Abstract
An illumination apparatus includes a monolithic support substrate and light emitting diodes (LEDs) on one or more external sides of the support substrate. The support substrate may comprise an elongated extrusion enclosing a hollow core. The LEDs may be affixed to rigid or flexible electrical substrates. Each electrical substrate may be affixed to an external side of the extrusion and may include embedded LED circuitry. The hollow core may enable the extrusion to be received in a recessed socket of a light fixture, wherein the recessed socket provides structural support for the applicable end of the extrusion, rendering end caps or end socket adapters unnecessary. The light fixture may include a contact protruding from the recessed socket and the electrical substrates may include circuitry configured to couple the LEDs to a source of power not coupled to the protruding contact.
Claims
1. A lamp apparatus, comprising: a monolithic support including an end configured to receive a protruding contact protruding from a recessed lamp socket; and one or more light emitting diode (LED) strings, affixed to the monolithic support, wherein each of the one or more LED strings includes: one or more LEDs; and circuitry configured to couple the one or more LEDs to a power source not electrically coupled to the protruding contact.
2. The lamp apparatus of claim 1, wherein one or more of the one or more LED strings includes an LED housing the monolithic support.
3. The lamp apparatus of claim 2, wherein one or more of the one or more LEDs includes a lens.
4. The lamp apparatus of claim 1, wherein the end of the monolithic support defines an opening configured to receive the protruding contact.
5. The lamp apparatus of claim 1, wherein the monolithic support comprises an extruded monolithic support.
6. The lamp apparatus of claim 5, wherein the extruded monolithic support defines a hollow core.
7. The lamp apparatus of claim 6, wherein the extruded monolithic support includes a plurality of external surfaces.
8. The lamp apparatus of claim 7, wherein one or more of the one or more LEDs strings are affixed to one or more of the plurality of external surfaces.
9. The lamp apparatus of claim 7, wherein the monolithic support includes four external surfaces.
10. The lamp apparatus of claim 9, wherein the monolithic support has a substantially square or rectangular cross section.
11. The lamp apparatus of claim 1, further comprising: a heat shrunk transparent sleeve affixing one or more of the one or more LED strings to the monolithic support.
12. The lamp apparatus of claim 11, further comprising a sealant applied at one or both ends of the heat shrunk transparent sleeve.
13. The lamp apparatus of claim 1, further comprising: an adhesive to adhere one or more of the one or more LED light strings to the monolithic support.
14. The lamp apparatus of claim 1, further comprising: one or more mechanical fasteners fastening one or more of the one or more LED light strings to the monolithic support.
15. The lamp apparatus of claim 1, wherein at least a portion of at least one of the one or more LED strings is encapsulated by an encapsulant.
16. The lamp apparatus of claim 15, wherein the encapsulant comprises a transparent and water resistant encapsulant.
17. A lighting apparatus, comprising: an elongated monolithic support including an end configured to receive a protruding contact protruding from a recessed lamp socket, wherein the protruding contact received in the end of the elongated monolithic support provides mechanical support for the monolithic support; and one or more light emitting diode (LED) strings, affixed to the elongated monolithic support, wherein each of the one or more LED strings includes: one or more LED substrates; one or more LEDs mounted on each of the one or more LED substrates; and power source circuitry configured to couple the LED string to an independent source of power for powering each of the one or more LEDs, wherein the independent source of power is not electrically coupled to the protruding contact.
18. The lighting apparatus of claim 17, wherein at least one of the one or more LED includes a moisture barrier to protect the one or more LEDs from moisture.
19. The lighting apparatus of claim 17, wherein at least one of the one or more LED strings is encased within a transparent substrate providing a barrier between the one or more LEDs and environmental moisture.
