Patent Publication Number: US-11041615-B2

Title: Light emitting diode (LED) lighting system

Description:
The current application claims a priority to the U.S. Provisional Patent application Ser. No. 62/798,318 filed on Jan. 29, 2019. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a light emitting diode (LED) lighting systems. More specifically, the present invention is a LED lighting system that allows for the maintenance and replacement of a light emitting diode-chip on board (LED-COB). 
     BACKGROUND OF THE INVENTION 
     In conventional lighting systems, light emitting diodes (LEDs) are permanently soldered to their substrate, often referred to as a printed circuit board (PCB) or metal core printed circuit board (MCPCB). PCBs come in many varieties; some rigid, some flexible, but all are considered PCBs. More specifically, some PCBs used in LED lighting system are referred to as a light emitting diode-chip on board (LED-COB). It should be noted that PCBs, MCPCBs, and LED-COBs can all be generically referred to as substrates. These substrates are electrified or electrically powered in order to cause the LEDs thereon to illuminate. Typically, when LED-COBs are manufactured, they have an exposed positive and negative junction (i.e., a P-N junction) on the “top side” (i.e., the side in which LEDs are affixed). This P-N junction includes a positive contact and a negative contact used for testing the LED-COB in testing chambers. The LED-COB is momentarily electrified or powered up. The testing chamber collects data on the light emitted and verifies that the LED-COB meets the applicable design specifications. These LED-COBs are typically incorporated in permanent housings, for example, streetlights, movie lights, light bulbs, etc., with electrical wiring permanently soldered to the P-N junction to the top side of the LED-COB. As a result, when the LEDs fail, the entire lighting is thrown away. This is somewhat analogous to disposing of an entire lamp every time a light bulb fails. 
     Therefore, it is an objective of the present invention to provide a LED lighting system that allows for the maintenance and replacement of a LED-COB. The present invention includes an arrangement of components that allows an individual to remove a faulty LED-COB in order to replace it with a new LED-COB. Additionally, the present invention allows an individual to use different LED-COBs when desired and/or upgrade to a newer model of LED-COBs. The present invention includes a means in order to electrify an LED-COB by traversing electrical conductors through a heat sink in a safe and efficient manner. Further, the present invention positions the positive and negative contacts to the the back side of an LED-COB. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the present invention. 
         FIG. 2  is an exploded top perspective view of the present invention. 
         FIG. 3  is an exploded bottom perspective view of the present invention displaying the plate cover, the substrate, the first contact, the second contact, the first electrical conduit, and the second electrical conduit. 
         FIG. 4  is a side view of the present invention. 
         FIG. 5  is a cross-sectional view taken along line  5 - 5  from  FIG. 4 . 
         FIG. 6  is a schematic diagram displaying the electrical connections of the present invention. 
     
    
    
     DETAIL DESCRIPTIONS OF THE INVENTION 
     All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention. 
     In reference to  FIGS. 1 through 6 , the present invention is a light emitting diode (LED) lighting system that allows for the maintenance and replacement of a light emitting diode-chip on board (LED-COB). Additionally, the present invention allows an LED-COB to be electrified by traversing electrical conductors through a heat transfer device. The present invention comprises at least one illumination system  1 , a plate cover  19 , a substrate  21 , a heat sink  24 , and a direct current (DC) power supply  28 . The at least one illumination system  1  is the light source of the present invention. In further detail, the at least one illumination system  1  is an LED chip. The substrate  21  is preferably a printed circuit board and preferably combines with the at least one illumination system  1  in order to form a LED-COB. The plate cover  19  is used to protect and conceal substrate  21  with the at least one illumination system  1  and to fasten the substrate  21  with the at least one illumination system  1  to the heat sink  24 . Further, the plate cover  19  is used to apply a compressive force to the substrate  21  with the at least one illumination system  1 . The heat sink  24  is used to absorb and dissipate heat produced by the at least one illumination system  1 . The DC power supply  28  is used to electrify the at least one illumination system  1 . The DC power supply  28  may be a current rectifier which allows the present invention to be plugged into a power outlet or may be a portable energy source such as, but not limited to, a rechargeable battery. 
     The general configuration of the aforementioned components allows for the maintenance and replacement of a LED-COB. With reference to  FIGS. 1 and 2 , the at least one illumination system  1  comprises an LED assembly  2 , a first contact  3 , and a second contact  4 . The LED assembly  2  is array of LEDs that forms the illuminating source of a LED chip. The first contact  3  and the second contact  4  is respectively the positive-negative junction of a LED chip. The substrate  21  comprises a first face  22  and a second face  23 . The LED assembly  2  is mounted onto the first face  22 , and the first contact  3  and the second contact  4  are mounted onto second face  23 . This arrangement forms a LED-COB between the substrate  21  and the at least one illumination system  1 . However, the positive-negative junction is on the second face  23  (backside) of the substrate  21  rather than the first face  22  (frontside) as found in conventional LED-COBs. The plate cover  19  is positioned adjacent to the first face  22 , and the heat sink  24  is positioned adjacent to the second face  23 . This arrangement positions the substrate  21  in between the plate cover  19  and the heat sink  24 . Further, the substrate  21  is compressed in between the plate cover  19  and the heat sink  24  in order to mitigate any vibration produced when the LED assembly  2  is powered on. The LED assembly  2  is in thermal communication with the heat sink  24  in order for the heat sink  24  to absorb and dissipate heat produced by the LED assembly  2  when powered on. With reference to  FIGS. 5 and 6 , the DC power supply  28  is positioned adjacent to the heat sink  24 , opposite to the second face  23 . This arrangement positions the DC power supply  28  in order to power the substrate  21  through the heat sink  24 . The first contact  3  and the second contact  4  are electrically connected to the DC power supply  28  in order for the DC power supply  28  to electrify the LED assembly  2 . Moreover, the electrical connection between the first contact  3 , the second contact  4 , and the DC power supply  28  traverses through the heat sink  24 . This arrangement eliminates the need to permanently solder the DC power supply  28  to the at least one illumination system  1 . 
