Abstract:
An electrical connector comprising, in combination a body defining first and second electrical terminal entry ports, the first entry ports including four ports, there being an LED unit having pin terminals respectively received in three of said four ports, three of said pin terminals adapted for delivering controllable electrical current for controlling color emitted by the LED unit, another of said pin terminals received in a fourth one of said four ports.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates generally to generating, and transmission of light, as from different LED sources; and more particularly concerns improvements in compact arrangement of entry ports for LED pin terminals, in electrical connectors. 
     There is need for improvements in apparatus and method to overcome deficiencies and problems with incompatibility of pin terminal entry ports of prior connections. 
     SUMMARY OF THE INVENTION 
     It is a major object of the invention to provide improved apparatus and methods as referred to. Basically the invention provides an improved electrical connector that comprises 
     a) a body defining first and second electrical terminal entry ports, 
     b) the first entry ports including a group of four ports, 
     c) there being an LED unit having pin terminals respectively received in three of said four ports, three of such pin terminals adapted for delivering controllable electrical current for controlling color emitted by the LED, 
     d) another of said LED pin terminals received in a fourth one of the ports to provide an electrical common. 
     As will be seen, and in addition, the second entry ports may include two ports which are spaced closer together than any two of said group of four ports. Those two second entry ports are typically located in interspersed relation with the first entry ports, as for example within an a real zone defined by the first four entry ports. 
     Another object include provision of female electrical terminals in alignment with the first and second entry ports; and typically four of the female electrical terminals associated with the first four entry ports are adapted to receive the four pin terminals of a selected LED. Likewise, two of the female terminals associated with the second entry ports are adapted to receive two pin terminals of another selected LED, whereby the six ports of the connector are compatible with the pins of either of the two LEDs. 
     A further object is to provide each female terminal to have a sleeve, a tapered guide surface within said sleeve, and a spring finger having an edge to frictionally engage the surface of an LED unit terminal pin received in the sleeve. 
     A yet further object is to provide 
     a) a holder in the form of a socket at one end of the holder and a connector at the opposite end of the holder, 
     b) internal threads in the holder to threadably connect to an lens unit, 
     c) the connector having terminal ports, 
     d) and an LED unit having a light transmitting end received into the holder, said unit having pins received into said connector ports, for electrical connection to circuitry that energizes one or more LEDs in said unit. 
     As will be seen, six of such ports may be provided; and three of such ports may be in one row to define a first plane with another three of the ports in another row to define a second plane, the planes being parallel. Alternatively the ports in each row may be staggered. 
     Yet another object is to provide an LED to connector coupling method that includes 
     a) selecting one of two LED units, the first characterized as having four pin terminals, and the second characterized as having two pin terminals, 
     b) and inserting the pin terminals of the selected LED unit into one of said connector first entry ports and second entry ports spaced apart, and typically interspersed, to receive said pin terminals. 
     That method may typically also include providing electrical female terminals in alignment with said entry ports to receive insertion of said related pin terminals. 
     Further a hollow lens may be provided in alignment with the LED unit, and to internally receive the LED unit within a cavity in the hollow lens, for extreme compactness. 
