Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02726875 2010-12-21
Attorney Docket No. OPTO-1 09
Customer No. 95,450
WATERPROOF FLEXIBLE AND RIGID LED LIGHTING SYSTEMS AND DEVICES
Cross-Reference to Related Applications
[0001] This application is a Continuation-in-Part of U.S. Application No.
12/499,306,
filed July 8, 2009, which claims priority to and the benefit of the filing
date of U.S. Application
No. 61/079,042, filed July 8, 2008; and this application claims priority to
and the benefit of the
filing date of U.S. Application No. 61/288,815, filed Dec. 21, 2009, the
disclosures of each of
which are hereby incorporated by reference herein in their entireties.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates to lighting strips and more particularly
to flexible
or rigid lighting systems and devices, which are waterproof. The lighting
strips are modular and
are capable of being physically and electrically connected with one another to
provide lighting
systems that are waterproof and adaptable to many situations.
Description of the Related Art
[0003] Waterproof modular strip lighting is highly desirable for numerous
applications,
including as decorative lighting in exterior settings or interior setting
where moisture is
common, such as bathrooms, bars, and kitchens. In exterior settings, it is
common for installed
lighting devices to be exposed to the elements, such as rain, condensation,
humidity, or other
moisture, as well as extreme temperatures. Lighting devices exposed to
moisture and/or
extreme temperatures, however, is often at risk for failure. If moisture,
especially water
droplets, is allowed to contact non-waterproof lighting devices, the water can
cause a short
circuit or other electrical failure of the device, requiring repair and/or
replacement of the failed
components.
[0004] Waterproofing materials of existing lighting devices typically include
as a
waterproof colloid layer an epoxy resin for covering the LEDs, electrical
circuits and
connections, and the substrate. In some cases in existing devices, the epoxy
resin or colloid
layer does not cover the surface of the LEDs to avoid compromising the light
output. By not
covering the LEDs, however, there is an increased chance of moisture being
introduced into the
system where the colloid layer meets the LEDs. This is especially applicable
in flexible designs
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where adherence between the colloid layer and the side of an LED may come
loose enough to
allow moisture into the system if the strip is flexed repeatedly. Further, in
some situations,
epoxy resin as colloid layer has been found to be inadequate, such as in
extreme temperature
situations, including in external weather or environmental conditions or due
to the use of high
brightness LEDs, which typically have a high heat output during operating of
such devices.
Under extreme low or high temperatures epoxy resin can craze or become
discolored or cloudy,
leading to cracks in the waterproof barrier and a decrease in the amount of
light output from
the device. Better waterproofing materials and techniques are thus desired.
[00051 Further, strip lighting that is easy and convenient to install is also
highly
desirable, especially lighting devices that can be adaptable to various
situations. For example,
lighting strips that are waterproof, are configured to be cut to a desired
length during
installation, minimize the number of electrical junctures for a lighting strip
system, can be cut
and re-connected by way of a waterproof connector, and/or are adaptable to
remain
waterproof after cutting would be highly desirable, however, existing lighting
strip devices and
assemblies do not satisfy this need.
[0006] What are needed are modular, waterproof lighting systems that are easy
and
quick to install and repair, and/or provide less opportunity for lighting
system failures by
providing fewer electrical and physical breaks in the circuit of the lighting
system, and/or
provide for high brightness output of the LEDs, and/or provide for custom
fitting of a lighting
system to a particular situation while remaining waterproof.
SUMMARY OF THE INVENTION
[0007] In light of the problems described above, embodiments of the present
invention
provide waterproof flexible and rigid strip lighting devices that can be
combined and
conveniently interconnected to form waterproof modular lighting systems.
Waterproof, as
used in this application, includes devices and systems which may be less than
completely
waterproof, such as moisture resistant.
[0008] Embodiments of the invention include waterproof flexible and rigid
lighting
strips that are additionally readily adaptable at the time of installation for
various applications
and can be repaired quickly and easily when light source failures occur or
changes to the
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Customer No. 95,450
lighting system are desired. Such devices and systems can be re-configured for
particular
situations without compromising the integrity of the waterproof or moisture
resistant
characteristics.
[0009] Portions of the waterproof lighting systems can be replaced should one
or more
LEDs fail. Simply, a portion of the lighting strip can be cut at predetermined
segments and
replaced with a new segment having waterproof connectors for inter-connecting
with the
installed lighting strip. Thus, repairs to portions of the installed devices
can be made quickly
and easily without replacing the entire lighting system and without
jeopardizing the waterproof
nature of the strips. Similarly, such modifications can be made when
necessitated by relocation
of a lighting system from one location to another more desirable location.
[00010] Included in embodiments of the invention are flexible or rigid modular
lighting
strips comprising: a non-conductive substrate strip comprising an electrical
circuit; a plurality of
high brightness LEDs operably connected to the electrical circuit; a colloid
coating covering
exposed surfaces of the substrate and circuit, and partially or completely
covering exposed
surfaces of the LEDs; and a plug at one end and a socket at an opposing end of
the substrate
which is integrally formed, or otherwise operably connected, with the strip to
provide for
waterproof electrical interconnection of two or more circuits or to a power
supply.
[00011] Embodiments of the invention can comprise latch-type securing
mechanisms,
preferably releasable, for securing the connection between lighting strips
when installed,
allowing for convenient disengagement of the components for repairs, and/or
allowing for a
waterproof or water resistant system.
[00012] Included in embodiments of the invention are modular lighting strips
comprising:
a non-conductive substrate strip comprising an electrical circuit; a plurality
of high brightness
LEDs operably connected to the electrical circuit; a colloid layer comprising
polyurethane resin
providing a waterproof coating over the substrate, the circuit, and the LEDs;
and a plug at one
end and a socket at an opposing end of the substrate which is integrally
formed with the strip
to provide for waterproof electrical interconnection of two or more circuits
or to a power
supply. Embodiments of the invention can comprise a latch-type securing
mechanism,
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Attorney Docket No. OPTO-109
Customer No. 95,450
preferably releasable, for securing the connection between lighting strips
when installed but
also allowing for convenient disengagement of the components for repairs.
