LED LIGHTING SYSTEM AND INSTALLATION METHODS
20230175656 · 2023-06-08
Inventors
Cpc classification
F21V23/003
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01L33/62
ELECTRICITY
F21S8/026
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2115/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V23/001
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2113/13
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S9/022
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H05B47/20
ELECTRICITY
H05B45/50
ELECTRICITY
F21W2131/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V23/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S8/046
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S2/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21W2131/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V25/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F21S8/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S8/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V23/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S9/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V25/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V23/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S2/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H05B45/50
ELECTRICITY
Abstract
A lighting system includes an LED downlight mountable to a ceiling, a driver, and an insulation displacement connector (IDC). Light from the downlight can be faced downward to project light or upward to reflect light off of the ceiling. The driver has an input with a first voltage and an output with a second voltage, the second voltage being lower than the first and being provided through a wire system extending from the LED driver. The IDC connects the downlight to the wire system. The lighting system can be changed from a first to a second configuration by at least one of adding an additional downlight using a corresponding MC or removing an existing downlight using a corresponding IDC. The second configuration does not significantly affect a desired output range of light from any downlight or any LED circuit of any downlight that remains or preexists from the first configuration.
Claims
1. An LED lighting device having selectable color temperatures of white light emission, the LED lighting device comprising: a water-resistant housing comprising a first lens and a second lens over the first lens; a first LED circuit and at least one additional LED circuit mounted on a single printed circuit board beneath the first lens, wherein the first LED circuit and the at least one additional LED circuit include at least two discrete LED packages that each contain a phosphor material and at least one LED chip configured to emit a wavelength of blue light into the phosphor material such that the at least two discrete LED packages in the first LED circuit emit a first color temperature of white light and the at least two discrete LED packages in the at least one additional LED circuit emit a different second color temperature of white light, wherein the combination of the first color temperature of white light and second color temperature of white light is emitted from the LED lighting device when the first LED circuit and the at least one additional LED circuit are powered, and wherein the first LED circuit and the at least one additional LED circuit are configured to be powered with one of at least two different selectable levels of low DC voltage that cause the first LED circuit to provide an output of at least two different levels of brightness and the at least one additional LED circuit to provide an output of at least two different levels of brightness; and a switch configured to be selectable by an end user to provide the end user with a means for (i) selecting one of the at least two different levels of the low DC voltage to be input to at least one of the first LED circuit and the at least one additional LED circuit to produce a change in brightness of the at least one of the first LED circuit or the at least one additional LED circuit and a change in color temperature of white light emitted from the LED lighting device, wherein the LED lighting device is configured receive a low voltage level of AC voltage from an output of a remote transformer configured to receive an input from an AC mains voltage source and provide the low voltage level of AC voltage onto a wire system extending from the remote transformer, wherein the LED lighting device includes an insulation displacement connector configured to make a direct electrical connection with the wire system, wherein one or more additional LED lighting devices having an insulation displacement connector are configured to be added to the wire system to receive the low voltage level of AC voltage from the remote transformer by using the insulation displacement connector, and wherein a location of the direct electrical connection of the insulation displacement connector is not limited by the wire system.
2. An LED lighting device having selectable color temperatures of white light emission comprising: a water-resistant housing comprising a first lens and a second lens over the first lens a first LED circuit and at least one additional LED circuit mounted on a single printed circuit board beneath the first lens, wherein the first LED circuit and the at least one additional :LED circuit include at least two discrete LED packages, wherein the at least two discrete LED packages in the first LED circuit each contain a phosphor material and at least one LED chip configured to emit a wavelength of blue light into the phosphor material such that the at least two discrete LED packages in the first LED circuit emit a first color temperature of white light from the at least two discrete LED packages, wherein the at least two discrete LED packages in the at least one additional LED circuit each contain a phosphor material and at least one LED chip configured to emit a wavelength of blue light into the phosphor material such that the at least two discrete LED packages in the at least one additional LED circuit emit a second different color temperature of white light from the at least two discrete LED packages through the first and