Note: Descriptions are shown in the official language in which they were submitted.
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LED CONNECTOR
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001]
This application claims priority to U.S. Provisional Patent Application
61/551,612 for an LED CONNECTOR, filed on October 26, 2011, the disclosure of
which
is incorporated herein by reference in its entirety for any purpose
whatsoever.
BACKGROUND
FIELD OF THE DISCLOSED EMBODIMENTS
[0002]
The disclosed embodiments relate to LED connectors that are adapted for
receiving electrical energy from a power source, and mounting an LED light
source to a
lighting board via conductive fasteners, whereby the LED connector transmits
power
from the power source and direct to the conductive fasteners, thereby powering
the LED
light source.
BACKGROUND OF THE DISCLOSURE
[0003]
LED boards have traditionally been mounted to a lighting frame by way of
soldered connections.
Applicant believes that the present application provides
advances over the state of the are.
SUMMARY OF THE DISCLOSED EMBODIMENTS
[0004]
Advantages of the present disclosure will be set forth in and become
apparent from the description that follows. Additional advantages of the
disclosure will
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be realized and attained by the methods and systems particularly pointed out
in the
written description and claims hereof, as well as from the appended drawings.
[0005] Among other things, connectors for a lighting board are disclosed
that are
adapted for receiving electrical energy from a power source, and via one or
more
conductive fasteners. This can facilitate mechanically connecting a lighting
board to a
lighting frame and transmitting power from a power source into electrical
contacts in a
lighting board to power a lighting board.
[0006] Thus, in one embodiment, a connector for a lighting board is
provided that
is adapted for receiving electrical energy from a power source, and via one or
more
conductive fasteners. The connector can both mechanically connect a lighting
board to
a lighting frame and transmit power from a power source into electrical
contacts in a
lighting board to power a lighting board.
[0007] In accordance with some implementations, the connector can include
a
central body containing first and second electrical contacts with respective
positive and
negative leads running through and extending away therefrom and toward the
power
source and a connector base capable of being seated against a first side of
the lighting
frame when the connector is connected to the lighting frame. The connector
base can
have a terminal portion which is positioned against an opening in the lighting
frame
when the connector is connected to the lighting frame. The connector base can
include
one or more members for mounting the connector to the lighting frame. The
mounting
member can be, for example, a first mounting wing extending in a first
direction away
from the body of the connector. If desired, the connector base can include a
second
wing extending away from the connector in a second direction. In such an
embodiment,
a first bottom surface of the first wing and a second bottom surface of the
second wing
can be on a common plane and form a connector base seat. The connector base
seat
can be positionable against the first side of the lighting frame for mounting
the
connector to the lighting frame.
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[0008] In accordance with further aspects, the first mounting wing can
extend
further away from the connector base than the second mounting wing, whereby
the first
and second mounting wings, in a plan view thereof, can be asymmetrically
disposed on
the connector. The first and second wings can fit into respective first and
second
asymmetrically disposed tabs on a lighting frame such that a predetermined
electrical
polarity configuration is obtained between the connector and a lighting frame
when the
connector is positioned on a lighting frame. A centerline through the first
and second
mounting wings that extends away from the body can form a straight line, if
desired.
The first and second conductive contacts can include respective first and
second top
portions, electrically connected to respective positive and negative leads.
Respective
first and second bottom portions of the connector can accordingly extend to
the
terminal portion of the connector base to define both respective first and
second fittings
which are said first and second electrical contacts. The terminal portion can
both
mechanically receive and electrically connect with respective first and second
conductive
fasteners. The connector can mechanically receive and electrically connect
with
respective first and second electrical contacts of a lighting board. The
lighting board can
be mechanically secured to a lighting frame.
