Patent Document

[0001]    This application claims the benefit of U.S. patent application Ser. No. 60,266,354 filed Mar. 21, 2001. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present invention relates to low voltage lighting systems and, more particularly, to multicolor illumination systems with flexible supports for forming shaped configurations of lights.  
           [0003]    Backlit devices such as signs, cove lighting and pool lighting often utilize various configurations of lights (or lamps) to follow predetermined paths that may have linear portions and/or non-linear portions such as bends. For example, signs are commonly made with “channel letters” which are backlit. It is known to achieve such backlighting by mounting light bulbs behind the letters so that light either illuminates opaque lettering in a transparent or translucent face or shines through translucent letters in an opaque face. In either case, the bulb placement produces bright areas at the bulb locations with less bright areas away from the bulb location.  
           [0004]    Similarly, it is known to employ commercially available round top light emitting diodes (LED) for backlighting. However, round top LEDs are also known to produce bright spots, which detract from the aesthetics of the backlighting effect. Backlighting is most effective when there is a wide angle of evenly distributed light to fill the structure being backlit. Chip-type LEDs have been used to overcome the creation of bright spots principally because of their wide viewing angle. One difficulty encountered with using chip-type LEDs on a standard circuit board is that they tend to break or come loose when the board is flexed due to the manner by which they are attached to the board. Conventional LEDs may also break, become dislodged or inhibit the flexibility of a standard circuit board when attached in a conventional manner. For example, conventional LEDs may be affixed to a circuit board so the body of the LED is perpendicular to one of the board&#39;s planar surfaces. If the base of the LED is affixed to the surface of the board with an epoxy or adhesive then the surface area of the board where the LED is affixed becomes more rigid and the board loses some of its flexibility. LEDs affixed in this manner are susceptible to breakage or coming loose when the board is flexed. An alternate method of backlighting uses fiber-optic cables to deliver light from a remote source to the device to be lit. Diffusing lenses may be used at the cable end to spread the light and minimize the bright areas characteristic of bulb lighting.  
           [0005]    Backlighting and other needs for lighting effects frequently require a range of color and light intensities. They may also require that the housing or supporting structure for the lights be flexible so that the lights may conform to a variety of shapes or patterns during installation in order to achieve a desired illuminating effect. Also, it may be desirable to have the lights connected with a flexible base so the lights extend perpendicular from a planar surface of the base for specific applications. It is known to configure flexible “strips” of lights in various manners. For example, U.S. Pat. No. 4,597,033 to Meggs. et al. discloses a flexible elongated lighting system adapted for use primarily as an emergency lighting system. This lighting system comprises an elongated flexible waterproof housing member that is capable of a directional transmission of light towards an optimum predetermined field angle. The housing member is transparent and can be bent to define a subjective outline of an exit. A plurality of individual lighting elements is electrically mounted in parallel in the housing member and spaced along a substantial portion of its length. The housing member is provided with a variable thickness upper portion to optimize both refraction and reflection of the generated light and with a lower portion to facilitate the mounting and positioning of the lighting elements along the length of the housing member and also to a support structure. The lighting elements may be light emitting diodes.  
           [0006]    Another example of a flexible lighting array is disclosed in U.S. Pat. No. 4,173,035 to Hoty, which discloses a tape strip having a plurality of light emitting diodes connected therewith to create a moving light display. The strip includes a plurality of light emitting diodes extending perpendicularly from one planar surface of the tape. The diode leads are inserted into a plurality of apertures and soldered and electrically connected to printed circuits. Another light strip disclosed in U.S. Pat. No. 5,746,497 to Machida describes a row of light emitting diodes arranged along the edge of a base plate rather than extending from a planar surface. Adjacent diodes share common leads that extend perpendicularly to the longitudinal axis of the strip. The leads are on one side of the strip and are connected by a conducting material that extends as a flat strip parallel with the longitudinal axis of the base plate. In this respect, the base plate is not susceptible to being flexed to conform to various configurations, if desired, because the connections between the leads could be damaged or break due to being flexed transverse to their longitudinal axis. This may cause an undesired failure of one or more of the lights in the row.  
