiments, the tilt surfaces have reflective layers for reflecting a light of the light strip to the light passing cover. For example, a reflective film or painting may be applied or attached on the tilt surfaces. 
     In  FIG. 10 , the tilt surfaces are mounted with an additional light source  656 . 
     The additional light source has a different optical parameter from the LED modules on the light strip. 
     In some embodiments, the bottom holder has an air flow channel  658  for heat dissipation, e.g. to carry heated air to an air passage  659 . 
     In some embodiments, a linear light apparatus includes a light strip, a light passing cover, a main bracket and a bottom holder. In addition, the linear light apparatus further has a metal clip. 
     The light strip having an elongated substrate mounted with LED modules. 
     The main bracket holds the light strip for the LED modules emitting a light passing through the light passing cover. 
     The main bracket has a first metal part. For example, the main bracket is mainly made of metal, forming the first metal part. Some components may be added to the main bracket in other embodiments. 
     A first insulation layer covers at least a portion of the first metal part. The first insulation layer is used for preventing unnecessary electrical contact among components. The first insulation layer may cover all or only a partial area of the main bracket. 
     The bottom holder has two side walls for respectively attaching to two lateral walls of the main bracket. 
     The bottom holder has a second metal part. For example, the bottom holder is mainly made of metal, forming the second metal part. Some components may be added to the bottom holder in other embodiments. 
     A second insulation layer covers at least a portion of the second metal part. The first insulation layer is used for preventing unnecessary electrical contact among components. The first insulation layer may cover all or only a partial area of the bottom holder. 
       FIG. 4A  shows an example of a metal clip. The metal clip has a first thorn  52  and a second thorn  53 . The metal clip is pressed to one side wall for the first thorn to stab the second insulation layer to electrically connect the bottom holder and the metal clip. 
       FIG. 7  shows an example of such design. The first thorn  42  stabs a second insulation layer on a side wall  21 . The second insulation layer is a layer covering the side wall of the bottom holder at least at the stabbing position of the first thorn  42  in  FIG. 7 . When the first thorn stabs the bottom holder, there is an electrical connection between the bottom holder and the metal clip. 
     The second thorn  43  stabs the first insulation layer of the main bracket in  FIG. 7 . The first insulation layer is a layer for prevent electricity connection applied on a surface of the main bracket, e.g. at the stabbing position of the second thorn  43  shown in  FIG. 7 . The second thorn  47  stabs the first insulation layer and thus making the metal clip electrically connected to the main bracket. 
     The second thorn stabs the first insulation layer for the metal clip to be electrically connect to the first metal part of the main bracket. 
     The metal clip is therefore a good medium for electrically connecting the first metal part of the main bracket and the second metal part of the bottom holder, for further connecting undesired electricity to ground for safety concern. 
     In  FIG. 4B , the metal clip is a U-shape structure with a top portion  412  and two wings  411 . 
     The two wings  411  define a clip opening  413  for clipping said side wall of the bottom holder, as shown in  FIG. 7 . 
     In  FIG. 4B , the second thorn  42  has two second thron units protruding from the two wings toward the clip opening  413 . 
     In  FIG. 4B , the first thorn  43  has two first thorn units protruding over the top portion  412  of the U-shape structure toward the main bracket, as shown in  FIG. 7 . 
     In  FIG. 4A , a positioning hole  416  is placed on the wing of the U-shape structure. 
     In some embodiments, a ground wire is fixed to the positioning hole. For example, a ground wire is connected to the bolt  44  in  FIG. 6  that fills the positioning hole. 
     In some embodiments, the first thorn and the second thorn have sharp edges to remove the second insulation layer and the first insulation layer, as shown in  FIG. 4A  and  FIG. 4B . 
     In some embodiments, the first thorn is defomred when stabbing to the main bracket, as shown in  FIG. 7 . 
     In  FIG. 14 , a ground path  672  is connected to the metal clip  671  for connecting to a ground  673 . 
     In some embodiments, the main bracket has a ladder groove between the two lateral walls, as shown in  FIG. 14  and  FIG. 15 . 
     The ladder groove has a central surface and two tilt surfaces. 
     The two tilt surfaces respected extends from top edges of the two lateral walls to lower the central surface. 
     The central surface is used for mounting the light strip. 
     In some embodiments, the two tilt surfaces define a spreading angle with respect to the central surface. 