20. The lamp apparatus of claim 17, wherein cross sectional dimensions of a body portion of the elongated monolithic support are substantially the same as cross sectional dimensions of the end of the elongated monolithic support.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
(1) FIG. 1 is a perspective view of the elongate support element;
(2) FIG. 2 is a top view of the LED String (Only Prior Art Depicted);
(3) FIG. 3 is a side view of the LED String (Only Prior Art Depicted);
(4) FIG. 4 is a perspective of the elongate support member with LED String attached on two exterior faces of the support element;
(5) FIG. 5 is perspective view of a T-12 lamp socket (Only Prior Art Depicted);
(6) FIG. 6 depicts how the invention is installed between two opposing lamp sockets;
(7) FIG. 7 depicts a light cabinet with the invention installed in the opposing lamp sockets.
DETAILED DESCRIPTION OF THE INVENTION
(8) Embodiments of the invention are directed to a extruded monolithic substrate for support of LEDs 1 (FIG. 1) to facilitate the replacement of florescent lamps 14 (FIG. 7), or other type of double contact lamps, with light emitting diodes (LED) to illuminate a light cabinet or other lighting applications. The extruded monolithic substrate is an elongate form that may have a hollow or solid cross section core. The preferred embodiment of the invention has a monolithic substrate with a square cross section with a hollow core. The monolithic substrate may be made of any material and in any cross sectional shape as may be extruded. The ends of the monolithic substrate may be machined to fit into the shape of the existing lamp sockets if the shape of the cross section of the monolithic substrate does not match the existing lamp socket. The monolithic substrate of the invention is a unitary piece and functions without the use of end caps or end socket adapters needed to connect the monolithic substrate with the existing lamp socket.
(9) Installation of the invention is easy and requires no additional support brackets or end cap adapters because the terminal ends 2a, 2b (FIG. 1) of the monolithic substrate 1 (FIG. 1) are designed to fit directly into the existing light fixture 12 (FIG. 7) lamp sockets 9 (FIG. 7) and use these as the structural supports. When the invention is installed in two opposing lamp sockets then it is secured in its service position 12 (FIG. 7). The existing lamp sockets are used as structural supports but are eliminated as live circuits and instead the light emitting diodes are wired directly to the power source. The monolithic substrate can accommodate various types of light emitting diodes 6 (FIGS. 2 and 3). The monolithic substrate may be straight, bent, or curved to accommodate different light cabinet shapes as needed.
(10) The configurations of LEDs that work with the monolithic substrate include but are not limited to the following examples. The LED can be mounted onto a flexible or rigid substrate defined as the electrical substrate 5 (FIGS. 2 and 3) and the electrical substrate may contain all the needed circuitry to deliver the appropriate power to the LED, as well as any other electronic components required to control the LED. When mounted on to an electrical substrate with all the needed circuitry contained within the electrical substrate; the electrical substrate, inner circuitry, and LEDs are referred to, and defined as, a LED String 4 (FIGS. 2 and 4). A String may contain one or more LEDs. The LEDs can also be mounted onto multiple electrical substrates. The multiple electrical substrates can contain the circuitry required for powering the LED or controlling the LED, facilitate the connection between the LED String and the monolithic substrate, and provide a weather and moisture barrier to protect the LED and circuitry. The electrical substrate may also be mounted on an adhesive substrate 8 (FIG. 3) that facilitates the connection of the LED String to the monolithic substrate. The LED String may also be encased in a transparent substrate to provide a weather and moisture barrier to extend the service life of the LED. The LED String may also be mounted onto a housing piece that facilitates the connection between the LED String and the monolithic substrate. The LED String may also have notches or holes in the Sting that facilitates the connection to the monolithic substrate.
(11) The monolithic substrate is comprised of two terminal ends 2a, 2b (FIGS. 1, 4, and 6) and an elongate solid or hollow body portion 1 (FIG. 1, 4, 6) between the two terminal ends. The elongate body portion has multiple exterior sides 15 (FIGS. 1, 4 and 6) upon which a LED String 4 (FIG. 2) can be affixed or connected. An external side of the support element can be either a flat external side of the monolithic substrate or be the external side of the elongate body of the monolithic substrate in the case of a monolithic substrate with a circular cross section.