[0009] In further accordance with the disclosure, the first and second
fittings at
the terminal portion can be female threaded for receiving male threaded first
and
second conductive fasteners. The top of the first contact can be fused to the
positive
lead, and the top of the second contact can be fused to the negative lead. The
terminal
portion of the connector base can extend below a surface plane defined by the
first and
second bottom surfaces of the respective first and second wings. The terminal
portion
of the connector base can extend into an opening of a lighting frame and can
be flush
with an interior surface of a lighting frame, against which a rear surface of
a lighting
board can be disposed when secured to the electrical connector. An outer end
of the
first wing can include a first wing eyelet, and/or an outer end of the second
wing can
include a second wing eyelet. The first and second wing eyelets can be adapted
for
aligning with eyelets in respective first and second mounting tabs on a
lighting frame for
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releasable locking of the connector to a lighting frame. The connector body
can be
molded plastic or other suitable material.
[000lo] In yet further accordance with the disclosure, a lighting system
is provided
including a connector as recited herein and a lighting frame. The lighting
frame can
include an opening through which the terminal portion of the connector base
extends,
and first and second tabs which can be asymmetrically disposed about the
opening for
engaging respective first and second wings and releasably locking the
connector thereto.
The first and second mounting tabs can open towards opposing directions about
the
frame opening. For example, the connector can be twisted in a first direction
about its
center axis for obtaining a locked configuration against the first and second
mounting
tabs. Moreover, the connector can be twisted in a second, opposing direction
about its
center axis for obtaining a released configuration against the first and
second mounting
tabs. The opening in the lighting frame can be circular or other suitable
shape, wherein
the terminal portion of the connector can be capable of unobstructed twisting
therein.
[cloon] In accordance with a further aspect, the lighting frame can be
thermally
conductive, so that mechanically connecting a lighting board with first and
second
conductive fasteners can electrically connect a lighting board to the
connector, and/or
bias a lighting board to the thermally conductive surface of the lighting
frame to permit
and facilitate dissipation of thermal energy resulting from electrically
powering a
lighting board through the connector. If desired, the raised height of the
terminal
portion of the base of the connector can be equivalent to the thickness of a
base of the
lighting frame, against which a lighting board is disposed when installed. The
opening
and tabs can be mutually width-wise aligned on the lighting frame, and offset
from a
width-wise centerline of the base of the lighting frame by a first offset
distance, whereby,
with first and second contacts of a lighting board offset from a width-wise
lighting board
centerline by the first offset distance, a predetermined electrical polarity
configuration
can be obtained between the connector and a lighting board when the connector
connects a lighting board to the lighting frame. The system can further
include a
lighting board, such as a LED array or LED point source.
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[00012] In accordance with further aspects, the lighting system can
include a
connector and one or more conductive fasteners (e.g., screws) for mechanically
connecting a lighting board to a lighting frame and electrically connecting a
lighting
board to the first and second fittings. The system can include a plurality of
spaced apart
connectors chained to each other via common, continuous positive and negative
leads.
[00013] It is to be understood that the foregoing general description and
the
following detailed description are exemplary and are intended to provide
further
explanation of the disclosed embodiments. The accompanying drawings, which are
incorporated in and constitute part of this specification, are included to
illustrate and
provide a further understanding of the disclosed methods and systems. Together
with
the description, the drawings serve to explain principles of the disclosure.
BRIEF DESCRIPTION OF THE FIGURES
[00014] Certain embodiments of the invention will be described through the
use of
the accompanying drawings, which are not to be considered as limiting, and in
which:
[00015] Figures 1 ¨ 4 illustrate prior art connections;
[00016] Figures 4A-4C illustrate an embodiment of an electrical connector
in
accordance with the disclosure;
[00017] Figures 5A-5E illustrate further details of the illustrated
electrical
connector;
[00018] Figures 6A-6F illustrate the disclosed connector against a
lighting frame;
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[00019] Figure 7 illustrates a heat dissipating feature of an illustrative
lighting
frame in accordance with the disclosure;
[00020] Figure 8 illustrates a plurality of connectors on a lighting
frame; and
[00021] Figure 9 illustrates a point light source installed on a lighting
frame.
DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS
[00022] In the disclosed embodiments, like elements are represented by
like
reference numerals.