    
    
     These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which: 
     DRAWING DESCRIPTION 
     FIG. 1 is a side elevational view of the preferred form of threaded lens; 
     FIG. 2 is an end elevation taken on lines  2 — 2  of FIG. 1; 
     FIG. 3 is a lengthwise section taken on lines  3 — 3  of FIG. 2; 
     FIG. 4 is a right end elevation of a lens holder, defining a connector having six terminals; 
     FIG. 5 is a section taken on lines  5 — 5  of FIG. 4; 
     FIG. 6 is a view like FIG. 5, but rotated 90° about an axis defined by the holder; 
     FIG. 7 is a left, end elevation of the holder taken on lines  7 — 7  of FIG. 6; 
     FIG. 8 is a section taken through an alternative lens holder in the form of an interiorly threaded retaining ring; 
     FIG. 9 is an end view of the FIG. 8 ring, taken on lines  9 — 9  of FIG. 8; 
     FIG. 10 is a side elevation taken on lines  10 — 10  of FIG. 9; 
     FIG. 11 is a side view of a terminal plug with four pins useful to plug into four receptacle terminals as seen in FIG. 4; 
     FIG. 12 is an enlarged view of a receptacle terminal; 
     FIG. 12 a  is an end view taken on lines  12   a — 12   a  of FIG. 12; 
     FIG. 13 is an enlarged view of a receptacle terminal receiving endwise reception of a terminal pin; 
     FIG. 14 is a view like FIG. 13 showing centering and interference connection of the pin to the terminal; 
     FIG. 14 a  is an end view taken on lines  14   a — 14   a  of FIG. 14; 
     FIG. 15 is a side elevation showing a plug or LED unit carrying an LED or LEDs, and having two terminal pins; 
     FIG. 15 a  is an end view taken on lines  15   a — 15   a  of FIG. 15; 
     FIG. 16 is a top plan view showing another form of plug or LED unit carrying an LED or LEDs, and having four terminal pins; 
     FIG. 16 a  is a side elevation taken on lines  16   a — 16   a  of FIG. 16; 
     FIG. 16 b  is a side elevation taken on lines  16   b — 16   b  of FIG. 16; 
     FIGS. 17-20 are enlarged fragmentary sections showing progressive connectors of an interiorly threaded retaining ring to an exteriorly threaded lens, in relation to a mounting panel; 
     FIG. 21 is axially exploded view of a threaded lens, threaded retainer ring and a locking ring also serves as a moisture seal, this being a preferred application of the threaded lens; 
     FIG. 22 is a view of the FIG. 21 components, in axially assembled relation; 
     FIG. 23 is a view like FIG. 22, showing the locking ring and moisture seal component assembled in an alternate position; 
     FIG. 24 is an exploded view of a threaded lens, threaded holder with connector terminals, pin terminals; LED plug having four terminals, and locking ring and in relation to a mounting panel; 
     FIG. 25 is a section showing the assembled positioning of the lens, panel and locking ring of FIG. 24; 
     FIG. 26 is a section showing the assembled positioning of the holder, LED plug, connector receptacle terminals, and supply power pin terminals; 
     FIG. 27 is an axially exploded view of a threaded lens, threaded holder with connector terminals; pin terminals, the LED plug having two terminals; and locking ring, in relation to a mounting panel; 
     FIG. 28 is a section showing assembled positioning of the holder, locking ring, LED plug, connector receptacle terminals and supply power pin terminals, of the FIG. 27 components; and 
     FIG. 29 is like FIG. 28, but showing the locking ring in position forward of the mounting panel. 
     FIG. 30 is a view like FIG. 4, showing in right end elevation a modified lens holder, defining a connector having six terminals; 
     FIG. 31 is a section taken on lines  31 — 31  of FIG. 30; 
     FIG. 32 is a view like FIG. 31, but rotated 90° about an axis defined by the FIG. 30 holder; 
     FIG. 33 is a left end elevation of the FIG. 30 holder, taken on lines  33 — 33  of FIG. 32; 
     FIG. 34 is a top plan view of a plug carrying an LED or LEDs, and having six terminal pins, that plug to be inserted into the FIG. 30 holder; 
     FIG. 35 is a side elevation taken on lines  35 — 35  of FIG. 34; and 
     FIG. 36 is a side elevation taken on lines  36 — 36  of FIG.  34 . 
    
    
     DETAILED DESCRIPTION 
     Referring first to FIGS. 1-3, a lens  10  is adapted to be secured to a holder, to be described, for transmission of light, as for example from an LED or LED array. The lens  10  has a body  10   a  defining a central axis  11 , and the body is shown as generally cylindrical defining an inner surface or bore  11 , an outer surface  12 , and opposite ends  13  and  14 . End  14  is shown in the form of an integral cap having a dome  14   a , and an outwardly projecting annular flange  14   b . The inner side of the dome defines Fresnel rings  15 , for diffracting light rays impinging in direction  17  on the rings, diffused light exiting from the convex outer side  18  of the dome. The body may consist of molded plastic material. 