[00013] Embodiments of the flexible and rigid lighting systems and devices can
comprise
a colloid waterproofing layer covering all, most, or some of the device or
system. For example,
when waterproof LEDs are used the colloid layer need only be applied on the
substrate and
circuit and contacting or completely covering one or more, all, or less than
all surfaces of the
waterproof LEDs. A preferred embodiment includes applying the colloid layer to
cover the
substrate and circuit and a portion of the sides of the LEDs that are
typically perpendicular to
the substrate, rather than also covering the top of the LED with the colloid
layer as well, or only
so much of the top of the LED as may be needed to render the lighting device
or system
waterproof. This may minimize materials costs as well as manufacturing time
needed for
ensuring a thinner layer of colloid material has set. Waterproofing or making
water resistant as
much of the devices and systems as possible is preferred.
[00014] The modular lighting strips of embodiments of the invention can
comprise a
printed circuit board, such as a flexible printed circuit board, as the
substrate strip and electrical
circuit. The overall lighting strip can be flexible or inflexible depending on
the materials used
for construction. For example, the lighting strips can comprise a printed
circuit board (PCB) on
an inflexible or flexible material, wherein the PCB is supported or not
supported by a rigid
material, such as a support with heat sink capabilities. Preferably, the
waterproof lighting strips
are flexible.
[00015] Further included in the invention are modular lighting strips having a
low profile
appearance, for example, with a height of less than about 3 mm, or having LEDs
that have a
height of about 3 mm or less.
[00016] It is also possible to cut the modular lighting strips of embodiments
of the
invention. For example, if desired, it is possible to cut a strip at the time
of installation, to
provide a length of strip lighting that is less than the length of the modular
segment provided in
whole. Likewise, the strips can be cut to provide for fewer LEDs than are
installed on the entire
strip. Cutting can be readily performed, such as at the time of installation
of the device(s) and a
terminal can be installed at the cut end to maintain the waterproof nature of
the strip. Such
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Attorney Docket No. OPTO-1 09
Customer No. 95,450
adaptability and modularity is especially applicable to the flexible lighting
devices and systems
of the invention but these features are equally applicable to rigid lighting
systems and devices
as well.
[00017] The lighting strips according to embodiments of the invention can be
configured
so as to provide plug-type ends to the strip at the point of cutting, for
example, by providing
intermediate electrical contacts at one or more positions along the length of
the strip which can
be cut to provide two ends each having plug-type electrical contacts which can
be operably
connected to a socket, upon exposing the electrical contacts at the cut end of
the substrate by
removing a portion of the colloid layer. The lighting strips can also be cut
at any point along the
strip where there is no intermediate electrical contact to provide a terminal
end of the circuit
and waterproofed.
[00018] Preferred are modular lighting strips described herein which are about
1 foot in
length, and/or comprise up to about 18 LEDs, such as 6, 9, or 18 LEDs, and/or
are capable of
being operably interconnected with one another to provide up to about 540
light sources from
one electrical power supply. The flexible lighting strips can further be
interconnected and
provided on reels to increase the convenience of installation. Exemplary hard
or rigid lighting
strips of the invention can be of any length, such as 1 foot, or 2, 3, 4, 5,
or 6 feet in length and
each can comprise, for example, 10 LEDs and can be interconnected with other
strips, such as 4
strips, for providing a modular lighting system having up to 10 LEDs, 20 LEDs,
30 LEDs, 40 LEDs
and so forth for example up to about 240 LEDs.
[00019] Modular lighting system embodiments are also included in the
invention. Such
lighting systems can comprise: a plurality of modular lighting strips each
comprising: a non-
conductive substrate strip comprising an electrical circuit; a plurality of
high brightness LEDs
operably connected to the electrical circuit; a colloid layer comprising
polyurethane resin
providing a waterproof coating over at least part of each of the substrate,
the circuit, and the
LEDs; and a plug at one end and a socket at an opposing end of the substrate
which operably
connected or integrally formed with the strip to provide for waterproof
electrical
interconnection of two or more circuits.
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Customer No. 95,450
[00020] Means for operably connecting a modular lighting strip to an
electrical power
supply can be provided by the plug or socket of the lighting strip, wire leads
irremovably and
operably connected to the lighting strip, or a non-conductive substrate strip
comprising an
electrical circuit and no light sources which is capable of operably
connecting to a lighting strip
by way of an integrally formed plug or socket. DC jack adapters can be used,
and in the case of
multi-color light displays for example the red, green, blue LED lighting
strips can comprise an
RGB-controller for controlling the timing, duration, and changes in color of
the display.
[00021] Each modular lighting strip can be configured to be any length, with 1-
foot
lengths being especially desired. Further, the lighting strips can comprise
any number of light
sources, such as 6, 9, 10, or 18 LEDs. Such strips are operably
interconnectable to provide up to
about 30 feet, for example, from about 15-30 feet, of strip lighting capable
of being powered by
one electrical power supply.
[00022] The modular lighting systems can be constructed so that the first PCB
is capable
of being connected to a power supply by way of a plug, socket, or wire leads
irremovably and
operably connected to the first PCB.
[00023] Further, the modular lighting systems according to embodiments of the
invention can comprise about 1-foot long PCBs with LEDs, and/or from about 6-
18 LEDs, and/or
are operably interconnectable to provide from about 15-30 feet of strip
lighting capable of
being powered by one electrical power supply.
[00024] Any of the modular lighting systems of the invention can be low
profile, for
example, having a height of less than about 3 mm.
BRIEF DESCRIPTION OF THE DRAWINGS
[00025] FIG. 1A shows a side elevation view of one embodiment of a low-
profile, flexible,
waterproof lighting strip according to the invention.
[00026] FIG. 1B shows a top plan view of one embodiment of a low-profile,
flexible,
waterproof lighting strip according to the invention.
[00027] FIG. 2A shows a side elevation view of one embodiment of a low-
profile, flexible,
waterproof lighting strip according to the invention.
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Customer No. 95,450
[00028] FIG. 2B shows a top plan view of one embodiment of a low-profile,
flexible,
waterproof lighting strip according to the invention.
[00029] FIG. 3A shows a side elevation view of one embodiment of a low-
profile, flexible,
waterproof lighting strip according to the invention.
[00030] FIG. 3B shows a top plan view of one embodiment of a low-profile,
flexible,
waterproof lighting strip according to the invention.
[00031] FIG. 4A shows a side elevation view of one embodiment of a low-
profile, flexible,
waterproof lighting strip according to the invention.
