Patent Publication Number: US-2020296832-A1

Title: Printed circuit board assembly forming a lighting pattern

Description:
FIELD 
     The invention relates generally to a printed circuit board (PCB) assembly. In particularly, the present invention relates to a PCB assembly having circuits arranged to form specific shapes. 
     BACKGROUND 
     In some lighting assemblies, to obtain a specific-shaped light emitting diode (LED) lighting arrangement, the PCBs are formed to match the shape of a desired lighting arrangement. For example, as shown in  FIG. 1 , the PCB  10  is shaped in an arc shape and comprises a plurality of LEDs  20  disposed in a corresponding shape. A plurality of these arc shaped PCBs  10  (e.g., four) are arranged together to create a circular shaped lighting arrangement. 
     Special circular PCB routing is necessary to electrically connect the PCBs  10  together to create the circular shaped lighting arrangement, which can be time-consuming and cause undesirable costs to be incurred. 
     SUMMARY OF THE EMBODIMENTS 
     Given the aforementioned deficiencies, it is desirable to have a PCB assembly capable of creating specific lighting patterns without the inconvenience of special wiring to achieve the electrical connections between the PCBs. 
     In one exemplary embodiment, PCB assembly is provided. The PCB assembly includes a plurality of PCBs to be electrically connected, and each being formed of a first shape and having a plurality of lighting elements arranged thereon to form of a second shape creating a lighting pattern of a desired shape with the plurality of lighting elements, when electrically connected together. The first shape of the printed circuit boards being different from the second shape of the arrangement of the lighting elements. 
     In another exemplary embodiment, a lighting assembly including the PCB assembly is also provided. 
     The foregoing has broadly outlined some of the aspects and features of various embodiments, which should be construed to be merely illustrative of various potential applications of the disclosure. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope defined by the claims. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a printed circuit board having LEDs of a conventional lighting assembly. 
         FIG. 2  is a PCB assembly for a lighting assembly, according to one or more exemplary embodiments of the present invention. 
         FIG. 3  is a PCB of the PCB assembly of  FIG. 2 , according to one or more exemplary embodiments of the present invention. 
         FIG. 4  is a perspective view of PCB assembly of  FIG. 2  within a lighting assembly, showing the electrical connection between the PCBs, according to one or more exemplary embodiments of the present invention. 
         FIGS. 5 and 6  depict PCB assemblies according to alternative embodiments of the present invention, with use of the PCBs as shown in  FIGS. 2 through 4  being connected to form different lighting patterns. 
     
    
    