     Threading indicated at  19  is formed on the lens body extending about said axis, for reception in threading associated with the holder. Such threading spirals about axis  11 , while advancing in direction  17 , as shown. Typically, multiple such threads  19   a  are employed, and are alike. The threads are foreshortened in length to allow for tightening into mating internal threading associated with the holder, to be described, in less than one full rotary turn of the lens  10 , relative to the holder. Each thread  19   a  extends only part way about the axis  11  at the lens body periphery, and preferably six threads  19   a  are employed, each of which extends only about half way (180°) about axis  11 . 
     FIGS. 5,  6  and  24  show one form of lens holder  25 , which is also integral with a reduced diameter connector  25   a  at one end  26  of the holder. The opposite end  27  of the holder is centrally open at  27   a , for threaded reception of the lens body  10   a , as the holder is rotated. At that time, the lens is typically retained by or mounted to a panel  28 , as shown in FIG. 25, with a locking ring  29  mounted on the lens body and engaging wall  28   a  of the panel, and lens flange  14   b  engaging the opposite wall  28   b  of the panel. 
     FIGS. 17-20 and  21 - 23  also show provision of a modified lens holder in the form of a retaining ring  31 . That ring has internal threads at  32 , the same as the internal threads  30  the holder  25 . See also FIGS. 8-10. 
     Lens threads and connector mating threads  30  or retaining ring threads are formed to permit the mating parts to be pushed onto the lens and then with a half a turn, secure the two parts together. This feature prevents the wire leads protruding from the connector as at  85  from being twisted during installation. Additional turning of the connector during assembly would tend to cause excessive torque on the wires, which would cause an opposing twisting action on the connector. 
     The pitch of the threads allows for the connector or retaining ring and lens to be secured in only one full turn. The connector and retaining ring typically have six separate half threads, equally spaced wrap around the diameter. The lens mating six threads have two full turns which permits the units to be secured to varying panels from a 32 nd  of an inch to ¼ th  inch thick. 
     The mating lens and connector or retaining ring are configured to be secured by hand tightening. If the connector or retaining ring are tightened past the secure point, then the threads will slip back onto a previous thread, as by over crest slippage seen in FIGS. 19 and 20. This feature prevents the plastic threads of the lens, connector or retaining ring from being stripped. 
     When a rubber grommet is used between the panel and the connector or retaining ring it functions as a locking unit. As the connector or retaining ring is tightened the grommet will compress. This compression causes back pressure on the threads of the mating parts providing a locking means. 
     When a rubber seal is installed between the lens and the panel it prevents the entry of water and dust through the panel opening. 
     FIGS. 17-20 show the thread interfitting sequence of the lens and holder elements, and the functioning of the compressible locking ring  29 , which may consist of elastomeric material, such as rubber. 
     Note in FIGS. 22 and 23 the reception of an LED plug type unit  34  into the interior  10   c  of the lens  10 , with the dome  34   a  of unit  34  proximate the Fresnel rings at the concave interior side of the lens cap end  14 . The leads  37  of the LED unit project from or through a circuit board  38  to which the leads are mounted, to support the unit  34 . A flange  34   b  on unit  34  is closely received in the bore of the lens, at location  40 , for centering. The lens has threaded attachment to the holder  31  as shown, and as described above. Holder ring  31  includes integral annular stiffeners  41  projecting outwardly. Ring  31  may consist of molded plastic material. 
     FIGS. 27 and 28 show the plug type LED unit  34  assembled to a connector  25   a  as described above, the internal threads of holder  25  assembled to the lens threads at  44 . The domed end  34   a  of unit  34  is received into the lens interior as described above; and locking ring  29  is held in compressed condition between the left end face of the holder and the panel  28 . The two pins or leads  37  of the LED unit are received into two parallel female terminals  46  received into and carried by slots  47  in the connector  25   a.    