           [0007]    In view of the above, it would be advantageous to provide a flexible strip with lighting elements attached thereto that could conform to a variety of shapes and contours while ensuring the integrity of the electrical connections. Providing the flexible strip with high intensity lighting elements having a wide viewing angel for a more even distribution of light is desirable. It would also be advantageous to provide a means for mounting a flexible strip to a support surface and allow for a plurality of flexible strips to be connected mechanically and electrically to form a longer assembly if desired.  
         SUMMARY OF THE INVENTION  
         [0008]    The present invention provides a flexible strip that may have a plurality of lighting elements advantageously attached thereto so that the strip may conform to a wide variety of shapes without impairing the integrity of electrical connections between lighting elements. In one exemplary embodiment light-emitting diodes (LEDs) may be provided as the lighting elements. One aspect of the present invention allows for a system for mounting and installing LEDs in various configurations. A flexible printed circuit board such as a commercially available PC board made of fiberglass, for example, may be provided to which a plurality of LEDs may be connected in accordance with one aspect of the present invention. The LEDs may be arranged with a fixed amount of space between sequential LEDs to provide an evenly distributed lighting effect. Other embodiments may space the LEDs in various arrangements.  
           [0009]    Each flexible PC board may be provided at one or both ends with a connector allowing it to be connected mechanically and electrically in series with other boards to form longer assemblies as desired. A single board or a plurality of boards connected in series is advantageous in that they may be mounted on one edge, that is, so the board is in an upright position. The light emitting elements may be connected to the board so they extend longitudinally from the board&#39;s upper edge when installed. This configuration advantageously conforms to fit letters for signs, cove lighting, pool lighting, channel letters, twisting about a column and other applications requiring linear and/or non-linear lighting. It also allows for the flexible board to be easily mounted to a support surface that is substantially parallel with the base. If desired, two or more boards may be mounted in parallel to accommodate wide lettering, for example.  
           [0010]    Each flexible circuit board may be produced in a conventional manner with electrical conductors formed on one or both planar surfaces of the board in accordance with one aspect of the present invention. The layout of the board may be designed such that any electrical component, such as the electrical conductors or a resistor, mounted to the board is positioned so its lengthwise axis is generally transverse or perpendicular to the longitudinal axis of the board. This orientation is advantageous in that it minimizes any stress applied to the components when the board is flexed or bent about an axis substantially normal to the board&#39;s longitudinal axis. That is, when the board is flexed along its longitudinal axis the stress on the components is minimize due to their orientation. In contrast, if an electrical component were mounted to the board with its length generally parallel to the board&#39;s longitudinal axis the component may resist bending when the board is flexed or bent in this manner. This may cause damage to or break the component.  
           [0011]    Electrical conductors may be provided on the board and may include a plurality of pads or terminations adapted for electrical connection to conductors of a light-emitting element such as LEDs, for example. Each LED typically has a pair of corresponding conductors or leads in the form of small gauge wire. The LED leads may be soldered to the terminations on the flexible board. The terminations may be arranged in adjacent pairs on the flexible board such that the LEDs can be positioned with their respective leads on corresponding terminations and soldered in place. In this exemplary embodiment, each termination&#39;s length may be oriented substantially transverse to the longitudinal axis of the flexible circuit board to minimize stress applied to a termination when the board is flexed or bent. Each termination may desirably extend so that a distal end is proximate the upper edge of the board. This arrangement allows the connected LEDs to extend longitudinally from the upper edge of the board. Both LED leads may be connected to terminations formed on the same side, or planar surface, of the board if desired.  
           [0012]    In another exemplary embodiment, the electrical conductors may be arranged on both or opposite planar surfaces of the board such that each termination of a pair of terminations is located on a planar surface of the circuit board opposite the other. In other words, one termination is on one planar surface of the board and the matching termination for connecting to a lighting element is on the opposite planar surface. In this respect, an LED may be positioned to extend from an edge of the board where one LED lead is connected to each surface of the board. This aspect, as well as connecting both LED leads to the same side of a board, is advantageous in forming the board along bends, around corners or following cursive lettering, for example, while maintaining the integrity of the electrical connections and avoiding breakage of the LED.  
