Patent Publication Number: US-11655946-B1

Title: Flexible LED illumination device

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of Applicant&#39;s prior provisional application, number U.S. 63/353,328 filed on Jun. 17, 2022, the contents of which are incorporated by reference in their entirety. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     The present invention relates to lighting devices or systems using a strip of light sources with light sources held by or within elongated flexible supports. More particularly, the present invention relates to a flexible LED illumination device. 
     BACKGROUND OF THE INVENTION 
     Neon lighting has been used extensively by advertisers and business establishments to convey information to the public for decades. Such systems are popular due to the bright, uniform, and colorful light distribution emitted from the lights. 
     Although popular, such systems are extremely labor intensive because each light must be individually constructed to form a shape within a sign or other such system. For example, to construct a segment of a neon sign, an artisan must go through the laborious process of heating lead glass tubing, shaping the tube into the desired form, and then attaching an electrode to each end of the tube. The artisan must then evacuate air and impurities from the tube and introduce gas such as Neon, Krypton, Xenon, Argon, or Helium. Finally, after each individual light segment of the neon sign has been formed, the artisan must assemble the segments into a single structure and must then wire each segment to a step-up transformer that typically increases the voltage from 120 volts to somewhere between 3,000 and 15,000 volts. 
     Conversely, Light Emitting Diodes (LEDs) convert electrical energy into distinct light colors of light. Advances in LED technology and material science have enabled semiconductor manufacturers to create very bright LEDs in various colors. LED lighting offers numerous advantages over neon lighting. LEDs do not require transformers that step-up voltages to dangerous levels instead, LEDs operate at potentials of 3 to 24 volts. LEDs can easily package in various safe materials and do not require large breakable tubular lead crystal structures. LED brightness can easily be controlled with a very quick response allowing for visual effects not possible with neon lights. LEDs may also be produced at a low cost. 
     Those concerned with using neon signs have long recognized the need for more controllable, safer, less fragile, and less expensive neon signs. Several prior arts were made to solve the pertinent technical problem. The invention with U.S. Pat. No. 7,850,341 B2 discloses an Elongated LED Illumination Device, which provides a LED strip that simulates the features of a neon sign. The illumination device is flexible and can be bent into shapes, letters, and other designs. However, the assembly of inserting a plurality of LED assemblies into the light guide is vulnerable to skid due to the tension during bending. Also, in another embodiment of the invention, the light guide is rigid in structure and requires extreme heat to bend it; thus, the bending process can&#39;t be done on-site. Lastly, one of the disadvantages of said invention is that it cannot be cut to match the length of a building&#39;s structural features or design parameters. 
     U.S. Pat. No. 10,520,143 B1 discloses a LED simulated Neon with structural reinforcement. Said invention provides strain relief to the linear lighting within the simulated neon. Moreover, said invention imparts teaching of a flexible covering with a translucent upper portion and an opaque lower portion. The covering is a flexible material and can be cut at specific points within. However, the invention failed to disclose whether the remainder of the linear lighting could be reconnected for an electrical connection. 
     U.S. Pat. No. 7,604,376 B2 discloses a flexible perimeter lighting apparatus which is an elongated flexible lighting system that comprises an array of light sources that are disposed inside of an elongated translucent extrusion flexible material. Said prior art provides the teaching of being able to cut to match the length of a particular structural feature. In the present embodiments of the invention, mounting pads are required to reconnect the electrical coupling to the DC power supply. Said feature is disadvantageous since a particular connector is vital to re-establish an electrical connection. Moreover, installing LEDs and circuit boards inside the elongated translucent extrusion flexible material is challenging since they must be covered by potting material. 
     The present invention directed to a Flexible LED Illumination Device differs from the teachings provided by the aforementioned prior arts. 
     SUMMARY OF THE INVENTION 
     The present invention relates to lighting devices or systems using a strip of light sources with light sources held by or within elongated flexible supports. More particularly, the present invention relates to a flexible LED illumination device. 
     In one embodiment of the invention, a flexible LED illumination device comprises a translucent positioning strip having a plurality of slots disposed at the center, a plurality of light modules, and wherein said plurality of light modules further comprises a plurality of LEDs being mounted at the top surface of a circuit board, a power terminal for electricity connection being disposed at the bottom of the circuit board, and a current regular mounted at the surface of the circuit board, a plurality of power conductors attached to the power terminal and said power conductor being configured to connect the plurality of light modules to a power source. The plurality of power conductors for this embodiment comprises a pair of conductors for the transmission of electricity. Also, the embodiment comprises a translucent housing being molded to cover the top and sides of the translucent positioning strip, the plurality of light modules, an elongated light diffuser tube disposed at the top of the translucent housing, and wherein said elongated light diffuser tube being configured to diffused light from the plurality of LEDs simulating a neon sign, a potting glue disposed at the bottom of the translucent housing and covering the plurality of power conductors. An exposed power conductor extruding in between the plurality of light modules, and wherein said exposed wire is being configured for electrical connection means during the installation process. 