[00023] Applicant has appreciated that there is an unsolved need to
provide a LED
connector configuration that enables connecting LED boards to a lighting frame
without
requiring the use of soldering connections 1, as illustrated in Figure 1, wire
splicing 2 as
illustrated in Figure 2, without resulting in visible wiring 3 as illustrated
in Figure 3, and
without flimsy connections 4 that can easily break as illustrated in Figure 4.
[00024] Turning to Figures 4A-4C and 5A-5E, a connector to for a lighting
board
14, such as an LED lighting board, is disclosed. The connector to is adapted
for
receiving electrical energy from a power source 12 (illustrated schematically
in Fig. 5A),
and to facilitate mounting the lighting board 14 to a lighting frame 16 or
internal base of
a lighting box, via first 15 and second 18 conductive fasteners, as
illustrated. From this
configuration, the connector to both mechanically secures a lighting board 14
to a
lighting frame 16, and powers a lighting board 14 via transmitting power from
a power
source 12 through respective first 15 and second 18 conductive fasteners and
into
respective first 17 and second 19 electrical contacts in a lighting board 14
(Figs. 6E-F).
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[00025] As illustrated in Figs. 4A-4C, the electrical connector to includes
a central
body 20 containing first 22 and second 24 electrical contacts with respective
positive 26
and negative 28 leads extending away therefrom and toward a power source 12.
The
contacts can be, for example, eighteen gauge wire, among other gages or
materials.
[00026] A base 30 of the connector to is capable of being seated against a
first side
32, that is, an outside, of a base member of a lighting frame 16 when the
connector to is
connected to the lighting frame 16. That is, the outside of a frame base forms
a seat for
the connector base 30.
[00027] The connector base 30 has a first portion 33 that is a terminal
portion 33.
The terminal portion 33 of the connector to is positioned against an opening
35 in a
lighting frame 16 when the connector to is connected to a lighting frame 16.
[00028] The connector base 30 includes at least a first mounting member 34
for
mounting the connector to to a lighting frame 16. The mounting member 34 is a
first
mounting wing 34 extending in a first direction away from the body 20 of the
connector
to. The connector base 30 includes a second mounting wing 36 extending away
from
the connector to in a second direction.
[00029] A first bottom surface 38 of the first wing 34 and a second bottom
surface
40 of the second wing 36 are on a common plane and form a connector base seat
37.
The connector base seat 37 is positionable against the first side 32 of the
lighting frame
16 for mounting the connector to to the lighting frame 16.
[00030] As illustrated, the first mounting wing 34 extends further away
from a
centerline of the base 30 than the second mounting wing 36. From this
configuration,
the first 34 and second 36 mounting wings, in a plan view thereof, are
asymmetrically
disposed on the connector to. As an example, the first mounting wing 34 can be
about
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an eighth of an inch longer, in the plan view, than the second mounting wing
36, when,
for example, the tip to tip measurements of the connector is about an inch and
a half.
[00031] From this configuration, the first 34 and second 36 wings fit into
respective first 42 and second 44 asymmetrically disposed tabs on a lighting
frame 16.
As a result, a predetermined electrical polarity configuration is obtained
between the
connector 10 and a lighting frame 16 when the connector 10 is positioned on a
lighting
frame 16.
[00032] As can be appreciated by the illustration of the connector 10, a
centerline
through the first 34 and second 36 mounting wings that extends away from the
body 20,
forms a straight line that is generally parallel with an axis of the lighting
frame 16.
[00033] In addition, as illustrated, the major axis of the oval shaped
body 20 is
perpendicular to the tip to top axis for the mounting wings 34, 36. In
addition, the outer
opposing tips of the mounting wings are each circular, and each tangentially
connects
with the major axis of the oval shaped body 20.
[00034] The first 22 and second 24 conductive contacts of the connector 10
include
respective first 46 and second 48 top portions. The top portions 46, 48 of the
connector
are electrically connected to respective positive 26 and negative 28 leads.
