Patent Publication Number: US-11022282-B2

Title: System and method for mounting LED light modules

Description:
RELATED APPLICATIONS 
     This application is a divisional application of U.S. patent application Ser. No. 29/657,390, filed Jul. 20, 2018, a divisional application of U.S. patent application Ser. No. 29/639,296, filed Mar. 5, 2018, and a continuation-in-part of U.S. patent application Ser. No. 16/282,039, filed Feb. 21, 2019, which claims priority from U.S. Prov. Pat. App. No. 62/635,362, filed Feb. 26, 2018, all of which are hereby incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to a system for supporting light-emitting diode (LED) light modules. 
     BACKGROUND 
     Common lighting includes incandescent lights, fluorescent lights and light-emitting diodes (LEDs). Incandescent lights operate by flowing electricity through a filament inside a glass bulb. The filament heats up and glows, creating light. However, this technology creates a lot of heat. An incandescent light bulb loses 98% of its energy producing heat, making it quite inefficient. On Jan. 1, 2014, in keeping with a law passed by Congress in 2007, 40- and 60-watt incandescent light bulbs could no longer be manufactured in the U.S., because they failed to meet federal energy-efficiency standards. This policy was the final step in a gradual phase-out beginning in 2012 with 100-watt bulbs, then progressing to discontinuation of the 75-watt variety. 
     Fluorescent lights are low pressure mercury-vapor gas-discharge lamps that use fluorescence to produce visible light. An electric current in the gas excites mercury vapor which produces short-wave ultraviolet light that then causes a light-emitting phosphor coating on the inside of the bulb to glow. Fluorescent lights are used as back lighting for signs and are also found in residences, such as in kitchens, basements, or garages, in schools and in businesses because the cost savings when using fluorescent lamps tend to be significant when compared to the cost of incandescent light use. Disposal and accidental breakage of fluorescent bulbs, which contain toxic mercury, can result in potentially dangerous chemical contamination. 
     The fastest-developing lighting technology today is the light-emitting diode (LED). Recent developments in LED technology have made LEDs more efficient and cheaper to use than both fluorescent bulbs and incandescent bulbs. A type of solid-state lighting, LEDs use a semiconductor to convert electricity directly into light, are often small in area (less than 1 square millimeter) and may emit light in a specific direction, reducing the need for reflectors and diffusers that can trap light. LEDs are also the most efficient lighting technology on the market. A light bulb&#39;s efficiency (also called luminous efficacy) is a measure of emitted light (lumens, lm) divided by power drawn (watts, W). A bulb that is 100 percent efficient at converting energy into light would have a luminous efficacy of 683 lm/W. To put this in context, a 60- to 100-watt incandescent bulb has a luminous efficacy of 15 lm/W, an equivalent compact fluorescent lamp (CFL) has a luminous efficacy of 73 lm/W, and current LED-based replacement bulbs on the market range from 70 to 120 lm/W with an average luminous efficacy of 85 lm/W. 
     LED light modules and strip lighting have been in existence for several years. A current trend is to retrofit incandescent and fluorescent lighting with energy and environmentally-friendly LED technology. Such a system is described, for example, in U.S. Pat. Pub. No. 2017/0023186 for “Method and Assembly for Replacing Fluorescent Lights”. In a retrofit replacement for a fluorescent light, typically one or more LED light modules are typically mounted onto a support, such as an aluminum tube, and support bases, such as end caps, configured to fit into the fluorescent light sockets are installed on or near the ends of the support. Power is provided to the LED light modules from a power supply through one or more of the end caps or through a wire that runs from the power supply to the LED light modules without going through the end caps. 
     LED light modules are typically manufactured having double-sided adhesive tape on the backside for mounting the LED light module onto the surface of a support and/or having holes for screws to mount the LED light module onto the support. The double-sided adhesive tape requires a clean surface to adhere to. The square aluminum stock tubes from which the supports are made in a sign shop have on their surfaces an oily residue, which can cause the adhesive on the tape to fail to hold the LED light module to the aluminum tubing, particularly when temperatures rise in a sign cabinet. Oil films continue to persist even after cleaning. The adhesive loses adhesion due to the heat and oily surface and the LED light modules may fall off the aluminum tubing. This problem dictates the additional use of adhesives (silicone/glue and/or fasteners (screws) to securely hold each LED light module in place, which requires drilling screw holes at the desired positions in the support and is time consuming. 
     Thus, it would be beneficial to enable easier, faster and more convenient mounting of LED light modules which does not require either adhesives or screws to obtain the advantages of high luminous efficacy LED lighting in place of older, less efficient lighting methods. 