     One embodiment of the flexible LED illumination device comprises a plurality of power conductors with a quintet of conductors. Said quartet of conductors is structured to accommodate red, green, blue, and white backlight produced by the plurality of light modules. Also, the embodiment comprises of translucent positioning strip, translucent housing, elongated light diffuser tube, and potting glue. 
     These and other features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The present invention will be better understood by reference to the accompanying drawings, which: 
         FIG.  1    is a perspective of one embodiment of a flexible LED illumination device according to the present invention; 
         FIG.  2    is a front view of one of the embodiments of the flexible LED illumination device according to the present invention; 
         FIG.  3    is a perspective view of a plurality of LED modules of one of the embodiments of the flexible LED illumination device; 
         FIG.  4    is a projected view of the plurality of LED modules of one of the embodiments of the flexible LED illumination device; 
         FIG.  5    is a perspective of view of another embodiment of the plurality of LED modules; 
         FIG.  6    is a perspective of view of the 3 rd  embodiment of the plurality of LED modules; 
         FIG.  7    is an illustrative view of the electrical connection of the 2 nd  embodiment of the plurality of LED modules; 
         FIG.  8    is an illustration of another embodiment of the exposed power conductors. 
         FIG.  9    is a perspective view of the 1 st  embodiment of the exposed power conductors. 
         FIG.  10    is a bottom view of a translucent positioning strip with a plurality of slots; 
         FIG.  11    is a perspective view of the translucent positioning strip, and the plurality of LED modules during assembly. 
         FIG.  12    is an isometric view of attaching the potting glue to the flexible LED illumination device. 
         FIG.  13    is an illustration of another embodiment of the plurality of power conductors extruding at the bottom of the flexible LED illumination device. 
         FIG.  14    is a perspective view of another embodiment of the plurality of power conductors with a quintet of conductors to accommodate the RGBW feature of the plurality of light modules. 
         FIG.  15    is a perspective view of another embodiment of the flexible LED illumination device where the elongated light diffuser tube has a flat surface. 
         FIG.  16    is an illustration of the flexible LED illumination device being bent in a direction. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Before describing the present invention in detail, it is to be understood that the phraseologies and terminologies used herein are for the purpose of description and should not be regarded as limiting. 
     It will be understood that, although the terms first, second, third, etc. may be used to describe various elements, these elements should not be limited by these terms. These terms may be used to distinguish one element from another. For example, a first element may be termed a first element without departing from the scope of the present invention. As used herein, the term “and/or” may include any and all combinations of one or more of the associated listed items. 
     Referring now to the drawings, wherein, like reference numerals designate the components or elements throughout the ensuing enabling description, the present invention provides a flexible LED illumination device regarded as  100 . 
     With reference to  FIG.  1   , the flexible LED illumination device  100  comprises an elongated light diffuser tube  102 , a plurality of power conductors  104 , and an exposed power conductors  106 . The flexible LED illumination device  100  is configured to be flexible and be bent into any shape to accommodate different design parameters as expected in the field. As viewed in  FIG.  1   , the plurality of power conductors  104  and exposed power conductors  106  are extruding at the bottom of the flexible LED illumination device  100 . During installation, the flexible LED illumination device  100  is adept at being cut into a plurality of segments. The plurality of power conductors  104  is configured as the primary input and termination connection of the power source of the flexible LED illumination device  100 . Moreover, the exposed power conductors  106  is configured as a jumping wire for 1 st  embodiment of the flexible LED illumination device  100 , which can serve as a new primary input of power when the flexible LED illumination device  100  is sliced into smaller segments. 
     As seen in  FIG.  2   , the elongated light diffuser tube  102  further comprises an air gap  202  disposed at the middle or at the cross-center section of the elongated light diffuser tube  102 . The air gap is provided in the elongated light diffuser tube  102  to diffuse and further refract light emitted from the plurality of LEDs  304  (not shown). The elongated light diffuser tube  102  can include any number of different shapes and can be constructed from different materials having varying levels of opaqueness. 