     The spreading angle is smaller than a main light angle of the light strip. 
     Please refer to  FIG. 10 . In  FIG. 10 , the light strip placed on a horizontal platform  11  has LED modules  30  emitting a light with a main angle about 120 degrees, e.g. a main portion like 80% of light is between the main angle. In other words, the design in  FIG. 10  causes a light area A and a dark area B appearing on the light passing cover  12 . 
     Please refer to  FIG. 11 , which shows a ladder groove for holding the light strip. 
     In  FIG. 11 , the ladder groove has a central surface  114  for holding the light strip  30 . Two tilt surfaces  115  are placed on two sides of the central surface  114 , forming a smaller spreading angle, the outer angle illustrated in  FIG. 15 , than the main light angle, the inner angle illustrated in  FIG. 15 , of the LED module of the light strip. 
     In some embodiments, the tilt surfaces have reflective layers facing to the light strip. 
     In some embodiments, a driver is placed between the bottom holder and the main bracket. 
     In some embodiments, the metal clip is not electrically connected to the driver. 
     In some embodiments, the linear light apparatus may also include two end covers on two sides of the main bracket. 
     The two end covers are respectively clipped between block plates of the bottom holder and the main bracket. 
     In some embodiments, the block plate has a socket for connecting to a power source and a ground. 
     The metal clip is electrically connected to the ground via the socket. 
     In some embodiments, the main bracket is formed completely by the first metal part and the first insulation layer. 
     In some embodiments, the bottom holder is formed completely by the second metal part and the second insulation layer. 
     In some embodiments, the metal clip is clipped by the side wall of the bottom holder and the lateral wall of the main bracket. 
     In some embodiments, the side wall has a first buckle unit and the lateral wall has a second buckle unit. 
     The main bracket and the bottom holder are attached by buckling the first buckle unit to the second buckle unit. 
     When the first buckle unit and the second buckle unit are buckled, the second thorn stabs the main bracket. 
     Please refer to  FIG. 1  to  FIG. 2 , which illustrates another detailed example. The same reference numerals refer to the same components among drawings. 
     In  FIG. 1 , the linear light apparatus  10  has a main bracket  11 , a bottom holder  20 , end covers  13 , a light passing cover  12 . 
       FIG. 2  shows an exploded view of the example in  FIG. 1 . In addition to the components mentioned above, the bottom holder  20  has multiple first buckle units  24 . The bottom holder  20  has two block plates  23  on two opposite sides. 
       FIG. 3  shows metal clip  40  with a first thorn  42  and a second thorn  43 . There is a positioning hole  416  for ensuring the metal clip  40  attaching to a required position of a side wall  21  of the bottom holder  20 . There is a clip opening  413  for clipping the side wall  21 . The metal clip  40  is made as a metal unit  41  for fixing a screw or a rivet  44  to guide undesired electricity to ground. 
       FIG. 4A  and  FIG. 4B  show two views of the metal clip. 
       FIG. 5  shows how the metal clip is placed on a side wall  21  of the bottom holder  20 . 
       FIG. 6  shows another zoom-up view of the connection between the metal clip  40  and the side wall  21  of the bottom holder  20 . 
       FIG. 7  shows stabbing relation of the first thorn  42  and the second thorn  43  when the main bracket  11  is attached to the bottom holder  20 . 
       FIG. 8  show block plate  23 , the end cover  13  and other components to be assembled as a two-part assembly. 
       FIG. 9  shows the end cover  13  has a corresponding structure for fitting and enclosing the ladder groove mentioned above. 
       FIG. 12  shows another metal clip embodiment. In  FIG. 12 , the metal clip  9920  has a main part  9921  and grooves  99211 . The thorn unit  99252  is formed on a curved surface  99251  forming a thorn  9925 . 
       FIG. 13  shows such thorn  9925  to stab a lateral wall  99111  of a main bracket  9911 . In this example, the metal clip is formed directly on the side wall of the bottom holder, which is illustrated in  FIG. 13 . 
     The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. 
     The embodiments were chosen and described in order to best explain the principles of the techniques and their practical applications. Others skilled in the art are thereby enabled to best utilize the techniques and various embodiments with various modifications as are suited to the particular use contemplated. 
     Although the disclosure and examples have been fully described with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of the disclosure and examples as defined by the claims.