Patent Publication Number: US-8525440-B1

Title: LED lighting fixture

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 12/074,969, filed Mar. 7, 2008, issued as U.S. Pat. No. 8,207,678 on Jun. 26, 2012, which claims priority to U.S. patent application 60/894,117, filed Mar. 9, 2007, which are incorporated by reference in their entirety along with all other references cited in this application. 
    
    
     BACKGROUND OF THE INVENTION 
     Embodiments disclosed herein generally relate to lighting systems. More specifically, embodiments disclosed herein relate to an improved system and method for distributing power and data signals in a lighting system. 
     Display units for entertainment, architectural, and advertising purposes have commonly been constructed from numbers of light emitting elements, such as light emitting diodes (LEDs) or incandescent lamps. The light emitting elements may be selectively turned on and off to create patterns, graphics, and video displays for both informational and aesthetic purposes. It is well known to construct tubular lighting and display devices using LEDs and various methods have been used for distributing data and power signals through such devices. 
     U.S. Pat. No. 6,472,823, issued to George Yen, uses a daisy-chain system where control and power enters one end of a tube fixture, is carried through the tube, and leaves the other end to connect to the next fixture. The power supply is at one end of the chain so that the system may be limited by the number of tubes that are connected in the chain by the capacity of that power supply. U.S. Pat. No. 6,857,924, issued to Ta-Hao Fu, and U.S. Pat. No. 6,860,007, issued to Li-wen Liu, are also similarly used. 
     U.S. Pat. No. 7,053,557, issued to Robert Cross, describes supplying power in parallel to multiple LED tube fixtures but does not disclose doing so in a way that allows multiple power supplies to be used or means to economically distribute and protect the cabling systems. In addition the low voltage power supplies are contained within the tube where heat management could be problematic. 
     U.S. Pat. No. 7,067,992, issued to Susan Leong, describes another method for connecting power to an LED tube fixture but does not explain how data signals may also be connected. 
     U.S. Pat. No. 6,676,284, issued to Wynne Willson, describes an LED tube fixture system with multiple power supplies and a data signal path but does not teach means for connecting the power supplies and routing the cables to minimize fixture size. 
     LED tube fixtures of this type are often used in architectural situations where it is a requirement to maintain a clean and tidy appearance for the fixture with hidden cabling and seamless joins between fixtures. Another requirement is that the power supplies are mounted in such a way that access for installation and maintenance is simple. Finally, it would be advantageous to provide protection for power and data cabling without the need to run separate cable conduits or trunking adjacent to the fixtures. 
     This invention seeks to provide means for distributing power and data signals in an LED lighting or display fixture that may minimize the size of the fixture and eliminate the need to run alternating current (AC) power in a separate cable alongside the fixture. 
     BRIEF SUMMARY OF THE INVENTION 
     In one aspect of one or more embodiments, an LED lighting system includes a power supply module, a data input line routed through the power supply module, an AC power input, and an LED fixture. The power supply module includes a power supply unit and an AC power cable. The AC power input is electrically connected to the power supply unit and the AC power cable. The LED fixture is electrically connected to an output of the power supply unit and the data input cable, and includes one or more LED assemblies disposed on a circuit board, a data signal output, and a power output. The AC power cable may be routed through the LED fixture. 
     In another aspect of one or more embodiments, a method of transmitting data and power within an LED lighting system includes receiving an AC power input and a data input signal at a power supply module, splitting the AC power input into an AC power cable and an AC power signal, connecting the AC power signal to a power supply unit disposed within the power supply module, generating a low voltage power signal from the AC power signal with the power supply unit, connecting the AC power cable, the low voltage power signal, and the data input signal to an LED fixture, receiving the low voltage power signal and the data input signal at a circuit board disposed within the LED fixture, wherein the circuit board comprises an LED assembly disposed thereon, and powering and controlling the LED assembly with the low voltage power signal and the data signal. 
     In yet another aspect of one or more embodiments, a method of transmitting data and power within an LED lighting system includes receiving an AC power input, a low voltage power signal, and a data signal at a power supply module, connecting the AC power input and the low voltage power signal to a power supply unit disposed within the power supply module, splitting the AC power input into an AC power cable and an AC power signal, powering the power supply unit with the AC power signal, amplifying the low voltage power signal with the power supply unit, connecting the AC power cable, the low voltage power signal, and the data signal to an LED fixture, receiving the low voltage power signal and the data signal at a circuit board disposed within the LED fixture, wherein the circuit board comprises an LED assembly disposed thereon, and powering and controlling the LED assembly with the low voltage power signal and the data signal. 