second lens when the first LED circuit and the at least one additional LED circuit are powered, and wherein the first LED circuit and the at least one additional LED circuit are configured to be powered with one of at least two different selectable levels of low DC voltage that cause the first LED circuit to provide an output of at least two different levels of brightness and the at least one additional LED circuit to provide an output of at least two different levels of brightness; and a switch configured to be selectable by an end user to provide the end user with a means for (i) selecting one of the at least two different levels of low DC voltage to be input to at least one of the first LED circuit and the at least one additional LED circuit to produce a change in brightness of at least one of the first LED circuit or the at least one additional LED circuit and a change in color temperature of white light emitted from the LED lighting device, wherein the LED lighting device is configured receive a low voltage level of AC voltage from an output of a remote transformer configured to receive an input from an AC mains voltage source and provide the low voltage level of AC voltage onto a wire system extending from the remote transformer, wherein the LED lighting device includes an insulation displacement connector configured to make a direct electrical connection with the wire system, wherein one or more additional lighting devices having an insulation displacement connector is configured to be added to the wire system to receive the low voltage level of AC voltage from the remote transformer by using the insulation displacement connector, and wherein a location of the direct electrical connection of the insulation displacement connector is not limited by the wire system.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
[0034]
[0035]
[0036]
[0037]
[0038]
[0039]
[0040]
[0041]
[0042]
[0043]
[0044]
[0045]
[0046]
[0047]
[0048]
[0049]
[0050]
[0051]
[0052]
[0053]
[0054]
[0055]
[0056]
[0057]
[0058]
[0059]
[0060]
[0061]
[0062]
DETAILED DESCRIPTION
[0063] While this invention is susceptible to embodiments in many different forms, there is described in detail herein, preferred embodiments of the invention with the understanding that the present disclosures are to be considered as exemplifications of the principles of the invention and are not intended to limit the broad aspects of the invention to the embodiments illustrated.
[0064] The present invention proposes that low voltage downlight systems that include downlights and remote drivers, can be installed similar to low voltage garden pathway lights, thereby providing a much simpler installation process with less work, reduced and simplified electrical wiring and lower cost to the end user by connecting downlights in parallel using insulation displacement “EDC” connectors across a low voltage pair of wires (similar to garden lighting) that are treated like a power buss that is coming from the output of the low voltage LED downlight driver. The driver may also be integrated into a junction box and then provide at least one pair of wires out that can be laced across a ceiling for installation of downlights at desired locations within the ceiling.
[0065] In most cases the present invention may also substantially reduce and or eliminate the need to pay for the expense of a professional electrician and allows an installer of these downlights to make the final electrical connections using only a simple tool such as pliers or the like. In the case of DC power supplier that require polarity, it is contemplated the IDC connector could be keyed and/or marked and that the wire could be keyed and or marked as one option, and another option is to have polarity sensing capability and circuitry in the LED downlight that would prevent and correct for any improper polarity connections to the IDC connectors.
[0066] Some illustrative embodiments are directed to an LED light emitting device and LED light system capable of operating during both the positive and negative phase of an AC power supply. In order to operate during both phases provided by an AC power, as is shown herein, the circuit must allow current to flow during both the positive and negative phases and LED light emitting devices may be configured such that at least one LED is capable of emitting light during one or both of the positive or negative phases. In order to accomplish this, the LED circuit itself may be configured so as to allow current to pass during both phases, or the device may include a bridge rectifier to rectify AC power for use by single LEDs, series strings of LEDs, and parallel series strings of LEDs. Rectification may be accomplished within the light emitting device, or prior to any power being provided to the same. Once integrated into a light system, the present invention further contemplates a driver having the ability to provide a substantially constant voltage at a substantially constant frequency, and that the driver be configured in a manner which will allow LED light emitting devices to be added to or subtracted from the system, regardless of configuration, without having to add, subtract, or change the values of discrete circuit components and without affecting the light output of any individual LED.
[0067]
[0068]
[0069]
[0070]
[0071]
[0072]
[0073]
[0074]
[0075]
[0076]
[0077]
[0078]
[0079]
[0080]
[0081]
[0082]
[0083] Rather than be packaged together and mounted on a single substrate, and no matter whether the LEDs and diodes are integrated into a single package or are discrete individual LEDs and/or diodes wire-bonded together, as disclosed in
[0084] Regardless of whether rectifier 302 and LEDs 306 are integrated or mounted in a single package or are discretely packaged and connected, in order to drop higher voltages any number of LEDs may be connected in series or parallel in a device to match a desired voltage and light output. For example, in a lighting device that is run off of a 120 V source and contains LEDs having a forward operating voltage of 3V each connected to a bridge rectifier having diodes also having a forward operating voltage of 3V each, approximately 38 LEDs may be placed in series to drop the required voltage.