     SUMMARY 
     An object of the invention is to provide a method and system for supporting LEDs. 
     An LED support clip includes a support element clamp for clamping onto a support element and at least one LED light module clamp for clamping an LED light module onto the LED support clip, thereby attaching the LED module to the support element without requiring the use of adhesives or threaded connectors. 
     The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more thorough understanding of the present invention, and advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is an isometric view of an LED support clip. 
         FIG. 2  is an end view of the LED support clip in  FIG. 1 . 
         FIG. 3  is an isometric view of an LED light assembly comprising an LED support clip and multiple LED light modules. 
         FIG. 4  is an end view of the LED light assembly in  FIG. 3 . 
         FIG. 5  is a side view of the LED light assembly in  FIG. 3 . 
         FIG. 6  is a top view of the LED light assembly in  FIG. 3 . 
         FIG. 7  is a first step in a method for constructing an LED light assembly. 
         FIG. 8  is a second step in a method for constructing an LED light assembly. 
         FIG. 9  is a third step in a method for constructing an LED light assembly. 
         FIG. 10  is a fourth step in a method for constructing an LED light assembly. 
         FIG. 11  is an isometric view of an LED light stick. 
         FIG. 12  is an end view of the LED light stick in  FIG. 11 . 
         FIG. 13  is a first step in a method for constructing an LED light stick. 
         FIG. 14  is a second step in a method for constructing an LED light stick. 
         FIG. 15  is a third step in a method for constructing an LED light stick. 
         FIG. 16  is a fourth step in a method for constructing an LED light stick. 
         FIG. 17  is a flowchart for construction of LED light sticks. 
     
    
    
     DETAILED DESCRIPTION 
     LED support clips are disclosed which are operable to enable simple Snap-On attachment of any LED light module to support elements, such as tubular mounting hardware (“tubing”). In embodiments, the LED support clip holds itself firmly on a support element by a clamp comprising spring tension jaws. One or more LED light modules may then be held firmly within the LED support clip by additional clamps also comprising spring tension jaws. For the various jaws, the springiness is typically designed into the jaws and occurs as a result of the jaw design and manufacturing. “Spring tension”, “springiness”, and similar terms as used herein do not imply the use of a separate spring element, but may result from the inherent springiness of the material from which the LED support clip is fabricated. 
     Since both attachment of the LED light assemblies to the LED support clip and the attachment of the LED support clip to the support do not utilize adhesives or screws, the LED support clip can thus be readily removed, for example, to replace a faulty LED light module. The LED support clip may also be positioned and/or repositioned at any position along the support to locate the LED light module where required. The LED support clip is preferably made from any material that is sufficiently elastic such that the LED support clip will clamp onto a support with sufficient force to be immobile during use. The material of the LED support clip is preferably also sufficiently flexible, and the spring tension not so great, so that that the LED support clip can subsequently be removed or repositioned as required at a later time. Suitable materials for fabrication of the LED support clip may include plastics or other polymers, including thermoplastics, such as acrylonitrile butadiene styrene (ABS) and elastomers. In some embodiments, the LED support clip is made from ABS and has wall thickness is 0.060 or 0.070 inches, which is sufficiently thick to clamp onto the support while sufficiently springy to allow for removal in order to reposition or replace an LED mount. In some embodiments, a relief radius is formed in the interior corner between each jaw and the top portions that the LED support element will fit within the LED mount without interference. A LED support clip may also be made of metal or other material. Whatever material is chosen, the wall thicknesses of the jaws in the clamps is selected to provide a balance between clamping force and ease of mounting and removing. The clamping force is sufficient to keep the LED clip  100  attached to a support element without the LED clip  100  sliding along the support element or detaching during normal operation. 
     In some embodiments, the jaws of the clamps may have a “toe-in” angle, i.e., the jaws may be angled slightly towards each other toward their distal ends. That is, the distance between the interior surface of the first support element jaw and the interior surface of the second support jaw is larger at the jaw mounting portion than at the distal end of the first support element jaw and the second support jaw. The “tow-in” angle is preferably less than 20 degrees on each jaw. When the jaws are described as “substantially parallel” or “substantially perpendicular to the jaw mounting portion,” substantially as used herein allows for a toe-in angle. The frictional force between the LED support clip and the support may be determined, therefore, by the material properties, such as the Young&#39;s modulus, of the LED support clip, the wall thickness, and the toe-in angle. The frictional force between the LED support clip and the support may also be affected by the material from which the support is made. Various mechanical geometries of the LED support clip will also affect the ease of mounting and removal of the LED support clip, as well as how well the LED support clip adheres to the support. For example, protrusions, such as hook-like projections or bumps, at the end of the jaws may trap the support between the jaws. Angled surfaces (leads) at the end of the jaws may facilitate momentarily springing the jaws apart as the LED support clip is pushed onto the support. 