     Further, in yet another aspect of one or more embodiments, an LED lighting system includes a first LED fixture electrically connected to a low voltage power input and a data signal input, a power supply module, and a second LED fixture. The first LED fixture includes a first AC power cable routed through the first LED fixture, thereby providing a first AC power output, a first low voltage power output, and a first data signal output. The power supply module includes a power supply unit electrically connected to the first AC power output, and provides a second low voltage power output, a second AC power cable electrically connected to the first AC power output, thereby providing a second AC power output, and a data input line electrically connected to the first data signal output and routed through the power supply module, thereby providing a second data signal output. The second LED fixture is electrically connected to the second low voltage power output and the second data signal output and includes a third AC power cable electrically connected to the second AC power output and routed through the second LED fixture, thereby providing a third AC power output, a third low voltage power output, and a third data signal output. 
     Other objects, features, and advantages of the present invention will become apparent upon consideration of the following detailed description and the accompanying drawings, in which like reference designations represent like features throughout the figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a block diagram of an LED light system in accordance with embodiments disclosed herein. 
         FIG. 2  is a block diagram of an LED light system in accordance with embodiments disclosed herein. 
         FIG. 3  is a block diagram of an LED light system in accordance with embodiments disclosed herein. 
         FIG. 4  is a block diagram of an LED light system in accordance with embodiments disclosed herein. 
         FIG. 5  shows a perspective view of an LED light system in accordance with embodiments disclosed herein. 
         FIG. 6  shows a top view of a connector used in accordance with embodiments disclosed herein. 
         FIG. 7  shows a perspective view of a connection used in accordance with embodiments disclosed herein. 
         FIG. 8  shows a perspective view of a connection used in accordance with embodiments disclosed herein. 
         FIG. 9  shows a perspective view of a connection used in accordance with embodiments disclosed herein. 
         FIG. 10  shows a perspective view of a connection used in accordance with embodiments disclosed herein. 
         FIG. 11  shows a perspective view of a connection used in accordance with embodiments disclosed herein. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Specific embodiments of the present disclosure will now be described in detail with reference to the accompanying figures. Like elements in the various figures may be denoted by like reference numerals for consistency. Further, in the following detailed description of embodiments of the present disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the embodiments disclosed herein may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. 
     Embodiments of the claimed invention are directed towards a light emitting diode (LED) light system that eliminates the necessity for separate power and data cables being run alongside the system. The LED light system may include LED fixtures and power supply modules. The LED fixtures serve to actually generate light to create patterns, graphics, and video displays for both informational and aesthetic purposes, whereas the power supply modules serve as a stable source of power for LED fixtures. Generally, there is a main source of alternating current (AC) power for the entire LED light system, but each of the LED fixtures may run on a low voltage DC power signal. Embodiments of the claimed invention may allow a cable carrying AC power to route through the LED light system itself in order to keep the cable out of sight. Data signal cables and low voltage supply cables may also be similarly routed through the system. 
     Referring to  FIG. 1 , a block diagram of an LED light system  100  in accordance with embodiments disclosed herein is shown. The system  100  includes an LED fixture  111  and a power supply module  101 . The power supply module  101  includes an AC power input  102  and a data signal line  106  as inputs. Within the power supply module  101 , an AC power input  102  may be split between an AC power signal and an AC power cable  103 . The AC power signal is electrically connected to a power supply unit  104 , also contained within the power supply module  101 . 
     After being split from the AC power input  102 , the AC power cable  103  is then routed through the LED fixture  111  exiting as AC power  103 . AC power cable  103  may be insulated within the LED fixture  111 , but LED fixture  111  provides routing and protection for the AC power cable  103 . Further, within the LED fixture  111 , AC power cable  103  may be electrically isolated and separated from low voltage areas and cables using internal barriers within the LED fixture  111  or using insulation on AC power cable  103 . 