[0085]
[0086]
[0087]
[0088] Any of the aforementioned AC drive methods may likewise be used with the devices embodied in
[0089] For example,
[0090] Similarly, AC drive Method 186 may be utilized may be used with a single or plurality of devices 214 as disclosed in
[0091]
[0092]
[0093]
[0094]
[0095]
[0096]
[0097]
[0098]
[0099]
[0100]
[0101]
[0102]
[0103]
[0104]
[0105] The LED downlight(s) 252 may also be referred to as a lighting fixture(s). Each LED downlight(s) 252 may be mounted to or mounted into a ceiling 310. For example, an LED downlight 252 may be at least partially integrated within a ceiling tile of ceiling 310,
[0106] The driver 258 may also be referred to as an LED driver. The LED driver may be a low voltage LED driver. In some example embodiments, the LED driver is configured to receive one of a plurality of voltage inputs. The driver 258 may be mounted to a wail, ceiling, or integrated into an electrical junction box 300. The driver 258 has an input and an output. In this illustrative example, the input is an AC voltage and the output is an AC voltage or DC voltage that is lower than the first voltage. The output of the driver 258 may provide an output voltage and an output current to the LED downlight(s) 252, the output voltage and output current being relatively constant when connected to the LED downlight(s) 252.
[0107] The wire system 256 may include at least one output wire. In some examples, the wire system 256 includes at least one pair of output wires connected to the output of the driver 258. Thus, the output voltage provided by the driver 258 is provided through the one or more output wires of the wire system 256.
[0108] As depicted, each LED downlight 252 is electrically connected to the driver 258 by a corresponding insulating displacement connector 254. In these example embodiments, the electrical connection is an indirect connection. Specifically, the corresponding insulating displacement connector 254 electrically connects the LED downlight 2582 to the wire system 256 to thereby electrically connect the LED downlight 252 to the driver 258. This electrical connection connects the LED downlight 252 to the output of the driver 258 such that the output voltage from the driver 258 is supplied to the LED downlight 252 through the wire system 256.
[0109] Each LED downlight 252 may be connected to the corresponding insulating displacement connector 254 directly or through at least one wired connection. This wired connection may be formed using one or more connecting wires 260. For example, the corresponding insulating displacement connector 254 may be connected to the LED downlight 252 via a connecting wire 260.
[0110] Each LED downlight 252 is integrated into ceiling 310 such that light faces (or projects) downward relative to ceiling 310. In some examples, an LED downlight 252 is configured to deliver one or more colors of light. in some embodiments, the LED downlighting system 250 that includes a first LED downlight for providing at least one of a different color, a different wavelength, or a different amount of light than at least one other LED downlight in the LED downlighting system 250. The driver or at least one LED downlight of the LED downlights 252 in the LED lighting system 250 may be able to produce light with at least one of a different color, a different wavelength, or a different amount of light in response to a change in voltage, in response to a dimmer, or in response to a controller.
[0111] In some example embodiments, the LED lighting system 250 is dimmable. In some cases, one or more of the LED downlights 252 in the LED lighting system 250 are configured to deliver light output during a power failure. For example, the LED downlight 252 may be powered using a battery during a power failure. The battery may be used for a battery backup system in one of a residential, commercial, or industrial building.
[0112] Each LED downlight 252 may include one or more LED circuits. An LED circuit in an LED downlight 252 may be capable of sensing and correcting reverse polarity being input to the LED downlight 252. Further, the LED circuit may be capable of emitting light during both a positive phase and a negative phase of a mains AC power source. The mains AC power source may be providing the input voltage to the driver 258.
[0113]
[0114]
[0115]
[0116] The cavity 314 helps position and hold (or retain) a portion of the wire system 256. For example, the cavity 314 may help position and hold a pair of output wires of the wire system 256. In other example embodiments, some other type of wire positioning area or element may be used to position and hold these output wires. The conductive pins 316 are used to pierce through the insulation jacket of the output wires of the wire system 256 and to make an electrical connection once the insulation displacement connector 254 has been closed and placed in a closed configuration.
[0117] The hinge 318 allows insulation displacement connector 254 to be opened and closed at least once in order to position the output wires of the wire system 256 within the cavity 314 of the insulation displacement connector 254. The closing of the insulation displacement connector 254 via the hinge 318 (e.g., mechanically closed or squeezed by hand or by a tool) allows the conductive pins 316 to pierce through the output wires and make an electrical connection. In this manner, the insulation displacement connector 254, which may be connected to the LED downlight 252 from
[0118] Thus, the LED downlighting system 250 from
[0119]
[0120] The method 4100 may begin by installing an LED downlighting system relative to a ceiling such that light projects at least one of downwards relative to the ceiling or upwards relative to the ceiling to reflect off of the ceiling, wherein the LED downlighting system includes an LED driver, at least one LED downlight, and at least one insulating displacement connector (step 4102). Step 4102 may include mounting one or more LED downlights to a ceiling or integrating the one or more LED downlights at least partially into the ceiling.