     Some embodiments may employ a biasing device, such as a spring, to hold the jaws closed, rather than using the natural springiness of the LED support clip material. The LED support clip can be manufactured to conform to support elements having any cross-sectional shape, for example, square, triangular, rectangular, pentagonal, hexagonal, “I”-shaped, “L”-shaped, and round. 
     LED Support Clip 
       FIGS. 1-2  illustrate an LED support clip  100 . Two LED light module clamps  120  and  130  at the left and right sides of  FIG. 2 , respectively, are operable to each hold an LED light module, such as LED light modules  330  and  430  as illustrated in  FIGS. 3-7 . A support element clamp  102  is operable for attaching the LED support clip to a support element, such as support element  1102  as illustrated in  FIGS. 11-12 . 
     Support element clamp  102  comprises two support element support element jaws  106  and  114 , which are connected together by curved spring elements  108  and  112 , connected together by straight section  110 , wherein spring elements  108  and  112  and straight section  110  comprise a jaw mounting portion  113 . In some embodiments, jaw mounting portion  113  may comprise only a straight section  110 . Spring elements  108  and  112  provide a relief, that is, a gap that prevents interference of the corners of the support element with the LED clip  100 . A protrusion or projection at the distal ends of support element jaws  106  and  114  tend to retain the support element within the support element clamp  102 . For example, in the embodiment shown, hook/lead  104  is positioned at a distal end of jaw  106  and hook/lead  116  at a distal end of jaw  114  are operable to capture a support element such as support element  1102  as illustrated in  FIGS. 11-12 . Hook/leads  104  and  116  also may function in conjunction with a first angled tab  142  extending from the first support element jaw  106  and a second angled tab  144  extending from the second support element jaw  114 , each of the first and second angled tabs  142  and  144  extending in a direction away from the center of the opening of clamp  102  between the first support element jaw  106  and the second support element jaw  114 , the angled tabs configured to spread the jaws and guide a support element into the opening. Angled tabs  142  and  144  to facilitate insertion of a support element  702  into clamp  102  during mounting of the LED light assembly  300  onto the support element  1102  as illustrated in  FIGS. 13-16 .  FIG. 2  shows that hook/leads  104  and  116  each includes an upper surface that is substantially perpendicular to support element jaws  106  and  114  to retain a support element, and a lower surface that is the angled with respect to support element jaws  106  and  114  to facilitate insertion of the support element. 
     LED light module clamp  120  comprises two LED module clamping jaws  124  and  126 , which are interconnected by jaw  106 . Hook/lead  122  at a distal end of LED module clamping jaw  124  and hook/lead  128  at a distal end of jaw  126  are operable to capture an LED light module, such as LED light module  430  in  FIG. 4 , and outer angled surfaces of hook/leads  122  and  128  may be operable as leads to facilitate insertion of the LED light module  430 . 
     LED light module clamp  130  comprises two LED module clamping jaws  134  and  136 , which are interconnected by jaw  114 . Hook/lead  132  at a distal end of LED module clamping jaw  134  and hook/lead  138  at a distal end of jaw  136  are operable to capture an LED light module, such as LED light module  330  in  FIG. 4 , and outer angled surfaces of hook/leads  132  and  138  may be operable as leads to facilitate insertion of the LED light module  430 . 
     Other embodiments of an LED clip can one or more LED light module clamps positioned in any combination of left side, right side, or above, that is, on the jaw mounting portion of clip  100 . 
     Clamping of LED Light Modules in the LED support clip to Form an LED Light Assembly 
       FIGS. 3-6  show views of an LED light assembly  300  comprising an LED support clip  100  which is clamping two LED light modules  330  and  430 . In embodiments, LED support clip  100  may be operable to clamp one, two, or more LED light modules. 
     LED light module  330  comprises an LED mount  322  with multiple LEDs  320  attached. A first pair of wires  312  and  314  may extend from one end of LED light module  330  and a second pair of wires  316  and  318  may extend from an opposite end of LED light module  330 . In some embodiments, wires  312  and  316  may correspond to a single first wire and wires  314  and  318  may correspond to single second wire. In some embodiments LEDs  320  may be connected in parallel between the first and second wires. In some embodiments, LEDs  320  may be connected in series, or in a combination of parallel and series connections. 
