Granted Patent B2

US 7,520,771 · App. 11/539,089 · Granted Apr 21, 2009

Abstract

Claims (41)

1. A string light engine comprising:

a flexible electrical conductor;

a plurality of supports each comprising a dielectric layer and circuitry;

a plurality of IDC connectors each extending away from a respective support and in electrical communication with the circuitry of the respective support, each IDC connector including a terminal that provides an electrical connection between the conductor and the circuitry of the respective support;

at least one LED mounted on each support and in electrical communication with the circuitry of the support; and

plurality of overmolded housings, each housing at least substantially surrounding at least one support of the plurality of supports.

2. The light engine of claim 1 , further comprising a plug in electrical communication with the conductor, the plug being configured to plug into an associated wall outlet.

3. The light engine of claim 1 , further comprising a mounting element associated with at least one of the housings.

4. The light engine of claim 3 , wherein the mounting element comprises a tab extending from a lateral side of the housing, the tab being configured to provide a friction fit between a side surface of a channel into which the light engine is placed.

5. The light engine of claim 3 , wherein the mounting element comprises a resilient clip that connects to the housing, the resilient clip including barbs.

6. The light engine of claim 3 , wherein the mounting element and the overmolded housing are an integrally formed unit.

7. The light engine of claim 3 , wherein the mounting element comprises a fastener and the at least one housing and the at least one support substantially surrounded by the at least one housing includes an opening to receive the fastener.

8. The light engine of claim 7 , wherein the housing comprises a dielectric material and the opening is surrounded by the dielectric material of the housing entirely through the opening.

9. The light engine of claim 1 , wherein the conductor is twisted between adjacent supports.

10. A string light engine comprising:

a flexible electrical conductor; and

a plurality of LED modules attached to the conductor, each module comprising:

an IDC connector,

an LED electrically connected to the IDC connector, an overmolded housing at least substantially surrounding the IDC connector and a portion of the conductor adjacent the IDC connector, and

a support including circuitry, the IDC connector being mechanically connected to the support and electrically connected to the circuitry and the LED being mounted on the support.

11. A string light engine comprising:

a plurality of LEDs;

a plurality of IDC connectors, each IDC connector being in electrical communication with at least one of the plurality of LEDs and operatively mechanically connected to at least one of the plurality of LEDs;

a flexible conductor including at least two wires, the IDC connectors including a terminal inserted into the conductor, the conductor being twisted between a first IDC connector of the plurality of IDC connectors and a second IDC connector of the plurality of IDC connectors.

12. In combination, the string light engine of claim 10 , and a device that is to be illuminated by the string light engine, the device including a channel and the string light engine being disposed in the channel.

13. The combination of claim 12 , wherein the housing of at least one of the plurality of LED modules is configured to engage a side surface of the channel to provide a friction fit of the housing inside the channel.

14. The combination of claim 12 , further comprising a clip connected to the housing of at least one of the plurality of LED modules, the clip engaging a surface of the channel to connect the string light engine inside of the channel.

15. The combination of claim 12 , wherein the device comprises at least one of a channel letter, a component of a reverse halo sign, a backlighting sheet, a box sign and a border tube.

16. A string light engine comprising:

a flexible electrical conductor; and

a plurality of LED modules attached to the conductor, each module comprising:

an LED in electrical communication with the flexible electrical conductor,

an overmolded thermoplastic elastomer housing at least substantially surrounding the LED and contacting a portion of the conductor adjacent the LED, and

a mounting element associated with the housing, wherein the mounting element comprises a tab extending from a lateral side of the housing, the tab being configured to provide a friction fit between a side surface of a channel into which the light engine is placed.

17. The string light engine of claim 16 , wherein the overmolded housing comprises thermoplastic elastomer material having heat conductive properties that are greater than air.

18. The light engine of claim 11 , further comprising a plurality of supports, each support being connected to at least one of the IDC connectors and at least one of the LEDs.

19. The light engine of claim 11 , further comprising an overmolded housing at least partially encapsulating at least one of the plurality of LEDs, at least one of the plurality of IDC connectors and at least a portion of the flexible conductor.

20. The light engine of claim 19 , wherein the overmolded housing comprises material having heat conductive properties that are greater than air.

21. The string light engine of claim 16 , wherein each LED module includes an IDC in electrical communication with the LED and the flexible electrical conductor.

22. The string light engine of claim 16 , wherein each LED module includes a support comprising a dielectric layer and circuitry, wherein the housing at least substantially surrounds the support.

23. The string light engine of claim 16 , wherein the housing includes a strain relief member configured to limit any forces on the conductor that are external the housing to transfer to the portion of the conductor that is in contact with the housing.

Assignments (7)