[0121] Optionally, optionally, one or more additional LED downlights may be added to the LED lighting system using one or more corresponding insulation displacement connectors (step 4104). Optionally, one or more existing LED downlights may be removed from the LED lighting system using one or more corresponding insulation displacement connectors (step 4106). In some example embodiments, both steps 4104 and step 4106 may be performed. In other example embodiments, one of step 4104 and step 4106 may be performed. Each of or both of steps 4104 and 4106 may be considered changing the LED downlighting system from a first configuration to a second configuration. Changing the LED downlighting system to the second configuration by adding one or more LED downlights in step 4104, removing one or more LED downlights in step 4106, or both does not significantly affect a predetermined desired output range of light from any LED downlight in the LED lighting system or from any LED circuit of any LED downlight in the LED lighting system that remains from or is preexisting from the first configuration. In these example embodiments, step 4106 may only be performed as long as at least one LED downlight remains in the second configuration of the LED lighting system after one or more existing LED downlights are removed from the LED lighting system to form the second configuration.
[0122] Optionally, a wireless signal may be sent to the LED driver or to one or more LED downlights in the LED downlighting system (step 4108). The wireless signal may be used to control the light that is emitted by each individual LED downlight in the LED downlighting system or the LED downlighting system overall. In some cases, the wireless signal is sent to all of the LED downlights in the LED downlighting system simultaneously. In other cases, the wireless signal is sent individually to one or more of the LED downlights in the LED downlighting system.
[0123] In some alternative implementations, the function or functions noted in the blocks of method 4100 above may occur out of the order noted in the figures. For example, in some cases, step 4104, step 4106, or both may be performed prior to step 4102. In still other examples, steps shown in succession may be executed substantially concurrently, or performed in the reverse order, depending upon the functionality involved. Also, other steps in addition to those illustrated in
[0124] Various portions of one or more of the embodiments described above may be used in combination with other portions of one or more other embodiments described above.
[0125] According to one broad aspect of the invention a lighting system is provided having one or more LED circuits. Each LED circuit has at least two diodes connected to each other in opposing parallel relation, wherein at least one of which such diodes is an LED. As used throughout the application, the term diode may mean any type of diode capable of allowing current to pass in a single direction, including but not limited to, a standard diode, a schottky diode, a zener diode, and a current limiting diode. A driver is connected to the one or more LED circuits, the driver providing an AC voltage and current to the one or more LED circuits. The driver and the LED circuits form a driven circuit. The driver and the LED circuits are also configured such that LED circuits may be added to or subtracted (intentionally or by component failure) from the driven circuit: [0126] (a) without significantly affecting the predetermined desired output range of light from any individual LED; and, [0127] (b) without the need to: (i) change the value of any discrete component; or, add or subtract any discrete components, of any of the preexisting driven circuit components which remain after the change.
[0128] In another embodiment of the invention at least one capacitor is connected to and part of each LED circuit. In yet another embodiment, at least one resistor is connected to and is part of each opposing parallel LED circuit noted above. The resistor is connected in series with the at least one capacitor.
[0129] According to another aspect of the invention an LED circuit (sometimes referred to as an “AC LED”) can comprise two opposing parallel LEDs, an opposing parallel LED string or an opposing parallel LED matrix. These opposing parallel LEDs may have a capacitor in series connected to at least one junction of the connected opposing parallel configurations within a single chip, a single package, an assembly or a module.
[0130] When a real capacitor is connected in series in one or more lines between an LED and an AC power source, there is a displacement current through that capacity of magnitude: I=2πfCV. The capacitor in the LED circuits of the invention regulates the amount of current and forward voltage delivered to the one or more opposing parallel LEDs based on the voltage and frequency provided by the AC driver. Based on the number of LEDs in the LED circuit the opposing parallel connections provide two or more junctions to which at least one series capacitor may be connected in series of at least one power connection lead. In some embodiments, LED circuits may also use a series resistor in addition to the capacitor providing an “RC” resistor capacitor network for certain LED circuit driver coupling that does not provide protection against surge currents to the LED circuits.