[00032] FIG. 4B shows a top plan view of one embodiment of a low-profile,
flexible,
waterproof lighting strip according to the invention.
[00033] FIGS. 5A-G are graphic representations of circuits for various
embodiments of
the flexible lighting strips according to the invention.
[00034] FIG. 5H shows a schematic diagram of an exemplary configuration for
installation
of multiple RGB flex strips in a lighting system.
[00035] FIGS. 6A-E are schematic diagrams of cross sections of various
waterproof
flexible lighting strips of the invention.
[00036] FIGS. 7A-E are schematic diagrams and photographs of various
waterproof rigid
lighting strips of the invention.
[00037] FIGS. 8A-D are schematic diagrams showing representative cross
sections of
various waterproof rigid lighting strips of the invention.
[00038] FIGS. 9A and 9B are schematic diagrams showing an example of a
lighting system
of the present invention and a method for installing a plurality of lighting
strips.
[00039] FIGS. 12A-E are photographs of various flexible waterproof lighting
strips
according to embodiments of the invention, showing representative connectors.
[00040] FIG. 13 is a schematic diagram showing waterproof flexible lighting
strips
arranged in a lighting system and prepared for installation on a convenient
reel.
[00041] FIGS. 15A-E show various views of a rigid waterproof lighting system.
[00042] FIG. 17 shows another waterproof embodiment of rigid lighting strips.
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DETAILED DESCRIPTION OF
VARIOUS EMBODIMENTS OF THE INVENTION
[00043] Reference will now be made in detail to various exemplary embodiments
of the
invention. The following detailed description is presented for the purpose of
describing certain
embodiments in detail and is, thus, not to be considered as limiting the
invention to the
embodiments described. Rather, the true scope of the invention is defined by
the claims.
Additionally, any features of any embodiment described herein are equally
applicable to any
other embodiment described herein or envisioned by one of ordinary skill in
the art. Thus, the
detailed descriptions provided herein should not be construed to exclude
features otherwise
described with respect to another embodiment.
[00044] FIGS. 1A, 2A, 3A, and 4A show side elevation views of embodiments of
flexible,
waterproof lighting strips according to the invention. As shown in FIGS. 1A,
2A, 3A an
embodiment of a single color waterproof flexible lighting strip (flex strip)
100, 200, 300 is
provided. The flex strip 100, 200, 300 comprises a non-conductive substrate
strip 101, 201, 301
comprising an electrical circuit (not shown); a plurality of light sources
109, 209, 309 operably
connected to the electrical circuit; a socket 111, 211, 311 operably connected
to the electrical
circuit of the substrate strip 101, 201, 301 at both ends of flex strip 100,
200, 300 in a manner
that provides for a waterproof connection, e.g., by way of wire leads encased
in waterproof
insulation 104, 204 and connected to the substrate by way of waterproof seals
110, 210. As
shown in FIGS. 3A and 4A the connectors can be integral with the lighting
strips and comprise a
plug and socket which are configured to provide a waterproof connection when
connected to a
corresponding socket or plug of another lighting strip. Coating 103, 203, 303,
403 encapsulates
the upper surface of substrate 101, 201, 301, 401 and light sources 109, 209,
309, 409 to
provide for waterproof protection of the electrical components (circuit on PCB
and wire leads)
of the flexible lighting strips 100, 200, 300, 400. In embodiments, the non-
conductive substrate
strip can be colored to match or complement the color of the surface to which
it will be
installed to provide a discrete installed lighting system when installed.
[00045] As further shown in FIGS. 1B, 2B, 3B, 4B lighting strip 100, 200, 300,
400
comprises a flexible printed circuit board (PCB) 101, 201, 301, 401 which
supports electrical
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Attorney Docket No. OPTO-109
Customer No. 95,450
contacts 102, 202, 105, 205 and the electrical circuit (only partially shown)
of the lighting strip
100, 200, 300, 400. As shown in cross-sections A-A, coating 103, 203, 303, 403
may cover and
completely encapsulate the upper surface of PCB 101, 201, 301, 401 to provide
waterproof
protection for the PCB and in particular the electrical components of the
lighting strips, which
are part of the PCB and/or which are mounted thereon. Coating 103, 203, 303,
403 may be
applied partially or completely to the upper surface of PCB 101, 201, 301, 401
to provide the
desired degree of moisture resistance or waterproofing to the system
components. For
example, the coating 103, 203, 303, 403 may completely cover the PCB 101, 201,
301, 401 and
the electrical circuit, contacts, or other electrical components of the
devices and partially cover
the sides of the LEDs that are perpendicular to the substrate, such as about
1/4, 1/3, or 1/2 of
the height of the LEDs. In preferred embodiments, waterproof LEDs are used
and/or only
enough of the LED is covered to provide waterproof protection to the system.
In embodiments,
the colloid layer is disposed on the substrate up to a level that is about the
level of the upper
surface of the LEDs but not covering the LEDs so that light emitted from the
device is not
affected by the waterproofing material or technique. Such a configuration is
applicable to
flexible or rigid strip lighting, but will more typically be employed with
respect to rigid lighting
systems. The waterproofing material can alternatively be disposed in a manner
to completely
encapsulate the LEDs, by for example covering the entire upper surface of the
LEDs.
[00046] As shown in cross-sections A-A of FIGS. 113, 2B, 3B, and 4B, coating
103, 203, 303,
403 forms a rounded profile. Here, coating 103, 203, 303, 403 is a
polyurethane resin, which
can be applied on the lighting strips in liquid form in a manner to allow for
the resin to flow
naturally into a rounded profile over the LEDs and substrate. In this
embodiment, the
polyurethane resin coating 103, 203, 303, 403 is of minimal thickness and just
covers the upper
surface of the LEDs so as not to interfere with the light output of the LEDs.
[00047] One technique for applying the colloid layer is to allow the material
to form
freely on the surface of the PCB and/or to provide gently rocking of the PCB
while the material
dries to ensure complete coverage of the components. Molds or guides can also
be used to
prevent overflow of the liquid colloid material over the edges of the PCB, or
to ensure complete
coverage of the PCB by the colloid material, or to allow for the application
to be performed
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using a more fluid solution of colloid material. For example, temporary walls
can be placed
lengthwise along the sides of the PCB to form a temporary cavity within which
the LEDs sit on
the PCB. Liquid colloid material can then be applied in the cavity and allowed
to settle by way
of gravity or in combination with gentle rocking of the PCB. Once the colloid
material has set in
the desired position, the temporary supports, guides, or walls can be removed,
leaving a colloid
layer on the PCB which has a square or rectangular cross section. Further, for
example, the
temporary guides can be combined as a single tool, basically forming a
structure with two walls
disposed at a right angle (or any angle less than 180 degrees) to one another.
