Patent Publication Number: US-11395390-B2

Title: LED lighting assembly with integrated power conversion and digital transceiver

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority under 35 U.S.C. § 119(e) to U.S. provisional patent application Ser. No. 62/808,383, filed on Feb. 21, 20190, which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     Locations use lights to provide illumination. Over the years, light sources of light fixtures that provide illumination have evolved from filament based Edison bulbs to more power efficient light emitting diodes (LEDs). LED light fixtures generally are designed with external power sources that provide power to the LEDs. 
     In addition, industry today relies on the transmission of data. Data is continuously transmitted for monitoring, automation control, and the like. Typically, data can be transmitted over wired and wireless networks that are deployed for transmitting data. For example, fiber optics networks and wireless networks with routers and gateways may be deployed to build a communication network. The cost to deploy these networks can be very expensive. 
     SUMMARY 
     In one embodiment, the present disclosure provides a light emitting diode (LED) assembly. In one embodiment, the LED assembly comprises a substrate, at least one LED coupled to the substrate, and a power converter module formed on the substrate, wherein the power converter module is to power the at least one LED. 
     In one embodiment, the present disclosure provides another embodiment of an LED assembly. In one embodiment, the LED assembly comprises a substrate, at least one LED coupled to the substrate, a power converter module formed on the substrate, wherein the power converter module is to power the at least one LED, and a digital transceiver coupled to the substrate. 
     In one embodiment, the present disclosure provides another embodiment of an LED assembly. In one embodiment, the LED assembly comprises a substrate, at least one LED coupled to the substrate, a power converter module formed on the substrate, wherein the power converter module is to power the at least one LED, a monolithic capacitor formed in the substrate and coupled to the power, and a digital transceiver coupled to the substrate. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments. 
         FIG. 1  depicts a block diagram of one embodiment of an LED lighting assembly of the present disclosure; 
         FIG. 2  depicts a cross-sectional block diagram of one embodiment of an example of the LED lighting assembly of the present disclosure; 
         FIG. 3  depicts a cross-sectional block diagram of another embodiment of an example of the LED lighting assembly of the present disclosure; 
         FIG. 4  depicts a block diagram of another embodiment of the LED lighting assembly of the present disclosure; 
         FIG. 5  depicts a block diagram of another embodiment of the I LED lighting assembly of the present disclosure; 
         FIG. 6  depicts a block diagram of another embodiment of the LED lighting assembly of the present disclosure; 
         FIG. 7  depicts a block diagram of another embodiment of the LED lighting assembly of the present disclosure; 
         FIG. 8  depicts a block diagram of another embodiment of the LED lighting assembly of the present disclosure; and 
         FIG. 9  depicts a block diagram of light fixtures that include the LED lighting assembly of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure provides an LED lighting assembly with integrated power conversion and digital transceiver. As noted above, light fixtures are used to provide illumination in various locations. Current LED based light fixtures are fabricated with external power supplies. This can lead to a bulkier and heaver LED light fixture design. 
     In addition, industry today relies on the transmission of data. Data is continuously transmitted for monitoring, automation control, and the like. Typically, data can be transmitted over wired and wireless networks that are deployed for transmitting data. For example, fiber optics networks and wireless networks with routers and gateways may be deployed to build a communication network. The cost to deploy these networks can be very expensive. 
     However, all facilities use lights to illuminate the facilities. Thus, using the lights inside of a facility to transport data may reduce the overall costs for implementing a separate communication network to transmit the data. Connected lighting systems may offer the promise of functioning as a portal for the collection and transport of a vast array of data, as well as signaling actuators for control applications. 
     Lighting systems have for many years offered a 0-10 Volt (V) analog control input for dimming the output of a fixture. The digitally encoded messages for affecting control and performing remote monitoring operations have become popular with the use of microprocessors. 
     Examples of the present disclosure provide an LED lighting assembly with integrated power conversion and a digital transceiver that provides a more compact and efficient design that can provide illumination and transmit or receive data. The present disclosure incorporates the LED light, a power converter module, and a digital transceiver onto a single or common substrate. The LED light may provide general illumination. The power converter module may receive alternating current (AC) input voltage and drive the LEDs on an output of the power converter module. The digital transceiver may provide bi-directional controls. The simplification of the product design onto a single substrate may offer advantages in cost and ease of assembly. 
       FIG. 1  illustrates an example LED assembly  100  of the present disclosure. In one embodiment, the LED assembly  100  may be part of an LED light fixture. For example, the LED assembly  100  may be enclosed within a housing with a heat sink to dissipate heat. The light fixture may then be mounted in a location to provide illumination. An example is illustrated in  FIG. 9  and discussed below. 