     Going back to  FIG.  2   , the flexible LED illumination device  100  further comprises a translucent housing  204 . The translucent housing  204  is provided to cover the sides and a portion of the bottom of the flexible LED illumination device  100 . Said translucent housing  204  is attached at the bottom of the elongated light diffuser tube  102 . The translucent housing  204  is configured to protect the components within the flexible illumination device  100  from being stretched, provide another protective layer, and provide weatherproofing. Although described above with regard to specific shapes, sizes, materials, or intended uses, this is for illustrative purposes only. To this end, other embodiments are contemplated wherein one or more of the device components are formed from other materials or include different shapes, sizes, or components than those described or include different shapes, sizes, or components than those described or illustrated. With this, the elongated light diffuser tube  102  is given with a semi-circle cross section for efficient refraction of light emitted and simulates a Neon tube. 
     With reference to  FIG.  3   , a plurality of light modules  302  further comprises a plurality of LEDs  304  attached to the top surface of a circuit board  306 . Furthermore, a plurality of resistors  308  is being mounted at the surface of the circuit board  306  to protect the plurality of light modules  302  from a current surge. 
     The plurality of light module  302  is arranged in a longitudinal direction of the translucent housing  204 , and connected with each other through the plurality of power conductors  104 , as shown in  FIG.  3   . Furthermore, said plurality of power conductors  104  are being attached to the power terminal  402  located at the bottom of the circuit board  306 , as shown in  FIG.  4   . 
     In another embodiment of the plurality of light module  302 , shown in  FIG.  5   , the plurality of light module  302  is provided with a shell  502  to further protect the plurality of LEDs  304 , the circuit board  306 , and the current regulator  308  from impact, damage, moisture, and water leak. The embodiment provides an optical lens  504  to further enhance the reflection of light from the plurality of LEDs  304 . In another embodiment of the optical lens  504 , a pattern of geometrical shapes is disposed on top of the optical lens  504  for better refraction and reflection of light from the plurality of LEDs  304 , as shown in  FIG.  6   . The same with the original embodiment, the current embodiments of the plurality of light module  302  is connected through the plurality of power conductors  104  as shown in  FIG.  6    and  FIG.  7   . 
     In the illustration supplied by  FIG.  8   , an embodiment of the exposed power conductors  106  are provided. Said exposed power conductor  106  is unitary with the plurality of power conductors  104 . Unlike in the original embodiment, as shown in  FIG.  9   , the exposed power conductor is a U-shaped jumper connector. 
       FIG.  10    shows a bottom view of a translucent positioning strip  1002 . The translucent positioning strip  1002 , an extruded silicone flex strip, is configured to hold and protect the plurality of light modules  302  and the plurality of power conductors  104 . The plurality of light modules  302  is slotted to the translucent positioning strip  1002  through the plurality of slots  1004 . Said insertion of the plurality of modules  302  to the plurality of slots  1004  is viewed in  FIG.  11   . Furthermore, a potting glue  1202  is disposed at the bottom of the translucent housing  204  and covers the plurality of power conductors  104  as shown in  FIG.  12   . During assembly, the translucent positioning strip  1002 , the plurality of light modules  302 , and potting glue  1202  are attached to firmly secure the attachments and additional feature for weatherproofing. Lastly, the elongated light diffuser tube  102  is fixed on top of the translucent positioning strip  1002  to complete the original embodiment of the flexible LED illumination device  100 . 
       FIG.  13    shows one embodiment of the flexible LED illumination device  100 , where the plurality of power conductors  104  extrudes at the bottom in the same manner as the exposed power conductors  106 . Initially, the plurality of power conductors  104  and exposed wire  106  are positioned horizontally at the bottom of the translucent positioning strip  1002 . Afterward, silicon glue or potting material is filled to firmly secure the position, thus creating the potting glue  1202 . The position of the plurality of power conductors  104  is arranged to be easily hidden during the installation process. 
     In reference to  FIG.  14   , the illustration previews another embodiment of the present invention where the plurality of power conductors  104  comprises a quintet of conductors. Said quintet of conductors is structured to accommodate red, green, blue, and white backlight produced by the plurality of light modules. Also, the embodiment comprises translucent positioning strip  1002 , translucent housing  204 , elongated light diffuser tube  102 , and potting glue  1202  (not shown). 
     In the illustration provided in  FIG.  15   , said illustration shows another embodiment of the present invention where the elongated light diffuser tube  102  with a flat surface. The flat surface of the elongated light diffuser tube  102  for this embodiment allows the flexible LED illumination device  100  to be bent in the direction of  1 , as shown in  FIG.  16   . Furthermore, the elongated light diffuser tube  102  is transparent allowing the light emitted from the plurality of LEDs  304  to be radiated. 
     Additional advantages and modifications of the present invention will readily occur to those skilled in the art in view of these teachings. The present invention, in its broader aspects, is not limited to the specific details, representative contrivances, and illustrative examples shown and described herein. Accordingly, various modifications may be made without departing from the spirit and scope of the general concept as defined in the appended claims and their equivalents.