This tool can
then be inverted over the PCB on the side with the LEDs to form a cavity
defined by the two
walls and the PCB. Liquid or semi-liquid colloid material can then be injected
into the cavity
and allowed to dry or form on the PCB, circuit, and or LEDs. Once the colloid
layer is formed or
otherwise sufficiently stiff, the colloid shaping tool can be removed, leaving
the colloid layer
having a trapezoidal cross section on the PCB, with its side walls
perpendicular to one another
or said another way having slopes between the upper colloid surface and the
PCB of opposing
45 degrees. Multiple shapes for the colloid layer can be achieved by modifying
this technique
appropriately and by using a corresponding or complementary tool. For example,
the colloid
layer can be configured in any shape, including having a cross section shaped
as a small moon,
half moon, big moon, square, rectangle, trapezoid, and so on. Exemplary cross
sections are
provided in FIGS. 6A-E and discussed in further detail below.
[00048] The colloid layer is typically a material that is transparent when
solid and has a
high tolerance for low and high temperatures, such as polyurethane resin, or
any other suitable
light transmissive encapsulation material. Any such waterproofing material can
be used that is
flexible, non-conductive, allows for a desired amount of light to be emitted
from the device,
and/or can tolerate extreme temperatures, for example, from -10 degrees
Celsius to 40 degrees
Celsius. The material can be a sheath surrounding the components, but is
preferably disposed
directly on the PCB, LEDs, and electrical circuit for the most protection.
Optically clear
materials can be used, such as silicone gels. Materials that do not degrade
(or that resist
discoloration) when exposed to ultra-violet (UV) light are included. Further
examples include
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polymethlymethacrylate (PMMA), epoxy or silicone resins, polycarbonate, nylon,
and silicone
rubber.
[00049] If desired, the colloid layer may be colored to add or otherwise
change the color
of the light output from the LEDs. Likewise, the PCB can be colored to match a
surface to which
it is intended to be applied to camouflage or otherwise reduce the aesthetic
impact an installed
lighting system may have. For example, if a lighting system is to be installed
on white walls, the
PCB can be colored white so that when installed on the wall surface the
lighting strip blends in
well with its surrounding.
[00050] The lighting strips 100, 200, 300, 400 can be connected with other
lighting strips
100, 200, 300, 400 by way of connectors comprising a female end 107, 207, 307,
407 and a
male end 106, 206, 306, 406 for example, at opposite ends of each lighting
strip 100, 200, 300,
400. When the connector 106, 206, 306, 406 of one lighting strip is joined
with connector 107,
207, 307, 407 of another lighting strip, waterproof seal 108, 208, 308, 408
ensures the
connection is waterproof. Connectors 106, 206, 306, 406 and 107, 207, 307, 407
are operably
connected to the PCB 101, 201, 301, 401 by way of wire leads (not shown),
which are operably
connected to electrical contacts 105, 205, 305, 405 at either end of the PCB,
wherein the wire
leads are protected with insulating/waterproofing material 104, 204, 304, 404.
Preferably,
connectors 106, 206, 306, 406 and 107, 207, 307, 407 together with insulation
104, 204, 304,
404 seals 108, 208, 308, 408 and 110, 210, 310, 410 and coating material 103,
203, 303, 403
combine to provide waterproof protection for a flexible lighting system with
multiple lighting
strips 100, 200, 300, 400.
[00051] The lighting strips 100, 200, 300, 400 can also be cut at pre-
determined
segments to provide a length of strip that custom fits a particular
application. The strips 100,
200, 300, 400 can be supplied with indicators 112, 212, 312, 412 where cutting
of the strip can
be performed. To maintain the waterproof characteristics of the strips once
cut, a terminal end
should be supplied, such as a plastic end that can be joined with the cut end
of the substrate
with silicone to ensure the end of the strip is waterproof. Alternatively, the
substrates can
comprise areas where electrical contacts can result as ends of the strips once
cut and
waterproof socket connectors can be provided to join two plug-type ends of
strips that have
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been cut. To ensure the waterproof nature of strips joined in this way it
would be best to seal
the juncture between the ends with silicone or other waterproofing material.
[00052] The flex strips 100, 200, 300, 400 can be single- or multi-color light
strips and can
comprise any predetermined number of light sources 109, 209, 309, 409.
Substrate or PCB 101,
201, 301, 401 comprises a flexible material. Flexible in the context of this
application is that the
lighting strip can conform to any surface shape to which it is intended to be
installed upon. In
preferred embodiments, a flexible lighting strip when held in the hand can be
manipulated with
very little force from the fingers or simply from gravity.
[00053] The substrate (e.g., printed circuit board or PCB) for the flexible
lighting devices
100, 200 and systems according to the invention can comprise any electrically
non-conductive
material, such as plastic. The exact materials for the substrate are not
critical and options
within the skill in the art are available, so long as the substrate provides
sufficient support for
the components mounted to it (such as LEDs, ICs, and resistors) and the
overall lighting devices
100, 200, 300, 400 are flexible and allow for the lighting strip devices 100,
200, 300, 400 to
conform to various surface shapes. Such substrates 101, 201, 301, 401 are also
referred to as
flexible printed circuits or FPCs. The electrically conductive pathway (only
partially shown) can
comprise any electrically conductive material such as aluminum or copper. The
conductive
pathway can be affixed to the PCB 101, 201, 301, 401 by any known means
available in the art,
including being sandwiched between two layers of electrically non-conductive
substrate.