     LED light module  430  comprises an LED mount  422  with multiple LEDs  420  attached. A third pair of wires  302  and  304  may extend from one end of LED light module  430  and a fourth pair of wires  306  and  308  may extend from an opposite end of LED light module  430 . In some embodiments, wires  302  and  306  may correspond to a single third wire and wires  314  and  318  may correspond to single fourth wire. In some embodiments LEDs  420  may be connected in parallel between the third and fourth wires. In some embodiments, LEDs  420  may be connected in series, or in a combination of parallel and series connections. 
     Any of the structures described with respect to support element clamp  102  can be applied to LED light module clamps  120  and  130 . For example, LED light module clamps  120  and  130  can include angled tabs similar to angled tabs  142  and  144  and spring portions similar to spring elements  108  and  112 . 
     LED modules come in various sizes and shapes. The design of light module clamps  120  and  130  and any other light module clamps will vary with the size and shape of the LED module being clamped in any particular embodiment. Similarly, the size and shape of support element clamp  102  will vary with the size and shape of the support element in any particular embodiment. The LED support clips shown in the figures are merely examples of one embodiment of an LED support clip. 
     Method of Forming an LED Light Assembly 
       FIGS. 7-10  show four steps in a method for constructing an LED light assembly  300 . In  FIG. 7  arrow  704  represents relative motion between the LED light module  430  and the LED support clip  100  wherein this relative motion brings the right two edges of LED light module  430  into contact with hook/leads  122  and  128  on LED support clip  100 . There may be a small “toe-in” angle (not shown) between LED module clamping jaws  124  and  126 —as LED module clamping jaws  124  and  126  are spread apart in  FIGS. 8-10  this initial “toe-in” angle may change to a positive “toe-out” angle (or a 0° angle in  FIG. 10 ) thereby generating a clamping force between LED module clamping jaws  124  and  126  and the LED light module  430 . 
     In  FIG. 8 , LED light module  430  has moved to the right as shown by arrow  804 , thereby causing the two right edges of LED light module  430  to slide along hook/leads  122  and  124 , forcing LED module clamping jaws  124  and  126  apart as shown by arrows  806  and  808  and changing the relative angle between LED module clamping jaws  124  and  126  to a small positive “toe-out” angle as shown. 
     In  FIG. 9 , the LED light module  430  is sliding along the edges of hook/leads  122  and  128  as shown by arrow  904 . There is no further spreading of LED module clamping jaws  124  and  126  at this point. Finally, in  FIG. 10 , the LED light module  430  is fully moved rightwards into the LED support clip  100 , allowing LED module clamping jaws  124  and  126  to snap-back as shown by arrows  1006  and  1008 . The angle between LED module clamping jaws  124  and  126  will typically be about 0° in this configuration (i.e., LED module clamping jaws  124  and  126  are approximately parallel, clamping the LED light module  430  along a substantial portion of the lengths of LED module clamping jaws  124  and  126 ). Hook/leads  122  and  128  may be configured with lengths in the vertical direction (i.e., parallel to the left side of the LED light module  430 ) sufficiently long to extend out past radii at the left edges of the left side of LED light module  430 , thereby enabling hook/leads  122  and  128  to exert rightward retaining forces on the LED light module  430  to securely retain the LED light module  430  within the LED support clip  100 . The spring force derived from the difference between initial “toe-in” angle in  FIG. 7  and the final angle in  FIG. 10 , combined with the coefficients of friction of the inner surfaces of LED module clamping jaws  124  and  126  and the coefficients of friction of the upper and lower sides of LED light module  430 , generates a clamping and retaining force between the LED light module  430  and the LED support clip  100 . 
     LED Light Stick 
       FIGS. 11-12  show views of an LED light stick  1100  comprising two LED light assemblies  300  mounted onto the support element  1102 . Wires  1104 ,  1106 ,  1108  may correspond to a single wire in embodiments. Wires  1114 ,  1116 ,  1118  may correspond to a single wire in embodiments. Wires  1124 ,  1126 ,  1128  may correspond to a single wire in embodiments. Wires  1104 - 1128  may correspond to any of wires  302 - 318  in  FIGS. 3-6 . 