     With reference to  FIGS. 1 and 2 , the present invention may further comprise a releasable attachment mechanism  29  in order to fully secure the plate cover  19  to the heat sink  24  and, thus, to also secure the substrate  21  with the at least one illumination system  1  to the heat sink  24 . The releasable attachment mechanism  29  is preferably a set of fasteners. The plate cover  19  is mounted onto the heat sink  24  by the releasable attachment mechanism  29 . This arrangement allows an individual to disengage the releasable attachment mechanism  29  and to subsequently remove the plate cover  19  when the at least one illumination system  1  requires maintenance or needs to be replaced. 
     With reference to  FIGS. 1 and 3 , the plate cover  19  comprises an aperture  20  that traverses through the center of the plate cover  19 . The aperture  20  allows light produced by the LED assembly  2  to be emitted by the present invention. Thus, the LED assembly  2  is aligned into the aperture  20  of the plate cover  19 . 
     With reference to  FIG. 6 , the at least one illumination system  1  further comprises a first electrical conduit  5  and a first channel  11 . The first electrical conduit  5  allows the DC power supply  28  to be electrically connected to the first contact  3 . The first channel  11  is a passageway that allows the first electrical conduit  5  to reach the first contact  3  through the heat sink  24 . Thus, the first channel  11  traverses through the heat sink  24  towards the first contact  3 , and the first electrical conduit  5  is positioned within the first channel  11 . Further, the first contact  3  is electrically connected to the DC power supply  28  through the first electrical conduit  5 . Thus, the DC power supply  28  is able to electrify the first contact  3 . 
     With reference to  FIG. 2 , the first electrical conduit  5  comprises a first conductive rod  6 , a first insulative cover  9 , and a first pogo pin  10 . The first conductive rod  6  is used to pass electrical energy from the DC power supply  28  to the first contact  3 . The first conductive rod  6  is preferably made of copper to optimize the conduction of electrical energy. The first insulative cover  9  is used to insulate the electrical energy being passed through the first conductive rod  6  and, thus, prevent the heat sink  24  from being electrified. The first pogo pin  10  is used to provide a compressive force in order to mitigate vibrations produced by the LED assembly  2  when in use. The first conductive rod  6  comprises a first proximal end  7  and a first distal end  8 . The first conductive rod  6  is sleeved by the first insulative cover  9  in order to prevent the heat sink  24  from being electrified when electrical energy is passed from the DC power supply  28  to the first contact  3 . The first pogo pin  10  is connected onto the first proximal end  7  and is pressed against the first contact  3 . This arrangement positions the first pogo pin  10  in order to establish the electrical connection between the first contact  3  and the DC power supply  28 . Additionally, this arrangement allows the first pogo pin  10  to provide a compressive force to the second face  23  in order to mitigate vibrations produced by the at least one illumination system  1 . Moreover and with reference to  FIG. 5 , the first distal end  8  is electrically connected to the DC power supply  28  in order for the first conductive rod  6  to pass electrical energy from the DC power supply  28  to the first contact  3 . 
     Similarly and with reference to  FIG. 6 , the at least one illumination system  1  further comprises a second electrical conduit  12  and a second channel  18 . The second electrical conduit  12  allows the DC power supply  28  to be electrically connected to the second contact  4 . The second channel  18  is a passage that allows the second electrical conduit  12  to reach the second contact  4  through the heat sink  24 . Thus, the second channel  18  traverses through the heat sink  24  towards the second contact  4 , and the second electrical conduit  12  is positioned within the second channel  18 . Further, the second contact  4  is electrically connected to the DC power supply  28  through the second electrical conduit  12 . Thus, the DC power supply  28  is able to electrify the second contact  4 . 