[0131] According to another aspect of the invention an LED circuit may comprise a single LED or a series string of diodes and/or LEDs connected to a full bridge rectifier capable of rectifying a provided AC voltage and current for use by the series string of diodes and/or LEDs. The rectifier may be formed as part of the LED circuit, or may be formed separately, having leads provided on both the output of the driver and the input of the LED circuit to allow the LED circuit to connect directly to the driver. In order to protect the LED circuit from voltage spikes a capacitor may be connected across the inputs of the bridge rectifier. The capacitor may also be used for smoothing the AC waveform to reduce ripple. A capacitor may likewise be connected between one rectifier input and the AC voltage and current source in order to limit the DC current flow to protect the LEDs. The bridge diode and LED circuit may be packaged separate or together, and may be configured within a single chip or two chips, a single package or two packages, an assembly, or a module.
[0132] According to another aspect of the invention, a single bridge rectifier may be used to drive parallel LEDs or series strings of diodes and/or LEDs. Alternatively, it is contemplated by the invention that each LED circuit requiring a bridge rectifier to utilize both the high and low phases of an AC power wave may include its own full bridge rectifier integrated or otherwise connected thereto. In embodiments where each LED circuit includes its own rectifier, additional LED circuits may be added in parallel across an AC voltage and current source to any existing LED circuits without concern of connecting to any existing bridge rectifiers or, where used, capacitors. Providing each LED circuit with its own bridge rectifier has the further advantage of scaling capacitors included in the circuit for voltage protection and/or current limiting to be matched to a particular LED or string of diodes and/or LEDs.
[0133] It should be noted that “package” or “packaged” is defined herein as an integrated unit meant to be used as a discrete component in either of the manufacture, assembly, installation, or modification of an LED lighting device or system. Such a package includes LED's of desired characteristics with capacitors and or resistors (when used) sized relative to the specifications of the chosen LED's to which they will be connected in series and with respect to a predetermined AC voltage and frequency.
[0134] Preferred embodiments of a package may include an insulating substrate whereon the LEDs, capacitors and/or resistors are formed or mounted. In such preferred embodiments of a package, the substrate will include electrodes or leads for uniform connection of the package to a device or system associated with an AC driver or power source or any individually packaged rectifiers used to rectify AC voltage and current. The electrodes, leads, and uniform connection may include any currently known means including mechanical fit, and/or soldering. The substrate may be such as sapphire, silicon carbide, galium nitride, ceramics, printed circuit board material, or other materials for hosting circuit components.
[0135] A package in certain applications may preferably also include a heat sink, a reflective material, a lens for directing light, phosphor, nano-crystals or other light changing or enhancing substances. In sum, according to one aspect of the invention, the LED circuits and AC drivers of the present invention permit pre-packaging of the LED portion of a lighting system to be used with standardized drivers (and when necessary full wave rectifiers) of known specified voltage and frequency output. Such packages can be of varied make up and can be combined with each other to create desired systems given the scalable and compatible arrangements possible with, and resulting from, the invention.
[0136] According to one aspect of the invention, AC driven LED circuits (or “driven circuits”) permit or enable lighting systems where LED circuits may be added to or subtracted (either by choice or by way of a failure of a diode) from the driven circuit without significantly affecting the predetermined desired output range of light from any individual LED and, without the need to: (i) change the value of any discrete component; or, (ii) to add or subtract any discrete components, of any of the preexisting driven circuit components which remain after the change. During design of a lighting system, one attribute of the LEDs chosen will be the amount of light provided during operation. In this context, it should be understood that depending on the operating parameters of the driver chosen, the stability or range of the voltage and frequency of the driver will vary from the nominal specification based upon various factors including but not limited to, the addition or subtraction of the LED circuits to which it becomes connected or disconnected. Accordingly, as sometimes referred to herein, drivers according to the invention are described as providing “relatively constant” or “fixed” voltage and frequency. The extent of this relative range may be considered in light of the acceptable range of light output desired from the resulting circuit at the before, during, or after a change has been made to the lighting system as a whole. Thus it will be expected that a predetermined range of desired light output will be determined within which the driven LED circuits of the invention will perform whether or not additional or different LED circuits have been added or taken out of the driven circuit as a whole or whether additional or different LED circuits have been added proximate any existing LED circuits or positioned remotely.