           [0013]    One aspect of the present invention allows for means for mounting the flexible circuit board to a supporting surface such as one that is oriented parallel to a planar surface of the flexible circuit board. For example, in one embodiment the means for mounting may include a plurality of spaced apertures formed along the length of the circuit board. The apertures may be used to mount the board to a support surface using known mounting implements such as nails or screws. The apertures may also be used to hang a circuit board from hooks affixed to the support surface. Another exemplary embodiment allows for the mounting means to include an elongated structure that is adapted to firmly secure the flexible circuit board by means of a plurality of clips extending from the structure. The structure may include a plurality of slots cut into its base so that the structure is sufficiently flexible to conform to a variety of shapes. A plurality of apertures may be provided within the structure so that it may be mounted to a support surface. In this respect, one aspect of the present invention allows for a method for mounting a flexible circuit board to a support surface. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    [0014]FIG. 1 is an exemplary embodiment of a flexible circuit board contemplated by the present invention;  
         [0015]    [0015]FIG. 2 illustrates an exemplary embodiment of a flexible board and LED mounting arrangement;  
         [0016]    [0016]FIG. 3 is a cross sectional view of FIG. 2 taken along line  3 - 3 ;  
         [0017]    [0017]FIG. 4 is a perspective view of an exemplary embodiment of a mounting means contemplated by the present invention;  
         [0018]    [0018]FIG. 5 illustrates another exemplary embodiment of a flexible circuit board secured within the mounting means of FIG. 4; and  
         [0019]    [0019]FIG. 6. is a cross sectional view of FIG. 5 taken along line  6 - 6 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0020]    [0020]FIG. 1 illustrates an exemplary embodiment of a flexible printed circuit board of the present invention generally referred to as  10 . The flexible printed circuit board  10  may be fabricated by known methods of know materials and may be a standard PC board made of fiberglass, for example. Other materials may be used provided the board  10  may be shaped into various configurations without cracking or breaking and so that any electrical components fabricated within board  10  will not become loose or dislodged from board  10  when it is flexed or bent into shape. This helps to maintain the integrity of any electrical connections affixed to the board. In one exemplary embodiment the board  10  may have a thickness in of about 0.03125 inches and a width of about 0.4 of an inch. A standard PC board with these dimensions provides sufficient flexibility in accordance with one aspect of the invention. The board  10  may be provided in varying lengths but typically may be about 20 inches long.  
         [0021]    The board  10  may include a plurality of conductive pads or terminations  12  arranged in pairs on one planar surface of board  10 , although it will be recognized that additional pairs of terminations  12 , or terminal pairs, may be arranged on the opposite planar surface. In this respect, a plurality of terminations  12  may be provided on one planar surface only or on both planar surfaces of board  10 . Various configurations will be readily apparent to those skilled in the art. For example, terminal pairs  12  could alternate sequentially from one surface of the board to the other along the longitudinal axis of the board  10 . Similarly, groups of terminal pairs  12 , such as four terminal pairs  12  grouped together for example, could alternate sequentially from one surface of the board to the other along its longitudinal axis. Board  10  may be constructed so that terminations  12  are located on one side of board  10  only or the terminations  12  may be located on both sides of board  10  simultaneously. The terminations  12  may be constructed of conventional material that provides electrical conductance to a lighting element when connected. In an exemplary embodiment of the present invention the lighting element may be an LED. Other embodiments may include different terminations depending on the lighting element. For instance, the terminations  12  could be housed in a female connector adapted to receive the male connector of a halogen lamp.  
         [0022]    One embodiment of the present invention allows for the terminations  12  to be arranged on the board  10  so that their length or longitudinal axis          is substantially transverse or perpendicular to the longitudinal axis L of board  10 . This arrangement minimizes stress on the terminations  12  when a portion of the board  10  is flexed or bent about an axis that is substantially normal to the board&#39;s  10  longitudinal axis. In one exemplary embodiment of the present invention the terminals  12  are designed to provide electrical connection with a low-voltage LED, such as LEDs  26  shown in FIG. 2. In one exemplary embodiment a flat top LED having a wide angle of about 60 degrees or greater may be used. It has been determined by the assignee of the present invention that using a flat top LED, such as those available from Agilent Technologies, significantly reduces or eliminates bright spots in the illuminating effect, which are often caused by conventional round top T1 ¾ LEDs. Using flat top LEDs arranged on board  10  in accordance with one aspect of the present invention also achieves a more even dispersion of light. It will be recognized by those skilled in the art that terminals  12  may be designed to provide electrical connection with various other types of lighting elements such as halogen bulbs or other such elements depending on the specific application.  