     With reference to  FIG. 2 , the second electrical conduit  12  comprises a second conductive rod  13 , a second insulative cover  16 , and a second pogo pin  17 . The second conductive rod  13  is used to pass electrical energy from the DC power supply  28  to the second contact  4 . The second conductive rod  13  is preferably made of copper to optimize the conduction of electrical energy. The second insulative cover  16  is used to insulate the electrical energy being passed through the second conductive rod  13  and, thus, prevent the heat sink  24  from being electrified. The second pogo pin  17  is used to provide a compressive force in order to mitigate vibrations produced by the LED assembly  2  when in use. The second conductive rod  13  comprises a second proximal end  14  and a second distal end  15 . The second conductive rod  13  is sleeved by the second insulative cover  16  in order to prevent the heat sink  24  from being electrified when electrical energy is passed from the DC power supply  28  to the second contact  4 . The second pogo pin  17  is connected onto the second proximal end  14  and is pressed against the second contact  4 . This arrangement positions the second pogo pin  17  in order to establish the electrical connection between the second contact  4  and the DC power supply  28 . Additionally, this arrangement allows the second pogo pin  17  to provide a compressive force to the second face  23  in order to mitigate vibrations produced by at least one illumination system  1 . Moreover and with reference to  FIG. 5 , the second distal end  15  is electrically connected to the DC power supply  28  in order for the second conductive rod  13  to pass electrical energy from the DC power supply  28  to the second contact  4 . 
     With reference to  FIGS. 1 and 2 , the present invention may further comprise an enclosing receptacle  30  in order to protect and conceal the heat sink  24  and the DC power supply  28 . Thus, the heat sink  24  and DC power supply  28  are positioned within the enclosing receptacle  30 . This arrangement further provides electrical safety measures for the present invention. The plate cover  19  is perimetrically mounted to a rim  31  of the enclosing receptacle  30 . This arrangement protects and conceals the at least one illumination system  1  and the substrate  21 . The plate cover  19  may be mounted to the enclosing receptacle  30  through a variety of methods including, but not limited to, using a set of fasteners, or being press-fitted. 
     With reference to  FIG. 2 , the present invention may further comprise at least one cooling assembly  32  in order to dissipate heat that is absorbed by the heat sink  24 . The at least one cooling assembly  32  comprises a vent  33  and a fan  34 . The vent  33  allows heat to be released from the present invention. The fan  34  is used to improve airflow within the present invention. Further, the fan  34  is used to directly cool the heat sink  24  and to direct heat out of the present invention. In order for the vent  33  to release heat from the present invention, the vent  33  is integrated into the enclosing receptacle  30 . The fan  34  is mounted within the enclosing receptacle  30 , adjacent to the vent  33 . This arrangement allows the fan  34  to direct heat out of the present invention. Further and with reference to  FIG. 6 , in order for the fan  34  to be electrically powered, the fan  34  is electrically connected to the DC power supply  28 . 
     With reference to  FIG. 2 , the present invention may further comprise an electrically-insulating plate  35  in order to prevent the heat sink  24  from being electrified when the LED assembly  2  is powered on. The electrically-insulating plate  35  is compressed in between the second face  23  and the heat sink  24 . This arrangement prevents electricity from being conducted between the at least one illumination system  1  and the heat sink  24 . 
     With reference to  FIGS. 2 and 3 , the present invention may further comprise a quantity of thermal paste  36  in order to improve the heat transfer between the at least one illumination system  1  and the heat sink  24 . The LED assembly  2  is in thermal communication with the heat sink  24  by the quantity of thermal paste  36 . This arrangement allows the heat produced by the LED assembly  2  to be efficiently transferred to the heat sink  24  in order to prevent thermal failure of the at least one illumination system  1 . 
     With reference to  FIG. 2 , the heat sink  24  may further comprise a first plate  25 , a second plate  26 , and a plurality of fin pins  27 . The first plate  25  is positioned adjacent to the second face  23  and is preferably made of copper. This improves heat conduction between the at least one illumination system  1  and the heat sink  24 . The second plate  26  is positioned adjacent to the first plate  25 , opposite to the second face  23 , and is preferably made of aluminum. This allows the heat sink  24  to dissipate heat transferred from the at least one illumination system  1 . The plurality of fin pins  27  is connected normal to the second plate  26 , opposite to the first plate  25 , and is oriented away from the first plate  25 . Further, the plurality of fin pins  27  is evenly distributed across the second plate  26 . The plurality of fin pins  27  further improves the heat dissipation of the heat sink  24 , and, thus, this arrangement efficiently removes heat transferred from the at least one illumination system  1 . 
     The main objective of the present invention is to allow easy maintenance and replacement of a LED-COB. This can be accomplished using the following instructions. An individual can easily remove the at least one illumination system  1  by first removing the enclosing receptacle  30  from the plate cover  19 . After this step is done, the individual can remove the plate cover  19  from the heat sink  24  which will expose the substrate  21  with the at least one illumination system  1 . Then, the individual can disconnect the at least one illumination system  1  from the DC power supply  28  by disconnecting the first electrical conduit  5  from the first contact  3  and by disconnecting the second electrical conduit  12  from the second contact  4 . The quantity of thermal paste  36  must be cleaned off the heat sink  24  after the substrate  21  with the at least one illumination system  1  is removed. Now, the individual can provide maintenance to the at least one illumination system  1  or replace the at least one illumination system  1 . Additionally, the individual can remove the at least one illumination system  1  if the individual simply desires to use a different LED assembly  2  or a newer version of a LED assembly  2 . 
     Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.