(12) The invention is made by determining the appropriate dimensions of the needed elongate body length of the invention and size of the terminal ends of the monolithic substrate so that they may fit, without modification, directly into the existing light fixture 12 (FIG. 7) lamp sockets 9 (FIGS. 5 and 7). Once the light fixture lamp socket dimensions have been determined then the terminal ends of the monolithic substrate can be designed to fit into the light fixture lamp socket. The light fixture lamp socket dimensions may determine the height and depth of the terminal ends of the monolithic substrate but the elongate body of the monolithic substrate may be of larger or smaller dimensions as is structurally required. Once the monolithic substrate is sized then one or more LED Strings 4 (FIGS. 2 and 4) are affixed to the external sides 15 (FIGS. 1, 4 and 6) of the monolithic substrate. After affixing or connecting the LED String or Strings to the external side or sides, of the monolithic substrate elongate body then a transparent plastic sleeve may be installed over the entire length of the monolithic substrate and LED Strings to provide a standalone or additional weather and moisture barrier. This transparent sleeve moisture barrier may be made of a heat shrinkable material. Furthermore, silicone, hot melt copolymer, epoxy, or other sealant may be injected inside the ends of the transparent sleeve to provide additional moisture resistance.
(13) The preferred embodiment of the invention is an elongate monolithic extrusion 1 (FIGS. 1, 4, 6 and 7) that is designed with terminal end 2a, 2b (FIGS. 1, 4 and 6) dimensions that fit securely into widely used existing T-12 sockets 9 (FIGS. 5, 6 and 7) of a light cabinet 12 (FIG. 7). The monolithic substrate has an elongate body with a square cross section and a hollow core 3 (FIGS. 1, 3 and 6). The elongate body of the monolithic substrate has the same cross section dimensions as those of the terminal ends, being a square cross section. The T-12 lamp sockets have a recessed rectangular hole 10 (FIGS. 5 and 6) that has a protruding contact piece 11 (FIGS. 5 and 6) within the recessed hole of the lamp socket 9 (FIGS. 5, 6 and 7). The monolithic substrate 1 (FIG. 6) is installed by pushing the terminal end 2a, 2b (FIG. 6) into the recessed opening 10 (FIG. 6) of the lamp socket 9 (FIG. 6) and the protruding contact 11 (FIGS. 5 and 6) fits snuggly within the hollow terminal end opening 3 (FIG. 6) of the monolithic substrate.
(14) The length of the invention is determined by the length of the florescent lamps 14 (FIG. 7) that are being replaced. Once the monolithic substrate has been cut to size for length then a LED String or LED Strings, are affixed to the external side or sides 15 (FIGS. 1, 4 and 6) of the monolithic substrate as needed. The LED String 4 (FIG. 2) contains one or more LEDs 6 (FIGS. 2 and 3) mounted on a flexible electrical substrate 5 (FIGS. 2 and 3) that contains and encloses all the needed circuitry within the flexible electrical substrate, the flexible electrical substrate has the LED on one external face of the flexible electrical substrate and an adhesive tape 8 (FIG. 3) on the opposite external face of the flexible electrical substrate. This adhesive tape facilitates the connection between the LED String and the monolithic substrate. After connecting the LED String to the monolithic substrate as needed a transparent heat shrinking sleeve is pulled over the elongate body of the monolithic substrate covering the entire body of the monolithic substrate and LED String. A commercial sealant is then added to one or both ends of the transparent sleeve between the sleeve and the monolithic substrate providing a moisture resistant barrier between the transparent sleeve and the monolithic substrate, particular care should be taken in applying the sealant when wiring 7 (FIGS. 2, 3 and 4) from LED String to the power source exit from within the transparent sleeve. If the LED String 4 (FIGS. 2 and 4) external wiring 7 (FIGS. 2, 3 and 4) to the power source does not enter through the end of the transparent sleeve but rather enters the transparent sleeve between the two ends of the transparent sleeve then sealant should be applied where the external wiring enters the transparent sleeve. After the sealant has been applied between the transparent sleeve and the monolithic substrate then heat is applied to the transparent sleeve so that the sleeve provides a tight fit around the LED String and the monolithic substrate.