         [0023]    Low voltage electronics may be provided on the board  10 , for example, for powering the LEDs or a separate voltage source may be provided. The LEDs may be adapted to produce a wide range of colors. For example, LEDs may be provided with the flexible circuit board  10  to produce red, blue, green, white, orange and amber, for example, which when used in combinations may produce almost any desired color. The LEDs may be grouped by color or colors to control the illuminating effect or the flexible circuit board  10  may be provided with a plurality of LEDs that produce the same color. A computer processor may be provided for controlling the red, green and blue LEDs or for controlling any combination of LEDs to produce a desired illuminating effect. One embodiment of the present invention allows for the processor to be programmed so that a momentary low-voltage power interrupt can be used to lock a desired color for illumination. This may be accomplished by pulse width modulation. The power interrupt routine may also stop other preprogrammed routines such as those designed to produce random or planned changes in the preprogrammed illumination schemes.  
         [0024]    One exemplary embodiment of the present invention may include electrical components such as resistors  14  where the resistors  14  may be arranged on the board  10  so that their length is substantially transverse or perpendicular to the longitudinal axis of board  10 . This arrangement minimizes stress on the resistors  14  when a portion of the board  10  is flexed or bent about an axis that is substantially normal to the board&#39;s  10  longitudinal axis. The resistors  14  may be conventional surface mount or hole mount resistors, for example. One aspect of the present invention allows for resistors  14  to be located on one side of board  10  only or the resistors  14  may be located on both sides of board  10  simultaneously. Similarly, terminations  12  and resistors  14  may be fabricated in various combinations on one side of board  10  only or they may be fabricated in various combinations on both sides of board  10  simultaneously.  
         [0025]    One exemplary embodiment of the present invention allows for board  10  to include adjacent pairs of pads  16  spaced along its longitudinal axis. Pads  16  may serve as joints where two or more segments  18  may be disconnected or joined together. For example, board  10  may be fabricated having a plurality of pads  16  in spaced relation. A notch or space may be formed between adjacent pairs of pads  16  to allow the board  10  to be cut into segments  18 . This aspect of the present invention allows for the length of the board  10  to be adjusted for different applications. Each end of a segment  18  may include an adjacent pair of pads  16  that function as a means for connecting one segment  18  to another segment  18 . Each segment  18  may be mechanically and electrically joined to other segments  18  by soldering adjacent pairs of pads  16  together, or by other suitable methods. Pads  16  may also function as a means for a segment  18  to be electrically connected with other components or a power source, for example. For example, an electrical connector may be affixed to the pads  16  for connecting to other devices or the devices could be connected directly to the pads  16 . One or more of the pads  16  may include a hole to facilitate the connections. Each segment  18  may be about  12  inches in length or it may be other lengths as desired. In this respect, each segment  18  may accommodate approximately five pairs of terminations  12  and two resistors  14 . This exemplary embodiment of the present invention allows for five LEDs to be affixed to the board  10  in each segment  18 . It will be recognized by those skilled in the art that the number of terminations  12  and resistors  14  per segment  18  may vary.  
         [0026]    Installation of one or more boards  10  may include means for mounting or affixing the board  10  in position on a support surface. For example, means for mounting board  10  to a support structure may include mounting holes or apertures such as indicated at  20  in FIG. 1 and may be provided in each segment  18 . Mounting holes  20  may be spaced from the terminations  12  and resistors  14  to minimize the risk of damage to those components when the board  10  is being affixed or mounted in place. In an alternate embodiment, as will be described more fully below, it may be preferable to use another means for affixing or mounting the board  10  to a supporting structure, which may provide for an increased ability to control the board&#39;s  10  positioning and bending during installation and/or use. FIG. 2 and  3  illustrate an exemplary embodiment of the present invention where a plurality of LEDs  26  is connected to a board  10 .  
