Abstract
An apparatus, manufacture and method of illumination support being a single monolithic substrate with light emitting diodes mounted on the external sides of the monolithic substrate. The necessary circuitry for the LEDs is embedded in one or more rigid or flexible electrical substrate that is affixed to one or more of the external sides of the monolithic substrate. The two terminal ends of the monolithic substrate are designed to fit into the lamp sockets of an existing or new light fixture without the use of end caps or end socket adapters, which provides structural support for the monolithic substrate.
Claims
1. An apparatus, comprising: a lamp support comprising an elongated extrusion including four sides enclosing a hollow core extending from a first end of the elongated extrusion to a second end of the elongated extrusion, wherein each end of the elongated extrusion is configured to fit securely within a recess of a recessed double contact socket, wherein a protruding contact structure, which protrudes from the recess, is received within the hollow core of the elongated extrusion; and one or more light emitting diode (LED) strings, affixed to one or more of the four sides of the elongated extrusion, wherein each LED string includes: one or more LEDs; and wiring suitable for connecting the one or more LEDs to a power source not connected to the protruding contact, thereby enabling powering of the LED string independently of the protruding contact.
2. The apparatus of claim 1, wherein a cross-section of the elongated extrusion is rectangular.
3. The apparatus of claim 2, wherein the cross-section of the elongated extrusion is square.
4. The apparatus of claim 1, wherein the elongated extrusion comprises a rigid plastic elongated extrusion.
5. The apparatus of claim 1, wherein the elongated extrusion comprises a metal elongated extrusion.
6. The apparatus of claim 1, wherein each LED light string includes a substrate, wherein the substrate includes circuitry and components configured to deliver power appropriate for the one or more LEDs.
7. The apparatus of claim 6, wherein the substrate comprises a flexible substrate.
8. The apparatus of claim 7, wherein the one or more LEDs are affixed to a first external surface of the flexible substrate and wherein adhesive tape is affixed to a second external surface of the flexible substrate.
9. The apparatus of claim 8, further comprising: a transparent sleeve, heat shrunk to encapsulate the lamp support and the one or more LED strings.
10. The apparatus of claim 9, further comprising a sealant applied at one or both ends of the transparent sleeve.
11. The apparatus of claim 6, wherein the substrate comprises a rigid substrate.
12. The apparatus of claim 6, further comprising: an adhesive substrate to facilitate connection between the one or more LED light strings and the elongated extrusion.
13. The apparatus of claim 1, wherein each end of the elongated extrusion is configured to fit securely within a recess of a T-12 recessed double contact socket.
14. The apparatus of claim 1, wherein one or more of the LED light strings are affixed to two or more of the four sides of the elongated extrusion.
15. The apparatus of claim 1, wherein one or more of the LED light strings are affixed to three or more sides of the elongated extrusion.
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 extruded and 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.