[00054] Any light source 109, 209, 309, 409 can be used but which is usually
dictated by a
specific application. Appropriate light sources 109, 209, 309, 409 can include
high brightness
PLCC-2 SMD LEDs and PLCC-6 SMD LEDs. Likewise, 3528 SMD LEDs may be used as
well as
5050 RGB SMD LEDs for particular applications.
[00055] The polyurethane resin as the colloid layer 103, 203, 303, 403 makes
high
brightness LEDs possible in these lighting strip applications. The
polyurethane resin is capable
of withstanding extreme high and low temperatures without crazing and thereby
jeopardizing
the waterproof nature of the strips and/or the quality of light emitted from
the devices. Such
SMD LEDs have a 120 degree viewing angle for even light and are available in
various colors,
including without limitation white (neutral, cool, and warm), red, yellow,
blue, and green. The
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lighting strips 100, 200, 300, 400 can be constructed to comprise single-color
or multi-color light
source 109, 209, 309, 409 configurations. For example, the lighting strips
100, 200, 300, 400
can comprise single-color red, yellow, green, blue, cool white, neutral white,
or warm white or
multi-color (RGB-color) red, green, and blue colored LEDs 109, 209, 309, 409.
Several color
combinations are possible and within the skill of the art. In FIGS. 1A, 2A, 3A
and 4A the light
sources 109, 209, 309, 409 are light emitting diodes (LEDs).
[00056] At one end of the light strips shown in FIGS. 1A, 2A, 3A and 4A there
is a socket-
type connector 107, 207, 307, 407. The socket-type connector 107, 207, 307,
407 provides for
physical connection of two lighting strips 100, 200, 300, 400 and electrical
connection of the
electrical circuits (not shown) of the strips 100, 200, 300, 400. The socket-
type connector 107,
207, 307, 407 can be of any known connector as long as it is capable of
providing both physical
and electrical connection of the components and a waterproof connection of
these
components. The lighting strips 100, 200, 300, 400 also comprise at the
opposing lengthwise
end of the strip 100, 200, 300, 400 a plug-type connector 106, 206, 306, 406.
The plug 106,
206, 306, 406 and socket 107, 207, 307, 407 connectors are complementary
configured to
provide for mating of the plug 106, 206, 306, 406 of one light strip 100, 200,
300, 400 with the
socket-type end 107, 207, 307, 407 of another strip 100, 200, 300, 400. As
shown in FIGS. 1A
2A, 3A, and 4A, the socket and plug can be of various configurations,
including a round quick-
release type plug and socket with an internal rubber gasket for maintaining
the waterproof
connection between the plug and socket.
[00057] The plug 106, 206, 306, 406 and socket 107, 207, 307, 407 typically
comprise
wire leads (not shown, but internal to insulation wrapping 104, 204, 304, 404)
for soldering or
otherwise adhering the electrically-conductive components of the plug 106,
206, 306, 406 and
socket 107, 207, 307, 407 to the electrical circuit of the PCB 101, 201, 301,
401. The plug 106,
206, 306, 406 and socket 107, 207, 307, 407 are operably connected to the
electrical circuit of
the PCB when their electrical components (wire leads and electrical contacts)
are capable of
providing for continuity in an electrical path from the circuit of one PCB to
the circuit of another
PCB during use of the lighting strips. The connection between the connecting
ends of the
lighting strips and the PCB should be waterproof.
13
CA 02726875 2010-12-21
Attorney Docket No. OPTO-109
Customer No. 95,450
[00058] The lighting strips 100, 200, 300, 400 can be manufactured in 6-inch,
1-foot, or
18-inch lengths, or any length increment, including 1.6 feet, each length
comprising any
number of LEDs 109, 209, 309, 409. Further, especially with respect to the
longer lengths, the
substrate 101, 201, 301, 401 can comprise a material that provides for cutting
of the flex strips
100, 200, 300, 400 typically at the time of installation, to a shorter length.
In one embodiment,
lighting strips 100, 200, 300, 400 can be provided in one length of 1.6 feet
(or 50 cm) with 30
LEDs 109 (single color), or 18 LEDs (multi-color), which is capable of being
cut into smaller
segments. The strips can be joined with other strips and packaged on reels. A
preferred
embodiment of reels of lighting strips provides 16 feet of lighting strips (10
1.6-foot strips),
which provides for a lighting system of 300 single-color LEDs or 180 multi-
color LEDs. Further
preferred are lighting systems comprising up to 32 feet of lighting strips, or
600 single-color
LEDs or 360 multi-color LEDs. Another preferred configuration is a 5M long
lighting strip,
capable of being cut at indicated points, comprising 300 LEDs. One or more of
the lighting
strips can be joined together to form a lighting system, such as combining two
5M lengths into
a lighting system that is 10M and comprises 600 LEDs.
[00059] FIGS. 113, 3B and 2B, 4B show a top plan view of respectively a single
color
flexible lighting strip 100, 300 and a multi-color flex strip 200, 400.
Emphasized in the cross-
section A-A of these views is the low-profile capability of the lighting
strips 100, 200, 300, 400.
For example, the PCB 101, 201, 301, 401 and light sources 109, 209, 309, 409
when
encapsulated or covered by coating material 103, 203, 303, 403 can be about 3
mm in height or
less. Combining low-profile characteristics with high brightness is a
challenge to LED lighting
manufacturers. Typically, as brightness increases, so does the size of the
LED. As a particular
example, an LED that is 0.5 mm or less in height typically will not be able to
output the same
amount of light as an LED with a 2.5 mm profile. Thus, obtaining lighting
strips which are as
low-profile as possible but as bright as possible is difficult, and is further
complicated by the
desire to have such lighting devices be waterproof. Thus it is highly
desirable to have lighting
strips that are waterproof and comprise LEDs that are greater than 0.5 mm
high, but less than 3
mm high. Any height LED from 1mm, 1.5 mm, 2 mm, 2.5 mm, 2.6 mm, 3 mm, 3.5 mm,
4 mm,
etc. would be possible with this invention.
14
CA 02726875 2010-12-21
Attorney Docket No. OPTO-1 09
Customer No. 95,450
[00060] Representative optical and electrical parameters for embodiments of
waterproof
single-color and multi-color LED flex and rigid strips according to the
invention include those
listed in Tables 1-7 below.