[0137] According to another aspect of the invention an LED circuit may be at least one pre-packaged LED and one pre-packaged diode connected together opposing parallel of each other, two opposing parallel pre-packaged LEDs, an opposing parallel LED string of pre-packaged LEDs, an opposing parallel LED matrix of pre-packaged LEDs optionally having a capacitor in series of at least one junction of the connected LED circuits. It is contemplated that the LED circuit may also be at least one of a single LED or series string of diodes and/or LEDs having a bridge rectifier connected across the single LED or string of diodes. In embodiments where a series string of diodes and/or LEDs and a rectifier is utilized, each LED may likewise be pre-packaged. The rectifier may optionally have a capacitor connected across the rectifier inputs and/or a capacitor connected between to an input of the rectifier for connection between the rectifier and an AC voltage and current source. In either embodiment, utilizing an. LED circuit capacitor may allow for direct coupling of at least one LED circuit to the LED driver without additional series components such as capacitors and/or inductors between the LED circuit driver and the LED circuits. The LED circuit driver provides a relatively fixed voltage and relatively fixed frequency AC output even with changes to the load using feedback AC voltage regulator circuitry. The LED circuit's may be directly coupled and scaled in quantity to the LED circuit driver without affecting the other LED circuit's lumen output as long as the LED circuit driver maintains a relatively fixed voltage and relatively fixed frequency AC output.
[0138] According to an aspect of the invention, an LED circuit driver provides a relatively fixed voltage and relatively fixed frequency AC output such as mains power sources. The LED circuit driver output voltage and frequency delivered to the LED circuit may be higher than, lower than, or equal to mains power voltage and frequencies by using an LED circuit inverter driver. The LED circuit inverter driver providing higher frequencies is preferable for LED circuits that are integrated into small form LED packages that include integrated capacitors or resistor capacitor “RC” networks. The LED circuit inverter driver has feedback circuitry such as a resistor divider network or other means allowing it to sense changes to the load and re-adjust the frequency and/or voltage output of the LED circuit driver to a desired relatively fixed value. The LED circuit driver may also provide a soft-start feature that reduces or eliminates any surge current from being delivered to the LED circuit when the LED circuit driver is turned on. Higher frequency and lower voltage LED circuit inverter drivers are preferred enabling smaller package designs of LED circuits as the capacitor at higher frequencies would be reduced in size making it easier to integrate into a single LED circuit chip, package, assembly or module.
[0139] According to the invention LED circuits may have a resistor capacitor (“RC”) network connected together in series or separate from the LED circuits. The maximum resistor value needed is only that value of resistance needed to protect the one or more LEDs within the LED circuit from surge currents that may be delivered by LED circuit drivers that do not provide soft start or other anti surge current features. Direct mains power coupling would require RC network type LED circuits as the mains power source delivers surge currents when directly coupled to an LED circuit.
[0140] The higher frequency LED circuit inverter driver may be a halogen or high intensity discharge (HID) lamp type driver with design modifications for providing a relatively fixed voltage and relatively fixed frequency output as the LED circuit load changes. Meaning if the LED circuit inverter driver is designed to have an output voltage of 12V at a frequency of 50 Khz the LED circuit driver would provide this output as a relatively constant output to a load having one or more than one LED circuits up to the wattage limit of the LED circuit driver even if LED circuits were added to or removed from the output of the LED circuit driver.
[0141] The higher frequency inverter having a relatively fixed voltage and relatively fixed frequency output allows for smaller components to be used and provides a known output providing a standard reference High Frequency LED circuit driver enabling LED circuits to be manufactured in volume in existing or reasonably similar LED package sizes with integrated capacitors or RC networks based on the number of LEDs desired in the LED circuit package.
[0142] U.S. Patent Publication No. 2003/0122502 entitled Light Emitting Diode driver (Clauberg and Erhardt) does not disclose the use of a high frequency inverter driver having a means of keeping a relatively fixed voltage and relatively frequency in response to changes in the load. According to the present invention described herein, by not having additional components such as an inductor or capacitor in series between the LED circuit and the LED circuit driver one LED circuit at a time may be added to or removed from the LED circuit driver output without having to change any components, the LED circuit driver or make adjustments to the LED circuit driver. Additionally, according to this invention the lumen output of the existing LED circuits stays relatively constant due to the self-regulating nature of each individual LED circuit when driven with the relatively fixed frequency and voltage of the LED circuit driver. This level of scalability, single chip LED circuit packaging and standardization is not possible with the prior art using an inductor in series between the LEDs or other components due to the voltage or current increase or drop across the inductors and capacitors in response to changes in the load.