     The data signal line  106  passes through the power supply module  101 , exits the module, and connects to the LED fixture  111 . In this embodiment, the data signal line  106  is insulated, or isolated, from the power supply module  101 , but power supply module  101  provides routing and protection for the data signal line  106 . In an alternate embodiment, not shown in the figures, the data signal line  106  may connect to the power supply module  101 . In this case, the power supply module  101  may amplify, or boost, a data signal transmitted on the data signal line  106 . In this embodiment data signal line  106  would not be an output, and there would be an additional data signal output from the power supply module  101  that may be transmitted to either a second power supply module or the LED fixture  111 . 
     The power supply unit  104  accepts the AC power signal split from the AC power input  102 , and generates a low voltage supply signal  105 . The low voltage supply signal  105  may, for example, be a DC power supply signal suitable for driving the LED fixture  111 . The power supply signals suitable for directly driving the LED fixture  111  are generally not suitable for being transmitted over long distances. Thus, the power supply unit  104  serves to refresh the low voltage supply signal for use in the subsequent LED fixture  111 . 
     LED fixture  111  accepts an AC power cable  103 , low voltage supply signal  105 , and data signal line  106  as inputs. As discussed above, the AC power cable  103  may be insulated from other components and pass straight through the LED fixture  111  to be used in further modules. The LED fixture  111  further includes a circuit board  112  and LED assemblies  113 . The LED assemblies  113  may include individual LEDs or arrays of LEDs. Further, each individual LED may be a typical light emitting diode, a polymer light emitting diode (PLED), an organic light emitting diode (OLED), or any other LED known in the art. The LED fixture may include, for example, an extrusion LED tube fixture, or any other LED fixture known in the art. 
     The circuit board  112  and LED assemblies  113  may be powered by the low voltage supply input  105  to produce light controlled based on information transmitted over the data signal line  106 . Hence, the circuit board  112  and LED assemblies  113  serve to display light from the LED lighting system  100 . Outputs from the LED fixture  111  include the AC power cable  103 , data signal output  114 , and low voltage supply output  115 . While the data signal output  114  and low voltage supply output  115  are shown to originate from the circuit board  112 , the outputs  114 ,  115  may also be tied directly to the corresponding inputs  106 ,  105 . 
     Referring to  FIG. 2 , a block diagram of an LED light system  200  in accordance with embodiments disclosed herein is shown. In this arrangement, three LED fixtures  211  are connected in series with two power supply modules  201  therebetween. This arrangement may be used to refresh the low voltage supply inputs for each of the LED fixtures  211 . Inputs to the topmost LED fixture include an AC power input  202 , data signal line  205 , and a low voltage supply input  206 . Subsequently, the outputs from the topmost LED fixture are fed directly into the topmost power supply module through a connection between the two. A power supply module  201  may then refresh the low voltage supply power for the next LED fixture in the series, using the AC power cable routed through the previous LED fixture for power. 
     Alternatively, multiple LED fixtures  211  may be connected together in series between power supply modules  201 . However, the length such a series of LED fixtures  211  is limited based on the power supplied by the original AC power input  202  and the power consumed in each of the LED fixtures  211 . The number of fixtures between power supply modules  201  may be similarly limited based on the low voltage supply power. The final LED fixture  211  shows an AC power cable output  203 , a data signal line output  214 , and a low voltage supply signal output  215 . These outputs may be used to drive further power supply modules  201  or LED fixtures  211 . However, if the LED fixture is the last in a chain, they may not be used at all, and the connections may be terminated. 
     Referring to  FIG. 3 , a block diagram of an LED light system  300  in accordance with embodiments disclosed herein is shown. In this arrangement, four LED fixtures  311  are connected in series with a single power supply module  301  in parallel. This arrangement may be used to refresh the low voltage supply inputs for each of the bottom two LED fixtures  311 . Inputs to the topmost LED fixture include an AC power input  302 , data signal line  305 , and a low voltage supply input  306 . Each of the four LED fixtures is directly connected to the next in the series. External connections for the AC power cable  303 , the data signal line output  314 , and the low voltage supply output  315  are disposed on the second LED fixture from the top to connect to the power supply module  301 . The power supply module  301  may then refresh the low voltage supply input  305  that is in turn fed into the third LED fixture from the top, as well as AC cable  303  and data signal line input  306 . 
     The final LED fixture  311  shows an AC power cable output  303 , a data signal line output  314 , and a low voltage supply signal output  315 . These outputs may be used to drive further power supply modules  301  or LED fixtures  311 . However, if the LED fixture is the last in a chain, they may not be used at all, and the connections may be terminated. 