Table 1
Representative Optical Parameters at Ta=77 F
of Waterproof Single-Color LED Flex Strips
LED Viewing Luminous
Part No. Color Quantity angle Wavelength flux LED Quantity
[pcs]/reel [ ] [1m]/reel [pcs]/segment
VO-FS-CW-12A0 Cool white 300 120 6000-8000k 1800 6
VO-FS-WW-12A0 Warm white 300 120 3000-3500k 1500 6
VO-FS-NW-12A0 Neutral white 300 120 4000-5000k 1600 6
VO-FS-R-12A0 red 300 120 625nm 600 6
VO-FS-Y-12A0 yellow 300 120 590nm 480 6
VO-FS-G-12A0 green 300 120 515nm 700 6
V0-FS-B-12A0 blue 300 120 470nm 320 6
VO-FS-R-12T1 Red 300 120 625nm 620 3
VO-FS-Y-12T1 Yellow 300 120 590nm 550 3
VO-FS-G-12T1 Green 300 120 515nm 470 3
VO-FS-B-12T1 Blue 300 120 470nm 300 3
VO-FS-CW-12T1 Cool white 300 120 6000-8000k 600 3
VO-FS-NW-12T1 Neutral white 300 120 4000-4500k 550 3
VO-FS-WW-12T1 Warm white 300 120 3000-3500k 500 3
VO-FS-R-24T1 Red 300 120 625nm 620 6
VO-FS-Y-24T1 Yellow 300 120 590nm 550 6
VO-FS-G-24T1 Green 300 120 515nm 470 6
VO-FS-B-24T1 Blue 300 120 470nm 300 6
VO-FS-CW-24T1 Cool white 300 120 6000-8000k 600 6
V0-FS-NW-24T1 Neutral white 300 120 4000-4500k 550 6
V0-FS-WW-24T1 Warm white 300 120 3000-3500k 500 6
Table 2
Representative Electrical Parameters of
Waterproof Single-Color LED Flex Strips
Parameters Symbol Values grill
Operating Voltage Vopr VO-FS- R/Y/ G/B/CW/NW/WW-12T1 12 (+5%0) V
Power Dissipation Max VO -FS-R/Y-12T1 2.2
(V=12VDC) PD VO -FS-G/B/CW/WW-12T1 2.4 W
Operating Temperature Topr -30-+85(-22-+185) 'C ('F)
CA 02726875 2010-12-21
Attorney Docket No. OPTO-109
Customer No. 95,450
Storage Temperature Tstg -30 - +85 (-22 -+185)
Parameters Symbol Values Unit
Operating Voltage Vopr VO-FS- R/Y/ G/B/CW/NW/WW-24T1 24 (+5%) V
Power Dissipation Max VO -FS-R/Y-24T1 2.2
(V=24VDC) PD VO -FS-G/B/CW/WW-24T1 2.4 w
Operating Temperature Topr -30 - +85 (-22 - +185) Storage Temperature Tstg -30
- +85 (-22 - +185) C ( F)
Parameters Symbol Values Unit
Operating Voltage Vopr VO-FS-XX (all colors) -12T5 24 (+5%) V
Power Dissipation Max VO-FS-R/Y-12T5 2.2
(V=24VDC) PD VO-FS-G/B/CW/NW/WW-12T5 2.4 w
Operating Temperature Topr -30-+50 Storage Temperature Tstg -30 - +65
[00061] The lighting strips can be cut to a desired length. Cutting marks can
be provided
along the length of the strips to provide convenience for cutting during an
installation. After
cutting a strip at the cutting mark, the ends of the strips that are exposed
should be sealed with
a terminal to provide waterproofing for the cut ends. As shown in FIGS. 14A-H,
silicone (or
other waterproofing material or adhesive) can be injected into a terminal and
the strip inserted
to provide a waterproof end. A similar process can also be used to join two
lighting strips at
their respective ends and/or in combination with a plastic sleeve to house the
ends.
[00062] Lighting strip embodiments of the invention can be connected through
DC 2.1 or
through wires to the power supply.
Table 3
Representative Optical Parameters at Ta=77 F of
Waterproof Multi-Color LED Flex Strips
Part No. LED LED Quantity Viewing angle Wavelength Luminous flux LED Quantity
Color [pcs]/strip [0] [nm] [lm]/strip [pcs]/segment
VO-FS-RGB- Red 630 9
12T1
Green 18 120 520 23 3
Blue 468 6.5
VO-FS-RGB- Red 630 9
24T1
Green 18 120 520 23 6
Blue 468 6.5
16
CA 02726875 2010-12-21
Attorney Docket No. OPTO-109
Customer No. 95,450
Table 4
Representative Electrical Parameters of
Waterproof Multi-Color LED Flex Strips
Parameters mbol M& UM
Operating Voltage Vopr 12 (+5%) V
Red 1.2
Power Dissipation Green 1.0
Max. (V=12VDC) PD Blue 1.0
Tota 1 3.2
Operating Temperature Topr -30-+85(-22-+185) C ( F)
Storage Temperature Tstg -30 - +85 (-22 -+185) C ( F)
Parameters Symbol Values Unit
Operating Voltage Vopr 24 (+5%) V
Red 1.2
Power Dissipation Green 1.0
Max. (V=24VDC) PD Blue 1.0 w
Total 3.2
Operating Temperature Topr -30 - +85 (-22 - +185) C ( F)
Storage Temperature Tstg -30 - +85 (-22 - +185) C ( F)
[00063] Additionally, the lighting strips of all embodiments of the invention
can be
configured to be cut at predetermined intervals to provide the desired number
of light sources
or the desired length of lighting materials for a particular application.
Exemplary positions
where the strips 100, 200, 300, 400 may be cut are provided at cut indicators.
Cut indicators
can be markings on the substrate to indicate where a cut may be made. Further
for example, in
particular embodiments, the lighting strips 100, 200, 300, 400 can be
configured with cut
indicators that provide for the substrate strip 101, 201, 301, 401 to be cut
into strips comprising
3 or 6 LEDs 109, 209, 309, 409 if desired, or any number appropriate for a
specific application.
[00064] Any of the lighting strips 100, 200, 300, 400 of embodiments of the
invention can
further comprise an adhesive (not shown) for mounting the lighting strips 100,
200, 300, 400 to
a surface. For example, the adhesive can be applied to the bottom surface of
the lighting strips
100, 200, 300, 400 and temporarily protected with tape which can be removed at
the time of
installation to expose the adhesive.
[00065] The flex strips 100, 200, 300, 400 can comprise any number of LEDs
109, 209,
309, 409 such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,
18, 19, 20, 21, 22, 23, 24,
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CA 02726875 2010-12-21
Attorney Docket No. OPTO-109
Customer No. 95,450
25, 26, 27, 28, 29, or 30 or more, with 3, 6, 9, or 18 preferred. Indeed, any
number of LEDs 109,
209, 309, 409 can be used for each flex strip 100, 200.