     In one embodiment, the LED assembly  100  may include a substrate  108 . The substrate  108  may be a printed circuit board or a metal core board with no through holes that includes integrated circuitry. In other words, electrical lines may be fabricated into the substrate  108  that allow various components of the LED assembly  100  to communicate with each other. The metal core board may also provide thermal management. 
     In one embodiment, the LED assembly  100  may include at least one LED  1021  to  102   n  (hereinafter also referred to individually as an LED  102  or collectively as LEDs  102 ). Although the LEDs  102  are illustrated in a particular arrangement in  FIG. 1 , it should be noted that the LEDs  102  may be arranged in any particular manner. For example, the LEDs  102  may be arranged in arrays. For example, each array of LEDs  102  may be controlled independently. 
     In one embodiment, the LED assembly  100  may include a power converter module (PCM)  104  and a digital transceiver (DT)  106 . In one embodiment, the PCM  104  and the DT  106  may be integrated on the same substrate  108  as the LEDs  102 . In other words, the PCM  104  and the DT  106  are not separate components that are coupled to the LEDs via an external connection, cable, wire, and the like. Rather, the PCM  104  and the DT  106  may be integrated to communicate with the LEDs  102  via circuits that are formed in the substrate  108 . Said another way, the PCM  104  and the DT  106  may be soldered to electrical pads on the substrate  108  that are in communication with the LEDs  102 . In other embodiments, the PCM  104  and the DT  106  may be fabricated or integrated as part of the substrate  108 . In other words, the PCM  104  and the DT  106  may be a part of the substrate  108  (e.g., cannot be physically removed from the substrate  108  like discrete power converter and digital transceiver components of prior designs/light assemblies). 
     In one embodiment, the PCM  104  may be a component that converts voltage received in a direct current (DC) waveform into a voltage that is in an alternating current (AC) waveform. For example, the LEDs  102  may operate with AC power. However, a power source may be a DC power source. The PCM  104  may convert the DC from the DC power source into an AC power source that is delivered to the LEDs  102 . Notably, the PCM  104  may be deployed without large metal power components (e.g., large housings) such that the PCM  104  can be integrated into the substrate  108   
     In one embodiment, the DT  106  may be a component that can receive, transmit, and/or process data. For example, the data may be used by the LED assembly  100  or be data received from a remote controller to control functionality of the LEDs  102 . 
     In one embodiment, the DT  106  may be a wired or wireless transceiver. For example, when the DT  106  is a wired transceiver, the DT  106  may be connected to another transceiver or communication module via a communications wire. In one embodiment, the communications wire may be an optical communications link or a fiber optic cable. The optical communications link may be realized via the user of visible light communications sent through the optical communications link (e.g., visible light communications (VLC) or Li-Fi). 
     In one embodiment, when the DT  106  is a wireless transceiver, the DT  106  may communicate via an antenna using radio signals. Examples of various embodiments of the antenna are illustrated in  FIGS. 6-8  and discussed in further details below. 
     It should be noted that the LED assembly  100  has been simplified for ease of explanation. For example, the LED assembly  100  may be electrically connected to other components that are not shown (e.g., a controller, a processor, and the like). 
     Since the LEDs  102 , the PCM  104 , and the DT  106  are integrated onto a single substrate  108 , the LED assembly  100  may provide a smaller footprint, lower manufacturing costs, and easier installation/assembly. For example, as noted above, the PCM  104  may be integrated without the bulky metal housings of external power converters. Moreover, assembly may require only installing the LED assembly  100  into a housing rather than having to electrically connect the LEDs to an external power converter, as in previous designs. 
       FIGS. 2 and 3  illustrate cross-sectional block diagrams of the LED lighting assembly  100 .  FIG. 2  illustrates a block-diagram where the LEDs  102 , the PCM  104 , and the DT  106  are mounted on a same side of the substrate  108 . For example, the substrate  108  may include a first side  110  and a second side  112 . The first side  110  and the second side  112  may be opposite one another. The first side  110  and the second side  112  may refer to opposite sides of the substrate  108  with the greatest surface area. 
       FIG. 2  illustrates an example where the LEDs  102 , the PCM  104 , and the DT  106  are on the second side  112 . However, it should be noted that the LEDs  102 , the PCM  104 , and the DT  106  may also be on the first side  110 . 
       FIG. 3  illustrates an embodiment where the PCM  104  and the DT  106  may be mounted on opposite sides of the substrate  108 .  FIG. 3  illustrates an example where the PCM  104  may be mounted on the first side  110  and the DT  106  may be mounted on the second side  112 . However, it should be noted that the PCM  104  may be mounted on the second side  112  and the DT  106  may be mounted on the first side  110 . 