     Method of Forming an LED Light Stick 
       FIGS. 13-16  show four steps in a method for constructing an LED light stick. In  FIG. 13 , arrow  1304  represents relative motion between the LED light assembly  300  and the support element  1102  wherein this relative motion brings the upper two edges of support element  1102  into contact with tabs  142  and  144  on LED light assembly  300 . Angle  1302  represents a small “toe-in” angle between support element jaws  106  and  114 —as support element jaws  106  and  114  are spread apart in  FIGS. 14-16  this initial angle  1302  changes to a positive “toe-out” angle (see angles  1402 - 1602 ) thereby generating a clamping force between support element jaws  106  and  114  and the support element  1102 . 
     In  FIG. 14 , the support element  1102  has moved upwards as shown by arrow  1404 , thereby causing the two upper edges of support element  1102  to slide along tabs  142  and  144  and hook/leads  104  and  116 , forcing support element jaws  106  and  114  apart as shown by arrows  1406  and  1508  and changing the relative angle between support element jaws  106  and  114  from a small negative “toe-in” angle to a small positive “toe-out” angle  1402  as shown. 
     In  FIG. 15 , the support element  1102  is sliding along the edges of hook/leads  104  and  116  as shown by arrow  1504 . There is no further spreading of support element jaws  106  and  114  at this point. Finally, in  FIG. 16 , the support element  1102  is fully moved upwards into the LED light assembly  300 , allowing support element jaws  106  and  114  to snap-back as shown by arrows  1608  and  1610 . The angle  1602  between support element jaws  106  and  114  will typically be about 0° in this configuration (i.e., support element jaws  106  and  114  are approximately parallel, clamping the support element  1102  along a substantial portion of the lengths of support element jaws  106  and  114 . Hook/leads  104  and  116  may be configured with lengths in the horizontal direction (i.e., parallel to the lower edge of the support element  1102 ) sufficiently long to extend out past radii at the lower edges of the support element  1102 , thereby enabling hook/leads  104  and  116  to exert upward retaining forces on the support element  1102  to securely retain the support element  1102  within the LED light assembly  300 . The spring force derived from the difference between initial “toe-in” angle  1302  and the final angle  1602 , coupled with the coefficients of friction of the inner surfaces of support element jaws  106  and  114  and the coefficients of friction of the left and right outer walls of the support element  1102  combine to generate a clamping and retaining force between the LED light assembly  300  and the support element  1102 . 
     OTHER EMBODIMENTS 
     In the embodiments shown, the support element was illustrated with a square cross-sectional shape with jaws shaped correspondingly. Other cross-sectional support element shapes fall within the scope of the invention, including: square, triangular, rectangular, pentagonal, hexagonal, “I”-shaped, “L”-shaped, and round. Jaws may be designed within the scope of the invention to provide secure mounting to these various support element shapes. 
     Embodiments may provide clamping to horizontal, vertical or both horizontal and vertical support elements. Embodiments may provide clamping to support elements in various spatial orientations. 
     In the LED support clip, the jaws of the LED light module clamps may be designed to accommodate clamping of various sizes and shapes of LED light modules. In the LED support clip, the jaws of the support element clamp may be designed to accommodate clamping of various sizes and shapes of support elements. 
     Flowchart for a Method of Constructing LED Light Sticks 
       FIG. 17  is a flowchart  1300  for construction of the LED light assemblies  300  of  FIGS. 3-6  and mounting the LED light assemblies  300  on a support element  1102  as shown in  FIGS. 11-12  to form the LED light stick  1100 . 
     In block  1702 , a first LED light module is inserted to a first LED light module clamp of a first LED support clip. 
     In block  1704 , a second LED light module is inserted into a second LED light module clamp if the first LED support clip, thereby forming a first LED light assembly as in  FIGS. 3-6 . 
     In block  1706 , the procedure in blocks  1702  and  1704  may be repeated to form additional LED light assemblies as in  FIGS. 3-6 . 
     In block  1708 , the LED light assemblies formed in blocks  1702 - 1706  are clamped to the support element using the support element clamps in each LED support clip to form the LED light stick. 
     In block  1710 , the wires from the LED light modules are interconnected. 
     In block  1712 , the steps in blocks  1702 - 1710  may be repeated to form additional LED light sticks. 
     In Block  1714 , the wires from the LED light sticks are connected to an LED power supply. 
     While the foregoing describes a preferred embodiment of the present invention, one skilled in the art will appreciate that various changes, substitutions and alterations may be made without departing from the scope of the invention. Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations may be made herein without departing from the scope of the invention as defined by the appended claims. LED modules can be attached on any surface of the support element, and on multiple surfaces of the support element to provide light output in different directions. Either a single LED support clip or multiple LED support clips may be attached to a single support element. The support element may be of any length, where the length of the support element may vary with the implementation. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.