[00066] FIGS. 5A-G provide representative circuits for embodiments of the flex
strips
according to the invention. More particularly, FIGS. 5A and 5B illustrate an
exemplary electrical
circuit configuration for the flex strip embodiments shown in FIGS. 1A and 1B.
FIGS. 5C and 5D
illustrate an exemplary circuit for the flexible lighting shown in FIGS. 2A
and 2B. Further, the
schematic electrical circuits shown in FIGS. 5E and 5F provide one design for
the lighting strips
shown in FIGS. 3A and 3B. Even further, the circuit schematic provided in FIG.
5G illustrates one
way of configuring the lighting strip of FIGS. 4A and 4B.
[00067] FIG. 5H provides a schematic diagram representing an exemplary way to
install
the lighting strip systems according to embodiments of the invention. As
shown, a plurality of
waterproof lighting strips can be interconnected with one another and one or
more power
sources to provide a lighting system.
[00068] FIGS. 6A-E provide schematic diagrams illustrating various examples of
lighting
strip embodiments of the invention. As shown, FIG. 6A provides a cross section
of a lighting
strip with a rectangular or square profile. Such a lighting strip can be
manufactured by
preparing a mold (two elongated planar supports) generally perpendicular to
the sides of the
PCB substrate to hold the colloid material in place for a sufficient amount of
time to provide a
square or rectangular shaped profile upon removal from the mold. Likewise, as
shown in
FIG. 6B, a generally trapezoidal shaped lighting strip can be formed by using
two elongated and
substantially planar supports disposed at an acute angle with respect to the
PCB. Further, a
triangular cross section can be achieved by placing elongated supports along
the sides of the
PCB at a desired angle to the PCB and the entire area between the supports and
the PCB filled
with the colloidal material, as provided in FIG. 6C. Even further, circular
and elliptical shaped
colloidal materials can be formed by using a corresponding mold to achieve
such a
configuration, as shown respectively in FIGS. 6D and 6E.
[00069] FIGS. 7A-E provide schematic diagrams and photographs of various
waterproof
rigid lighting strips according to embodiments of the invention.
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CA 02726875 2010-12-21
Attorney Docket No. OPTO-109
Customer No. 95,450
[00070] Cross-sectional views of yet additional embodiments of rigid lighting
strips are
provided in FIGS. 8A-D. Such T-tube type bulbs can be provided with waterproof
or non-
waterproof configurations.
[00071] Further, as shown in FIGS. 12A and 12B, the plug/socket connection can
be
performed in part by a friction fit between the corresponding electrical
components of the plug
and corresponding socket and/or by a screw-type connection. Even further, as
shown in FIGS.
12C, 12D and 12E, the connection between the plug and socket can be configured
to be a
latchless type connection, where the components are held together by insertion
of the male
electrical components into the corresponding female components. A protective
sleeve can also
be installed over the connection between two strips alone or in combination
with additional
waterproofing material, such as silicone gel to fill in any gaps.
[00072] Packaging of the flexible lighting strips can be performed in any
conventional
way known or available to those of skill in the art. For example, ten strips
(16 ft) can be
packaged in a reel in an anti-static bag. Such an embodiment is shown in FIG.
13A. Two lighting
strips packaged on reels may be connected using their waterproof connectors,
as shown
unconnected (FIG. 13B) and connected (FIG. 13C).
[00073] FIGS. 15A, 15B, 15C, 15D, and 15E show various views of a waterproof
lighting
system according to the invention. In this embodiment, high brightness 0.5W
SMD PLCC-6 LEDs
can be used for the light sources 1502. The LEDs 1502 are mounted to a
substrate 1501, which
is supported by support 1515. Lighting strips 1500 of this embodiment can be
of any length,
with 1-, 2-, or 3-foot segments being preferred. The strips 1500 are connected
to a power
source by wire leads 1509, which exit the lighting strip at hole 1520. A
waterproofing substance
1523, as shown in FIGS. 15C and 15D, can fill the area around the LEDs 1502,
either partially or
completely covering the sides and/or upper surface of the LED. The wire leads
1509 can
comprise insulation or other waterproofing material to completely fill the
hole 1520 and
thereby waterproof the strip 1500. The lighting strips can be mounted to a
surface by way of
holes 1521 in support 1522, through which screws or any other attaching
mechanism can be
used. Substrate 1501 can be secured to housing 1515 by way of screws 1514.
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CA 02726875 2010-12-21
Attorney Docket No. OPTO-109
Customer No. 95,450
[00074] FIG. 17 shows another waterproof embodiment similar to that shown in
FIGS.
15A-E. Here, lighting strip 1700 comprises a housing 1715 for supporting
substrate 1701.
Mounted onto substrate 1701 are at least one LED 1702. Insulated wire leads
1709 are
attached to the substrate 1701 in an operable fashion to permit the flow of
electricity from the
power source through the circuit of the PCB, through wire leads at the
opposing end of strip
1700, and into a subsequent lighting strip 1700 operably connected in the
lighting strip series.
Socket-type end 1703 comprises structure 1706 for engaging and operably
connecting with
complementary structure 1717 of plug-type end 1704. The connectors 1703, 1704
in this
embodiment provide for a waterproof, releasable engagement with a friction-
fit. Additionally,
waterproofing material 1723 is added to lighting strip 1700 to cover the LEDs
1702 and
substrate 1701 and fill the holes 1720 through which wire leads 1709 exit the
lighting strip
1700. The waterproofing material can be a resin or epoxy or any suitable
material that does
not interfere with operation of the light sources 1702, e.g., transparent.