Respective
first 50 and second 52 bottom portions of the connector 10 extend to the
terminal
portion 33 of the base 30 to define respective both first and second fittings
and the
noted contacts 22, 24. With this configuration, the terminal portion 33 both
mechanically receives and electrically connects with respective first 15 and
second 18
conductive fasteners. Accordingly, from this configuration, the connector 10
mechanically receives and electrically connects with respective first 17 and
second 19
contacts of the lighting board 14. Moreover, from this configuration, the
lighting board
14 is mechanically secured to the lighting frame 16.
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[00035] Additionally, the first 22 and second 24 contacts/connector
fittings at the
terminal portion 33 are female threaded for receiving male threaded first 15
and second
18 conductive fasteners. For example, the electrical connection between the
fittings and
the leads can be accomplished via, for example, a threaded, electrically
conductive PEM
insert, such as model number IBB-632-4, obtainable through, for example, Tower
Fasteners Company, Inc., at 1690 North Ocean Avenue, Holtsville, NY 11742-
1823. In
such an instance, the fasteners can be metallic screws or other desired
fastener
including a conductive portion adapted to maintain electrical continuity to
permit
operation of the device in operation.
[00036] Moreover, the top 46 of the first contact 22 is fused to the
positive lead 26
and the top 48 of the second contact 24 is fused to the negative lead 28.
[00037] The terminal portion 33 of the base 30 extends below a surface
plane
defined by the first 38 and second 40 bottom surfaces of the respective first
34 and
second 36 wings. From this configuration, the terminal portion 33 of the base
30
extends into an opening 35 of a lighting frame 16 and is flush with an
interior surface 58
of a lighting frame 16, against which a rear surface 59 of a lighting board 14
is disposed
when secured to the electrical connector to.
[00038] The connector includes first 62 and second 64 strengthening ribs,
serving
as gussets. The ribs 62, 64 extend from a first top surface 65 and a second
top surface
66 of respective first 34 and second 36 wings to respective first 68 and
second 70
portions of a side surface 72 of the central body 20. As illustrated, the
first 68 and
second 70 portions of the side surface 72 of the central body 20 are opposing
sides of the
minor axis of the oval shaped central body 20.
[00039] An outer end of the first wing 34 includes a first wing eyelet.
Additionally,
an outer end of the second wing 38 includes a second wing eyelet. The first
and second
wing eyelets are adapted for being aligned with matching tab eyelets when
positioned
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within respective first 42 and second 44 mounting tabs on a lighting frame 16.
From
this, the connector to is releasably locked to a lighting frame 16. It should
be
appreciated that while turning the connector to in a first direction, such as
clockwise,
locks the connector to against lighting frame tabs, and turning in the
opposing direction
releases the connector to.
[00040] The body 20 of the connector to can be molded plastic or other
suitable
material. Accordingly, the process of forming the different shapes and ribs is
relatively
straightforward.
[00041] While the connector to, itself, has been a focus of the present
disclosure, a
lighting system, as a unit, can include the electrical connector to and a
lighting frame 16
or lighting box as indicated above. The lighting frame 16, as also indicated
above,
includes an opening 35 through which the terminal portion 33 of the connector
base 30
extends.
[00042] The lighting frame 16 also includes the above identified first 42
and second
44 tabs which are asymmetrically disposed about the opening 35, for engaging
respective first 34 and second 38 wings, and releasably locking the connector
to thereto.
The first 42 and second 44 tabs can be stamped or punched out of the lighting
frame 16,
which is typically formed from a metallic sheet.
[00043] The first 42 and second 44 tabs are "L" shaped brackets which open
in
opposing directions about the frame opening 35 as illustrated in Figures 6A-
6D. From
this, the connector to is twisted in a first direction about its center axis
for obtaining a
locked configuration against the first 42 and second 44 mounting tabs. On the
other
hand, the connector to is twisted in a second, opposing direction about its
center axis
for obtaining a released configuration against the first 42 and second 44
mounting tabs.
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[00044] The opening 35 in the lighting frame 16 is circular. With this
shape, the
terminal portion 33 of the connector is capable of unobstructed twisting
therein to
facilitate assembly. For example, as illustrated, the terminal portion 33 can
have an oval
shape. If the opening 35 also had an oval shape, the twist for engaging the
wings 34, 26
into respective tabs 42, 44, would be obstructed at the interface between the
terminal
portion 33 and the opening. By way of further example, the shape of terminal
portion
could alternatively be round, or any other shape adapted to rotate within
circular
opening 35.