         [0027]    [0027]FIG. 4 shows a perspective view of one exemplary embodiment of a means for mounting the flexible board  10  and generally referred to as  30 . The mounting means  30  may include a base section  32  that may have a plurality of notches  34  formed therein. The notches  34  may extend substantially but not completely across the base section  32  thereby allowing the base section  32  to be bent or flexed at the notches  34 . In an alternate embodiment the base section  32  may be formed of a sufficiently flexible material and would not require notches  34 . In one exemplary embodiment the notches  34  may extend across the base section  32  in opposite directions, as shown in FIG. 4, so that the base section  32  may be flexed to about the same degree in either direction. Alternate embodiments may have notches  34  extending across the base section  32  in only one direction on one side of the base section  32  if desired. Such an embodiment may be useful for forming a specific shape such as a circle or oval, for example. Other embodiments may space notches  34  in a range of patterns along the base section  32  to accommodate any specific need for forming a desired pattern. Another alternate embodiment may include a plurality of notches formed longitudinally within base section  32  or a plurality of apertures to provide sufficient flexibility to the mounting means  30 .  
         [0028]    The mounting means  30  may be constructed of a plastic or other suitable material. Mounting means  30  may include a plurality of holes or apertures  36  extending through the base section  32  for attaching the mounting means  30  to a support structure. A countersunk portion  36   a  may also be provided. A hole  36  may be located between each adjacent pair of notches  34  so that each segment  33  of base section  32  may be independently attached to a support surface. In an alternate embodiment, holes  36  may be formed at various locations along the longitudinal axis of base section  32 . In another alternate embodiment an appropriate adhesive may be used to mount the base section  32  to a support structure rather than holes  36 .  
         [0029]    Mounting means  30  may also include means for securing board  10  to the base section  32  such as a plurality of clips  38  extending substantially perpendicular from an upper surface  37  of base section  32 . The clips  38  may extend upward from the base section  32  and may be sized and shaped so as to receive and retain the flexible board  10 . In one exemplary embodiment each clip  38  may include a first flexible arm  38   a  and a second flexible arm  38   b . The first arm  38   a  and the second arm  38   b  may each have a frontal portion  39  and an overhanging portion  40 . The arms  38   a  and  38   b  may be affixed to the upper surface  37  in an opposing manner so that the frontal portion  39  of first arm  38   a  faces the frontal portion  39  of second arm  38   b . Similarly, in this exemplary embodiment the arms  38   a  and  38   b  may be situated on the upper surface  37  so that the overhanging portion  40  of each arm  38   a  and  38   b  face toward one another. Each overhanging portion  40  may include a substantially beveled portion  41  to facilitate grasping an arm  38   a  or  39   b  so that the arms may be flexed away from each other for inserting a board  10  there between. For example, an end user may place a finger or thumb on the beveled portion  41  to urge that arm away from the other to insert the board  10 . It will be recognize by those skilled in the art that the means for securing the board  10  may be embodied as clips  38  or alternate structures such as being formed similar to alligator clips, hooks or the grasping end of a paper clip, for example.  
         [0030]    In one embodiment of the present invention the first and second flexible arms  38   a  and  38   b  may be affixed to upper surface  37  so that their opposing frontal portions  39  define a space there between viewed along a longitudinal axis of the base section  32 . The space may be substantially the same as the thickness of board  10 . Also, each arm  38   a  and  38   b  may include a lower surface  43  that may be formed as part of the overhanging portion  40 . The lower surface  43  may form a substantially right angle with the frontal portion  39 . One aspect of the present invention allows for the distance between the lower surface  43  and upper surface  37  to be substantially the same as the width of board  10 . The distances between the frontal portions  39  of opposing arms  38   a  and  38   b , and the upper and lower surfaces  37  and  43  provide a secure grasp on the board  10  when inserted within the clips  38  of the mounting means  30 .  