     Advantageously, this arrangement allows power supply modules  311  to be placed along the series of LED fixtures  301  as often as necessary. For example, the power provided may be sufficient for a chain of three or more LED fixtures  301  to be connected in series before an external power supply module  311  is needed to refresh the low voltage supply. As discussed above, this is limited by the AC power input, the power drawn from the LED fixtures, and any undesired power dissipation. 
     Referring to  FIG. 4 , a block signal and power flow diagram that includes features to isolate an LED lighting system  400  at the points where the system connects to house power is shown. At the start a LED fixtures  411  is a connection between the LED fixtures  411  and a house power distribution point  421 . These power distribution points  421  may be inserted as often as desired. In some cases, it may be desirable to use frequent power distribution points to minimize the impact of failure by any single distribution point. In this example, the first house power distribution point  421  powers two LED fixtures  411 , with one power supply module  401  to refresh the low voltage supply input to the second LED fixture  411 . A second house power distribution point  422  powers a new series of LED fixtures below. At any point in a series, an additional house power distribution point may be added. A transformer may be included within a house power distribution point so as to supply both the AC power input  403  and the low voltage supply input  405 . 
     Referring to  FIG. 5 , a perspective view of an LED lighting system  500  in accordance with embodiments disclosed herein are shown. LED fixtures  501 ,  503  are connected to power supply module  502  at each end through connections  504 . Alternatively, each of the sections  501 ,  502 , and  503  may comprise either a LED fixture or a power supply module. Connections  504  may include, but are not limited to the AC power inputs or outputs, data signal line inputs or outputs, and low voltage supply signal inputs or outputs, as discussed above with respect to various other embodiments disclosed herein. Further, connections capable of mating with connections  504  may be included on the end portions of power supply module  502 . Advantageously, using the housings and connections shown, the connections between various modules may be completely hidden from view. 
     Referring to  FIG. 6 , an end view of a first mating connection  600  used in accordance with embodiments disclosed herein is shown. The mating connection  600  includes contact points  601 ,  602 , and  603 , for positive, ground, and negative connections. Referring to  FIG. 7 , a perspective view of a connection within a LED lighting system  700  shows a second mating connection  701  connecting to first mating connection  600  in accordance with embodiments disclosed herein. First mating connection  600  and second mating connection  701  are capable of joining to form electrical connections. These electrical connections may include, but are not limited to the AC power inputs or outputs, data signal line inputs or outputs, and low voltage supply signal inputs or outputs, as discussed above with respect to various other embodiments disclosed herein. Further, first and second mating connections  600 ,  701  may be examples of the connections  504  shown in  FIG. 5 . Finally, referring to  FIGS. 8 and 9 , two alternative perspective views of the connection within a LED lighting system  700  show a first mating connection  600  mating with a second mating connection  701  as they are used in accordance with embodiments disclosed herein. 
     Referring to  FIGS. 10 and 11 , two perspective views of an LED lighting system  1000  show a first mating connection  1001  mating with a second mating connection  1002  as they are used in accordance with embodiments disclosed herein. First and second mating connections  1001 ,  1002  are alternative embodiments of the first and second mating connections  600 ,  701  discussed above with respect to  FIGS. 6-9 . First mating connection  1001  and second mating connection  1002  are capable of joining to form electrical connections. These electrical connections may include, but are not limited to the AC power inputs or outputs, data signal line inputs or outputs, and low voltage supply signal inputs or outputs, as discussed above with respect to various other embodiments disclosed herein. Further, first and second mating connections  1001 ,  1002  may be examples of the connections  504  shown in  FIG. 5 . 
     Embodiments disclosed herein may provide for one or more of the following advantages. First, the present disclosure may provide for an LED lighting system that does not require that separate data or power cables be run alongside the system. Because the system is directed towards displaying patterns, graphics, and video displays for both informational and aesthetic purposes, keeping data and power cables out of sight may provide for a better visual experience. Next, the present disclosure may provide for protection of data and power cables, because the data and power cables are run through the housing of the system itself. Finally, the present disclosure may provide for minimizing the number of power supply modules in an LED lighting system, because the embodiments disclosed herein allow for power supply modules to be inserted between, or alongside, LED fixtures as often as necessary. 
     This description of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications. This description will enable others skilled in the art to best utilize and practice the invention in various embodiments and with various modifications as are suited to a particular use. The scope of the invention is defined by the following claims.