[00045] The first 42 and second 44 tabs have first 82 and second 84 tab
eyelets.
These tab eyelets 82, 84, as indicated, are aligned with respective wing
eyelets enabling
releasable locking of the first 34 and second 36 wings against the lighting
frame 16,
using, e.g., a screw.
[00046] According to an embodiment, the lighting frame 16 is thermally
conductive, as illustrated in Figure 7. From this configuration, mechanically
connecting
a lighting board 14 with first 15 and second 18 conductive fasteners achieves
the
following results: (i) electrically connecting a lighting board 14 to the
connector to, and
(ii) biasing a lighting board 14 to the thermally conductive surface of the
lighting frame
16. This configuration enables the dissipation of thermal energy resulting
from
electrically powering a lighting board 14 through the connector to. In other
words, the
configuration creates a heat sink when an LED light source 14 is drawn flush
to the
lighting frame 16.
[00047] As indicated, the terminal portion 33 of the base 30 extends below
a
surface plane defined by the first 38 and second 40 bottom surfaces of the
respective
first 34 and second 36 wings. From this configuration, as illustrated in
Figures 6D and
6E, the terminal portion 33 of the base 30 extends into an opening 35 of a
lighting frame
16 and is flush with an interior surface 58 of a lighting frame 16. The raised
height of the
terminal portion 33 of the base 30 of the connector to is equivalent to the
thickness of a
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base of the lighting frame 16, against which a lighting board 14 is disposed
when
installed. This assures that the PCB board forming the light source will not
bend when
drawn to the terminal portion 33 by the fasteners 15, 18.
[00048] As illustrated in Figures 6E, 6F and 8, the opening 35 and tabs 42,
44 are
mutually width-wise aligned on the lighting frame 16, and offset from a width-
wise
centerline of the base of the lighting frame 16 by a first offset distance.
From this, with
first 17 and second 19 contacts of a lighting board 14 offset from a width-
wise lighting
board centerline by the first offset distance, a predetermined electrical
polarity
configuration is obtained between the connector to and a lighting board 14
when the
connector to connects a lighting board 14 to the lighting frame 16.
[00049] The system, as a unit, can also include the mentioned first 15 and
second
18 conductive fasteners for mechanically and electrically connecting a
lighting board 14
to the first 22 and second 24 contacts/fittings. As indicated, the first 15
and second 18
conductive fasteners are screws.
[0005o] In addition, the system, as a unit, can include a the mentioned
lighting
board 14, which can be either an LED array or LED point source as illustrated
in Figure
9. As indicated and illustrated in Figure 6E, the LED light source can include
a PCB
board with PCB pads 17, 19 used as contacts, which is typical for such boards.
It should
be noted that if the electrical connection is low voltage, there is no safety
risk of
touching a live connector, enabling swapping out LED boards as may be
required.
[00051] It is to be appreciated that the system, as illustrated in Figure
8, can
include multiple connectors to in a lighting box 16, where the connectors to
are spaced
at, for example, one foot lengths. This enables securing and powering long
lengths of
LED boards, depending on the application.
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[00052] Accordingly, a connector 10 for a lighting board 14 has been
disclosed,
adapted for receiving electrical energy from a power source 12, and via one or
more
conductive fasteners, both mechanically connecting a lighting board 14 to a
lighting
frame 16 and transmitting power from a power source 12 into electrical
contacts in a
lighting board 14 to power a lighting board 14.
[00053] The disclosed embodiments may be configured in other specific forms
without departing from the spirit or essential characteristics identified
herein. The
embodiments are in all respects only as illustrative and not as restrictive.
The scope of
the embodiments is, therefore, indicated by the appended claims and their
combination
in whole or in part rather than by the foregoing description. All changes that
come
within the meaning and range of equivalency of the claims are to be embraced
within
their scope.
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