[00075] Representative optical and electrical parameters for embodiments of
waterproof
single color LED hard strips according to the invention include:
Table 5
Representative Optical Parameters at Ta=77 F of
Waterproof Single-Color LED Rigid Strips
Part No. Color Size (mm) PCB Size Lum Wave- LEDs Segmen View
(mm) ens length t Angle
(Im)
VO-HS-R-12T1 Red 1000x12x10 1000xlOxl.0 300 624nm 60 1 120
VO-HS-Y-12T1 Yellow 1000x12x10 1000x10x1.0 300 590nm 60 1 120
VO-HS-G-12T1 Green 1000x12x10 1000x10x1.0 400 515nm 60 1 120
VO-HS-B-12T1 Blue 1000x12x10 1000x10x1.0 200 470nm 60 1 120
VO-HS-CW-12T1 Cool 1000x12x10 1000x10x1.0 600 5000- 60 1 120
white 10000K
V0-HS-NW-12T1 Neutral 1000xl2xlO 1000x10x1.0 550 3700- 60 1 120
white 5000K
VO-HS-WW-12T1 Warm 10004240 1000x10x1.0 500 2600- 60 1 120
white 3700K
VO-HS-R-24T1 Red 1000x12x10 1000x10x1.0 300 624nm 60 1 120
VO-HS-Y-24T1 Yellow 1000xl2x10 1000x10x1.0 300 590nm 60 1 120
VO-HS-G-24T1 Green 1000x12x10 1000x10x1.0 400 515nm 60 1 120
VO-HS-B-24T1 Blue 1000x12x10 1000x10x1.0 200 470nm 60 1 120
VO-HS-CW-24T1 Cool 1000x12x10 1000x10x1.0 600 5000- 60 1 120
white 10000K
VO-HS-NW-24T1 Neutral 1000x12x10 1000x10xl.0 550 3700- 60 1 120
CA 02726875 2010-12-21
Attorney Docket No. OPTO-109
Customer No. 95,450
white 5000K
VO-HS-WW-24T1 Warm 1000x12x10 1000x10x1.0 500 2600- 60 1 120
white 3700K
VO-HS-R-24T1-101 Red 990x24x8 96 624nm 48 1 120
VO-HS-Y-24T1-101 Yellow 990x24x8 96 590nm 48 1 120
VO-HS-G-24T1-101 Green 990x24x8 96 515nm 48 1 120
VO-HS-B-24T1-101 Blue 990x24x8 40 470nm 48 1 120
VO-HS-CW-24T1-101 Cool 990x24x8 96 5000- 48 1 120
white 10000K
V0-HS-NW-24T1-101 Neutral 990x24x8 80 3700- 48 1 120
white 5000K
VO-HS-WW-24T1-101 Warm 990x24x8 80 2600- 48 1 120
white 3700K
Table 6
Representative Electrical Parameters of
Waterproof Single-Color LED Rigid Strips
Parameters Symbol Values Unit
Operating Voltage Vopr 12(+/-S%) V
Power Dissipation Red/Yellow 2.5
Max. (V=12VDC) PD W
G/B/CW/NW/WW 3.5
Operating Temperature Topr -30-+85 (-22 -+185) C ( F)
Storage Temperature Tstg -30-+85 (-22 - +185) C ( F)
Parameters b I Valu nit
Operating Voltage Vopr 12(+/-5%) V
Forward Current IF 200 mA
Power Dissipation PD 4.8 W
Max. (V=12VDC)
Operating Temperature Topr -20- +50 (-4-+122) C ( F)
Storage Temperature Tstg -20 - +75 (-4 - +167) C ( F)
Table 7
Representative Optical Parameters at Ta=77 F of
Waterproof Multi-Color LED Rigid Strips
Part No. Color Size (mm) Lumens VDC Power LEDs Segment View
(Im) (W) Angle
VO-HS-RGB-24T1-201 RGB 990x24x8.2 96 24 9.6 48 1 120
VO-HS-RGB-24T1-208 RGB 990x36X9 96 24 9.6 48 1 120
VO-HS-RGB-24T1-408 RGB 990x36X9 96 24 9.6 48 1 120
VO-HS-RGB-12T1-216 RGB 990x36X9 40 12 9.6 48 1 120
VO-HS-RGB-12T1-416 RGB 990x36X9 96 12 9.6 48 1 120
[000761 Components of the lighting systems can comprise means for connecting
the
substrates to a power source (not shown) for providing power to the LEDs by
way of the
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Customer No. 95,450
electrically conductive pathways incorporated into or onto the PCBs. The
connection to the
power source can be made by way of wire leads that can be permanently secured
to a PCB
(with or without LEDs) and the power source. Likewise, the connection can be
made by having
a power source with a complementary mating receptacle to accept either the
socket or plug-
type end of the lighting strip system.
[00077] The lighting devices of the present invention can be dimmable and/or
programmable so as to provide color mixing, a chasing circuit, flashing, etc.
Further, the light
strips can operate at voltages of 12 or 24 VDC. To keep the electrical current
consistent during
operation, integrated circuits, transistors, and/or resistors can be used. For
example, with the
24 VDC flex strips, integrated circuits (ICs) can be used, typically
incorporated onto the PCB at
predetermined intervals between the LEDs. In one embodiment of the 24 VDC flex
strips, one
IC can be used for every 6 LEDs. Likewise, for example, resistors can be used
with the 12 VDC
flex strips.
[00078] The lighting systems and strip lighting devices of the present
invention are useful
in many applications where strip-type lighting can be used. For example, the
lighting devices
and systems according to the invention can be used in any residential or
commercial application
where such lighting is desired for decoration, backlighting or functional
lighting, including for
aisle, path, and contour lighting, such as in theatres, hospitals, airplanes,
concert halls,
stadiums, and auditoriums; elegant interior decoration, such as in
restaurants, nightclubs,
casinos, piers, malls, streets, stations, stages, offices and lobbies; homes,
including as accent
lighting in living rooms, under cabinet lighting in kitchens, backlighting in
display cases and
shelving systems, functional and decorative lighting in entryways and
recreational rooms;
seasonal applications, such as for holiday decorations or landscape lighting;
automobiles;
architectural lighting, even including tent or canopy lighting; signal
lighting; and backlighting
larger size signs. The applications mentioned are merely representative of the
numerous
applications for which the lighting systems and strip lighting devices of the
present invention
may be applicable.
[00079] The present invention has been described with reference to particular
embodiments having various features. It will be apparent to those skilled in
the art that various
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Customer No. 95,450
modifications and variations can be made in the practice of the present
invention without
departing from the scope or spirit of the invention. One skilled in the art
will recognize that
these features may be used singularly or in any combination based on the
requirements and
specifications of a given application or design. Other embodiments of the
invention will be
apparent to those skilled in the art from consideration of the specification
and practice of the
invention. It is intended that the specification and examples be considered as
exemplary in
nature and that variations that do not depart from the essence of the
invention are intended to
be within the scope of the invention.
23