[0143] Prior art for single chip LED circuits, for example those disclosed in WO2004023568 and JP2004006582 do not provide a way to reduce the number of LEDs within the chip below the total forward voltage drop requirements of the source. The present invention however, enables an LED circuit to be made with any number of LEDs within a single chip, package or module by using, where desired, transformers, capacitors, or RC networks to reduce the number of LEDs needed to as few as one single LED. Improved reliability, integration, product and system scalability and solid state lighting design simplicity may be realized with LED circuits and the LED circuit drivers. Individual LED circuits being the same or different colors, each requiring different forward voltages and currents may be driven from a single source LED circuit driver. Each individual LED circuit can self-regulate current by matching the capacitor or RC network value of the LED circuit to the known relatively fixed voltage and frequency of the LED circuit driver whether the LED circuit driver is a mains power source, a high frequency LED circuit driver or other LED circuit driver capable of providing a relatively fixed voltage and relatively fixed frequency output.
[0144] When a real capacitor is connected in series in one or more lines between an LED and an AC power source, there is a displacement current through that capacity of magnitude: I=2πfCV. This means that one can predetermine the amount of current to be delivered through a capacitance based upon a known voltage and frequency of an AC source, allowing for each LED circuit containing a series capacitor to have the specific or ideal current required to provide the desired amount of light from the LED circuit.
[0145] According to other aspects of the invention, the LED circuit driver may be coupled to a dimmer switch that regulates voltage or frequency or may have integrated circuitry that allows for adjustability of the otherwise relatively fixed voltage and/or relatively fixed frequency output of the LED circuit driver. The LED circuits get brighter as the voltage and/or frequency of the LED circuit driver output is increased to the LED circuits.
[0146] One form of the invention is at least one LED and one diode connected together opposing parallel of each other, two opposing parallel LEDs, an opposing parallel LED string and/or opposing parallel LED matrix having a capacitor in series of at least one connected junction of the connected opposing parallel LED configurations within a single chip, a single package, an assembly or a module. When desired, the LED circuit with capacitor may be placed on an insulating substrates such as but not necessarily ceramic or sapphire and/or within various LED package sizes; materials and designs based of product specifications or assembled on printed circuit board material. Any integrated LED circuit capacitors should be scaled to a predetermined value enabling the LED circuit to self-regulate a reasonably constant and specific current when coupled to an LED circuit driver that provides a relatively fixed voltage and frequency output. Utilized LED circuit capacitors may be of a value needed to provide the typical operating voltage and current of the LED circuit when designed for coupling to a specific LED circuit driver.
[0147] Another form of the invention is an LED circuit comprising at least one LED and one diode connected together opposing parallel of each other, two opposing parallel LEDs, an opposing parallel LED string and/or opposing parallel LED matrix having a series resistor capacitor (“RC”) network connected together in series or independently in series between at least one connected junction of the opposing parallel LEDs and the respective power connection of the LED circuit. When desired, the opposing parallel LEDs and RC network may be placed on an insulating substrate such as but not necessarily ceramic or sapphire and/or within various LED package sizes; materials and designs based of product specifications or assembled on printed circuit board material. The LED circuit RC network may be of a value needed to provide the typical operating voltage and current of the LED circuit when designed for coupling to a specific LED circuit driver.
[0148] Another form of the invention is an LED circuit comprising a matrix of two opposing parallel LEDs connected together in parallel with every two opposing parallel LEDs having an individual capacitor in series to the power source connection if desired. The entire parallel array of opposing parallel LED circuits, including capacitors when used, may be may be placed on an insulating substrate such as but not necessarily ceramic or sapphire and/or within various LED package sizes; materials and designs based of product specifications or assembled on printed circuit board material. The opposing parallel matrix of LED circuits integrated in the LED circuit package may be RC network type LED circuits.
[0149] Another form of the invention is an LED circuit comprising a matrix of opposing parallel LEDs connected together in parallel with every set of opposing parallel LEDs having an individual RC network in series to the power connection lead if desired.
[0150] Another form of the invention is an LED circuit comprising a matrix of opposing parallel LEDs connected together in parallel, a capacitor connected in series to at least one side of the line going to the matrix of opposing parallel LEDs with every set of opposing parallel LEDs having an individual resistor in series to the power connection if desired.
[0151] Yet another form of the invention is an LED circuit comprising opposing parallel series strings of LEDs connected together and driven direct with a high frequency AC voltage equal to or less than to total series voltage drop of the opposing parallel series strings of LEDs within the LED circuit.
[0152] Yet another form of the invention is an LED circuit comprising a single LED or a series string of diodes and/or LEDs and a bridge rectifier connected across the LED or string of diodes and/or LEDs. The rectifier may optionally include a capacitor connected across the inputs of the rectifier. The rectifier may additionally, or alternatively, optionally include a capacitor connected in series with one input, the capacitor being capable of connecting the rectifier input to an AC voltage and current source.