     The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the disclosure. Given the following enabling description of the drawings, the novel aspects of the present disclosure should become evident to a person of ordinary skill in the art. This detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of embodiments of the invention. 
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     As required, detailed embodiments are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of various and alternative forms. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. 
     In other instances, well-known components, systems, materials, or methods that are known to those having ordinary skill in the art have not been described in detail in order to avoid obscuring the present disclosure. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art. 
     Exemplary embodiments of the present invention provide a PCB assembly capable of creating lighting patterns with lighting elements without special PCB wiring routing. Details of the PCB assembly our described below with reference to  FIGS. 2 through 6 . 
       FIG. 2  provides an illustration of an exemplary PCB assembly  100 . The PCB assembly  100  includes a plurality of PCBs ( 110 ) including a first PCB  110   a , a second PCB  110   b , a PCB  110   c  and a PCB  110   d . The present invention is not limited to a particular number of PCBs  110  being implemented within the assembly  100  and can vary based on the desired lighting design, for example as depicted in  FIGS. 5 and 6 . The PCBs  110   a  through  110   d  are all formed of the same shape. For example, according to one embodiment, the PCBs  110   a - 110   d  are each formed of a rectangular shape. However, the present invention is not limited thereto and the PCBs  110   a - 110   d  can be formed of different shapes. According to one embodiment, the PCBs  110   a - 110   d  are manufactured by using a scoring machine capable of cutting a series of parallel lines to the edge of a larger PCB sheet, and rotating by approximately 90° to create orthogonal lines thereby creating the rectangular shape of the PCBs  110   a - 110   d . However, the present invention is not limited thereto and the PCBs  110   a - 110   d  can be formed of different shapes, for example, the shape of a triangle, hexagon, trapezoid and parallelogram. 
     As shown in  FIGS. 2 and 3 , each PCB  110   a - 110   d  includes a plurality of lighting elements  120  disposed thereon to form a desired lighting pattern  125 . According to an embodiment, the lighting elements  120  are LEDs. The lighting elements  120  are disposed in a side-by-side configuration in rows. The rows are spaced apart and in parallel, forming a desired lighting pattern  125  (as depicted in  FIG. 2 ) when the PCBs  110   a - 110   d  are electrically connected together. According to an embodiment, the lighting elements  120  can be arranged to form either a full circle, half-circle, or ¼ circle arcs. 
     According to one embodiment, the lighting pattern  125  has a circular form factor, but does not require circular PCB routing to facilitate an electrical connection. The present invention is not limited to the lighting pattern  125  being formed of a circular shape and can therefore vary in shape and size as desired, for example, as shown in  FIGS. 5 and 6  discussed below. 
     In the embodiments, each PCB  110   a - 110   d  is formed of a first shape and comprising the lighting elements  120  arranged thereon to form a second shape. A lighting pattern of a desired shape is created with the lighting elements  120  when the PCBs are electrically connected together when the first shape is different from the second shape. As shown in  FIGS. 2, 3, and 4 , for example, the PCBs  110   a - 110   d  are of a rectangular shape while the configuration of the lighting elements  120  thereon form an arc (or a half-moon) shape to create the circular shape lighting pattern  125 . 
     The lighting elements  120  can be semiconductor, organic or polymeric LEDs or similar devices. The lighting elements  120  are configured to receive output power from a lighting driver (not shown) and to emit light as controlled. 
     The PCBs  110   a - 110   d  are arranged and physically connected to a lighting assembly housing  210  (depicted in  FIG. 4 ), by attachment means  50  at a respective corner of each PCB  110   a - 110   d . In one embodiment, in which the desired lighting pattern is circular, the arrangement of the PCBs  110   a - 110   d  is such that fasteners connecting the PCBs  110   a - 110   d  to the lighting assembly housing  210  via the attachment means  50  also physically connects PCBs  110   a - 110   d  together. In another embodiment, such as those lighting patterns shown in  FIGS. 5 and 6  discussed below, the attachment means  50  would affix the PCBs  110  to a lighting assembly housing but not to one another. 
     Further, as shown in  FIGS. 2 and 3 , each PCB  110   a - 110   d  includes connectors  130   a  and  130   b . The connectors  130   a  and  130   b  are for positive and negative electrical terminals to facilitate electrical connection of each PCB  110   a - 110   d . These connectors  130   a  and  130   b  are formed at a center area of each PCB  110   a - 110   d  and adjacent to an inner row of the lighting elements  120  nearest the center of the PCB assembly  100  when assembled. 
     In the exemplary embodiments, the connectors  130   a  and  130   b  are vertical through board connectors, which extend through a heatsink  220  as depicted in  FIG. 4  (e.g., a LED heatsink) situated on a back surface thereof opposite the side having the lighting elements  120  thereon, where the electrical connections occur. The electrical connection to the PCBs  110   a - 110   d  can be made with other types of connectors such as push-in, solder pads, or any other suitable connectors. 
     As further shown in  FIG. 4 , a lighting assembly  200  is provided and includes a housing  210  for housing the PCB assembly  100  therein. As shown at the heat sink  220 , the lighting assembly  200  further includes wiring  140   a  and  140   b  arranged thereon for respectively connecting to the positive and negative terminals  130   a  and  130   b  of each PCB  110   a - 110   d  to provide the electrical connection for supplying power thereto. 
       FIGS. 5 and 6  depict PCB assemblies according to alternative embodiments of the present invention, with use of the same PCBs shown in  FIGS. 2-4  to be connected to form different lighting patterns. For example, as shown in  FIG. 5 , the PCB assembly  300  includes PCBs  110  arranged to form a complex closed loop shape. In  FIG. 6 , in the PCB assembly  350  the PCBs  110  may be arranged to form a lighting pattern of serpentine shape. 
     One of the advantages of the embodiments of the present invention, includes that PCBs of a PCB assembly can be arranged to form a desired lighting pattern thereon, when connected together, without the need for special PCB routing based on the shape of the lighting pattern and the PCB. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. 
     The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.