     In one embodiment, the LEDs  102  may be mounted all on the first side  110  or the second side  112 . In another embodiment, as shown in  FIG. 3 , the LEDs  102  may be mounted on both sides of the substrate  108 . For example, a first subset of the LEDs  102  may be mounted on the first side  110  of the substrate  108 , and a second subset of the LEDs  102  may be mounted on the second side  112  of the substrate  108 . 
     In the embodiment of  FIG. 3 , the substrate  108  may include integrated circuit lines that travel between each first side  110  and the second side  112  of the substrate  108 . In other words, the substrate  108  may include electrical contacts on both the first side  110  and the second side  112  to electrically connect the LEDs  102  on both sides of the substrate  108  and/or electrically connect/integrate the PCM  104  and the DT  106  to either side  110  or  112  of the substrate  108 . 
       FIG. 4  illustrates an embodiment where the substrate may be an application specific integrated circuit (ASIC) substrate  202 . For example, the LEDs  1021  to  102   m , the PCM  104 , and the DT  106  may be mounted on a monolithic ASIC substrate  202 . In other words, the LEDs  102 , the PCM  104 , and the DT  106  may be integrated into a single integrated circuit (IC) package. 
       FIG. 5  illustrates an embodiment of an LED assembly  500 . The LED assembly  500  may include one or more monolithic capacitors  502 . The monolithic capacitors  502  may be used to filter out DC power and deliver AC power to the LEDs  102 . The monolithic capacitor  502  may also filter the AC input power to an output that is suitable for driving the LEDs  102 . 
     In one embodiment, the monolithic capacitor  502  is formed in the substrate  108 . For example, the monolithic capacitor  502  can be formed by manufacturing electrodes and a dielectric gap in the substrate  108  using semiconductor processing methods when the substrate  108  is manufactured. 
       FIGS. 6-8  illustrate various embodiments of an antenna that may be coupled to the DT  106  when the DT  106  is a wireless transceiver.  FIG. 6  illustrates an example of an LED assembly  600 . In one embodiment, the LED assembly  600  may include the LEDs  102 , the PCM  104 , and the DT  106 . The DT  106  may be a wireless transceiver that is coupled to an external antenna  602 . The external antenna  602  may be coupled to the DT  106  via a coaxial cable. 
       FIG. 7  illustrates an example of an LED assembly  700 . In one embodiment, the LED assembly  700  may include the LEDs  102 , the PCM  104 , and the DT  106 . The DT  106  may be a wireless transceiver that is coupled to an internal antenna  702 . The internal antenna  702  may be mounted onto the substrate  108 . For example, the internal antenna  702  may be mounted on a same side of the substrate  108  as the side on which the DT  106  is mounted. The internal antenna  702  may be directly wired to the DT  106 . 
       FIG. 8  illustrates an example of an LED assembly  800 . In one embodiment, the LED assembly  800  may include the LEDs  102 , the PCM  104 , and the DT  106 . The DT  106  may be a wireless transceiver that is coupled to a substrate antenna  802 . The substrate antenna  802  may be integrated into the substrate  108  and electrically connected to the DT  106 . For example, metal traces may be fabricated into the substrate  108  to form the substrate antenna  802  using semiconductor/PCB manufacturing techniques used to manufacture the substrate  108 . 
     It should be noted that portions of the various embodiments illustrated in  FIGS. 1-8  can be combined. For example, the various antennas illustrated in  FIGS. 6-8  can be combined with the ASIC substrate  202  illustrated in  FIG. 4 . In addition, the monolithic capacitors  502  illustrated in  FIG. 5  may be added to any embodiment where the DT  106  is wired or wireless as illustrated in  FIGS. 6-8 . In other examples, the monolithic capacitors  502  may be mounted on a side of the substrate  108  with the PCM  104 , with the DT  106 , or on an opposite side of the DT  106 , as illustrated in  FIGS. 2 and 3 . 
       FIG. 9  illustrates a block diagram of light fixtures  9021  and  9022  that each include the LED assembly  100  of the present disclosure. Although two light fixtures  9021  and  9022  are illustrated in  FIG. 9 , it should be noted that any number of light fixtures can be deployed. 
     In one embodiment, the light fixtures may include a housing that positions optics around the LED assembly  100 . As a result, the light emitted from the LEDs  102  of the LED assembly  100  may be transmitted in a desired direction or pattern in a particular location. 
     In one embodiment, the light fixtures  9021  and  9022  may be networked together to communicate with one another. For example, data can be transmitted between the light fixtures  9021  and  9022  via the DT  106 , as described above. In one embodiment, the light fixtures  9021  and  9022  may communicate with an application server (AS)  904 . For example, the AS  904  may be a remotely located controller or server that can send control signals to the light fixtures  9021  and  9022 . The control signals can be received by the DT  106  to control operation or functionality of the LEDs  102 , as noted above. 
     While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.