     FIGS. 12-14 show progressive reception of a pin or lead  37  into a terminal  46 . The tapered end  37   a  of the pin or lead penetrates into the tubular body  50  of the terminal, and between tapered guide  51  and internal barb  52 . The guide and barb project laterally into the interior  50   a  of the body  50 , with the guide slidably guiding the pin, and the barb  52  having an edge  52   a  riding along the side of the pin, with friction, to center the pin in the interior  50   a . Edge  52   a  also gouges into the side of the pin to block endwise retraction or loosening of the pin from the terminal. Both  51  and  52  are resilient cantilever spring fingers. Wiring is retained to  46  at  46   a.    
     Another form of LED unit is seen at  60  in FIGS. 11,  16 ,  16   a  and  16   b . Unit  60  has a polygonal body  61 , a domed end  62  from which light is emitted, and four pins  63  located at corners of a square. Those pins or leads are adapted to receive controlled electrical energization as from a circuit  64 , to control different colored light emission from three LEDs in the unit, the fourth pin being a common or ground. Color emission from unit  60  can thereby be controlled, by light color mixing within  60 , for emission from domed end  62 . FIGS. 24 and 26 show pins or leads  63  endwise received within, and electrically connected, to four female terminals  65 . The latter are in turn received in four slots  66  in the connector  25   a . A control circuit appears at  64 , as in FIG.  16 . See also FIGS. 5 and 6. 
     The connector  25   a  of FIGS. 4-7 is configured to receive the pins of either type LED unit,  34  or  60 , i.e. it has four slots  66  at corners of a square, to receive the four terminals  65  of a unit  60 . It also has two slots  47  to receive terminals  46  of a unit  43 . Slots  47  are located within the square (see FIG. 7) defined by slots  66 . A highly versatile and compact connector  25   a  is thereby provided. 
     The connector terminals also provide a method of extracting heat from the LED, which prevents over heating and extends the operating life of the device. 
     From the foregoing, it will be seen that the holder body  25  defines a less holder having a receptacle portion with internal threading to receive an externally threaded lens to transmit light of a controlled color emitted by the LED unit. The lens holder body may define a reduced size connector portion  25   a , as at one end of the holder, and containing said first and second entry ports. The LED unit has a light emitting zone received in said holder receptacle portion, between said internal threading and said first and second entry ports in said connector portion. 
     Referring now to FIGS. 30-36, they show a modified form of the invention in which the holder body  75  defines first and second pairs of electrical terminal entry ports, and an additional pair of entry ports. See for example the first two entry ports  81  and  86 ; the second two entry ports  83  and  84 ; and the additional pair of entry ports  82  and  85 . 
     Electrical sleeve terminals to be received in those ports appear at  81 ′ and  86 ′;  83 ′ and  84 ′; and  82 ′ and  86 ′. Such terminals correspond to  46  in FIGS.  12 - 14 . Ports  82  and  86  are located, i.e. interspersed or interposed relation section, ports  81  and  86 , and ports  83  and  84 . Ports  81 ,  82  and  83  define a primary plane  88 ; and ports  84 ,  85  and  86  define a secondary plane  89 , parallel to  88 . 
     A representative LED unit, with six pin terminals, is seen at  90 . Pin terminals  91  and  96  are respectively receivable in sleeve terminals  81 ′ and  86 ′; LED unit pin terminals  93  and  94  are respectively receivable in sleeve terminals  83 ′ and  84 ′; and LED unit pin terminals  92  and  95  are respectively receivable in sleeve terminals  821  and  85 ′. Three LEDs in  90  appear schematically at  101 ,  102  and  103 , where LED  101  is electrically connected between pin terminals  91  and  96 ; LED  102  is electrically connected between pin terminals  93  and  94 ; and LED  103  is electrically connected between pin terminals  92  and  95 . Controllable circuitry  104  controls energization of LED  101 ; controllable circuitry  105  controls energization of LED  102 ; and controllable circuitry  106  controls energization of LED  103 . Sockets  111  in  75  limit insertion of the Led pin terminals  91 - 96 . The LED head  90 ′ is then received in internal zone  112 , in  75 . 
     It will also be noted that holder  75  is hollow and open at end  114 ; and internal threads  116  are provided to mesh with lens threading, of the type seen in prior figures, such as in FIGS. 1 and 21.