[0153] Yet another form of the invention is an LED circuit comprising a single LEDs or a series strings of diodes and/or LEDs connected in parallel across the output of a bridge rectifier, The rectifier may optionally include a capacitor connected across the inputs of the rectifier. The rectifier may additionally, or alternatively, optionally include a capacitor connected in series with one input, the capacitor being capable of connecting the rectifier input to an AC voltage and current source.
[0154] Another form of the invention comprises a method of driving LED circuits direct from an AC power source (“LED circuit driver”) having a relatively fixed voltage and relatively fixed frequency. The LED circuit driver may be a mains power source, the output of a transformer, a generator or an inverter driver that provides a relatively fixed voltage and relatively fixed frequency as the load changes and may be a higher or lower frequency than the frequencies of mains power sources. The LED circuit driver provides a relatively fixed voltage and relatively fixed frequency output even when one or more LED circuits are added to or removed from the output of the LED circuit driver. Higher frequency inverters with lower output voltages are used as one LED circuit driver in order to reduce component size and simplify manufacturing and standardization of LED circuits through the availability of higher frequency LED circuit drivers. The LED circuit driver may also include circuitry that reduces or eliminates surge current offering a soft-start feature by using MOSFET transistors, IGBT transistors or other electronic means. The LED circuit driver may also be pulsed outputs at a higher or lower frequency than the primary frequency.
[0155] Another form of the invention is an LED lighting system comprising an LED circuit array having a plurality of different LED circuits each drawing the same or different currents, each having the same or different forward operating voltages, and each delivering the same or different lumen outputs that may be the same or different colors and an LED circuit driver coupled to the LED circuit array. The LED circuit driver delivering a relatively fixed t frequency and voltage output allows for mixing and matching of LED circuits requiring different forward voltages and drive currents. The LED circuits may be connected to the output of an LED circuit driver in parallel one LED circuit at a time within the limit of the wattage rating of the LED circuit driver with no need to change or adjust the LED circuit driver as would typically be required with DC drivers and LEDs when increasing or reducing the load with LEDs and other components. Never having to go back to the power source allows for more efficient integration and scalability of lighting systems designed with LED circuits and allows for a single driver to independently provide power to multiple independently controlled LED circuits in the system. Introducing an inductor and/or an additional capacitor such as the impedance circuit described in prior art between the LED circuit drive source and the LED circuits would require changes to the driver or components and prohibit scalability, standardization and mass production of AC-LEDs with integrated capacitors or RC networks.
[0156] With the LED circuit driver providing a known relatively constant AC voltage and frequency, mass production of various LED circuits with specific capacitor or RC network values would deliver 20 mA, 150 mA or 350 mA or any other desired current to the LED circuit based on the output of the specified LED circuit driver. The relatively fixed voltage and frequency allows for standardization of LED circuits through the standardization of LED circuit drivers.
[0157] In another aspect, a transistor is coupled to at least one power connection of the LED circuit or built into the LED circuit package in series between the power connection lead and the LED circuit with the transistor being operable to control (e.g., varying or diverting) the flow of the alternating current through the LED circuit through a capacitance within the transistor.
[0158] According to another form of the invention, a low voltage downlight system is having downlights with IDC connectors integrated and/or mounted to the downlights to provide for simple electrical connectivity of the downlights to a low voltage power supply that may or may not have polarity requirements, polarity control and/or polarity indication means within the LED downlights and/or IDC connectors.
[0159] According to another aspect of the invention, the present invention proposes that low voltage downlight systems can be installed with a much simpler process with less work, reduced and simplified electrical wiring and lower cost to the end user by connecting downlights in parallel using insulation displacement “IDC” connectors across a low voltage pair of wires that are treated like a power buss. In most cases the present invention may also substantially reduce and or eliminate the need to pay for the expense of a professional electrician and allows an installer of these downlights to make the final electrical connections using only a simple tool such as pliers or the like. In the case of DC power supplier that require polarity, it is contemplated the IDC connector could be keyed and/or marked and that the wire could be keyed and or marked as one option, and another option is to have polarity sensing capability and circuitry in the LED downlight that would prevent and correct for any improper polarity connections to the IDC connectors.
[0160] The above-described embodiments of the present invention are intended to be examples only. Alterations, modifications and variations may be effected to the particular embodiments by those of ordinary skill in the art without departing from the scope of the invention, which is defined by the claims appended hereto.