         [0031]    [0031]FIG. 5 illustrates a board  22 , fabricated substantially the same as board  10 , secured within the mounting means  30 . Board  10  is secured within the mounting means  30  in the same manner as shown for board  22  in FIGS. 5 and 6. Board  22  may include one termination on one surface of board  22  and the other termination of a pair on the opposite surface of board  22  rather than both terminations of the pair being on one surface as shown on board  10  in FIG. 1. FIG. 6 illustrates an end view of board  22  where one electrical lead  28  extending from an LED  26  is connected with one of the pair of terminations  12  (not shown) on each surface of the board  22 . In this respect, the electrical leads  28  straddle a top edge  29  of board  22  when connected with the terminations  12 . In this exemplary embodiment the resistors  14  may be in the same or similar locations as those depicted in FIG. 1. In alternate embodiments the number and location of resistors  14  may vary as a function of the LED or other lighting element performance specifications and length of the board  10  or  22 .  
         [0032]    [0032]FIG. 5 illustrates board  22  inserted between a plurality of first arms  38   a  and second arms  38   b  on one embodiment of a mounting means  30  as shown in FIG. 4. The board  22  may be aligned within the flexible arms so that the first and second arms  38   a  and  38   b  do not exert force on or otherwise interfere with electrical components such as the resistors  14 , terminations  12  or the electrical leads  28  of an LED, for example. FIG. 6 illustrates an end view of the embodiment shown in FIG. 5 with the board  22  held by a pair of arms  38   a  and  38   b.    
         [0033]    One aspect of the present invention allows for the mounting means  30  to be affixed on a support surface first and then the flexible circuit board  10  or  22  to be inserted in the clips  38  of the mounting means  30 . Other mounting methods are contemplated such as by attaching the flexible board  10  or  22  directly to a shaped surface by mounting implements such as screws or nails extending through holes  20  into the support surface. In another embodiment, the clips  38  could be affixed to separate, individual base pieces that are individually mounted to a support surface to define a pattern. Portions of the flexible circuit board  10  or  22  may then be inserted into the mounted clips  38 . Still another embodiment of mounting a board  10  or  22  may include passing the board through an extruder to encapsulate the board within a mounting means similar to that shown in FIG. 4. This embodiment may have a base section that is wider than that shown in FIG. 4 so that apertures formed integral with the mounting means through which mounting screws or nails would be inserted are offset from the base section  32 . This would avoid interference between the screws or nails and the flexible board  10  or  22  encapsulated within the mounting means.  
         [0034]    The LEDs are low voltage elements and avoid the electrical hazard associated with use of regular incandescent, fluorescent or neon lighting. Color LEDs in such colors as red, green, blue, white, orange and amber are commercially available and may be used with various embodiments of the present invention. Further, the LEDs can be mounted in groups, such as red, green, blue and the intensity of each controlled individually and/or together so as to produce a broad range of perceived colors. It is contemplated that the LEDs  26  on each flexible circuit board  10  or  22  can be controlled by a local processor to produce any desired pattern of colors, both fixed and changing. Commercially available processors can be programmed to provide such color control. For example, PIC chips can be programmed using pulse width modulation at a simple level to cyclically vary the voltage applied to the LEDs to control color. The advantage of such simple, local control is that the flexible circuit board  10  or  22  having LEDs connected to it can be treated as a single module requiring only two low voltage leads to the module for power. The PIC can be programmed so that a momentary power interrupt can cycle the PIC to another operating mode, such as to maintain a fixed LED color, for example.  
         [0035]    It will be recognized that the flexible circuit board  10  or  22  with low-voltage, controlled LED lighting can be applied to many applications where it is desirable to avoid risks associated with normal household or commercial voltages. For example, pool lighting can be simplified using an encapsulated flexible circuit board  10  or  22  with LED lamps such that water cannot get to the electrical connections at the lamps. Further, adding a PIC to control color produced by the light emitting elements may be desirable. Track lighting or channel lighting also becomes simpler to implement and avoids the risks associated with handling higher voltage lighting apparatus.  
         [0036]    While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of invention which is to be given the full breadth of the claims appended and any and all equivalents thereof.

Technology Category: f