This application claims benefit of united states provisional application serial No. 61/174,980, entitled No. 2009, 5/1/2009, from 35u.s.c. § 119(e), which is incorporated herein by reference.
Throughout this application, several patent applications and references are cited, the disclosures of which are hereby incorporated by reference in their entirety.
Disclosure of Invention
According to a first aspect, the invention relates to a lighting connector comprising: (a) an upper shell having: a plurality of connector pins, and one or more interlocking grooves; and (b) a lower housing having a plurality of connector pin guide holes and one or more interlocking tongue members, the upper and lower housings being connected to form a lighting connector by: coupling at least one of the one or more interlocking grooves with at least one of the one or more interlocking tongue members and coupling at least one of the plurality of connector pins with at least one of the connector pin guide holes.
In another aspect, each of the plurality of connector pins includes an embedded portion located within the upper case and a plurality of protruding portions, at least one of the protruding portions being configured to couple with a respective corresponding one of the at least one connector pin guide holes.
In another aspect, the upper and lower housings are shaped to facilitate coupling with at least two segments of the lighting device to mechanically and electrically connect the at least two segments to each other when the upper and lower housings are coupled to form the lighting connector.
In another aspect, each of the at least two segments of the lighting device coupled to the connector includes an encapsulant and at least one conductive bus embedded in the encapsulant, and when the upper housing is coupled to the lower housing, the raised portion of each connector pin passes through the encapsulant of at least one lighting device such that the raised portion contacts the at least one conductive bus and creates an electrical coupling between the at least two segments of the lighting device.
In another aspect, the lower housing further includes at least one aperture for receiving an end of a length of the lighting device.
In another aspect, the gasket is located on an inner wall of the at least one opening.
In another aspect, the upper and lower housings are shaped to facilitate joining of the ends of two lighting devices at right angles to the connector to form an L-branch lighting connector when the upper and lower housings are coupled.
In another aspect, the upper and lower housings are shaped to facilitate substantially linear engagement of the ends of two lighting devices with the connector to form an I-branch lighting connector when the upper and lower housings are coupled.
In another aspect, the upper and lower housings are shaped to facilitate coupling of the connector with the ends of first and second segment lighting devices oriented in a generally linear direction with respect to each other, and to facilitate coupling of the connector with the longitudinal portion of a third segment lighting device oriented generally perpendicular to the linear direction, so as to form an X-shaped branch lighting connector when the upper and lower housings are coupled.
In another aspect, the upper and lower housings are shaped to facilitate coupling of the connector with an end of a first segment of the lighting device and to facilitate coupling of the connector with a longitudinal portion of a second segment of the lighting device that is substantially perpendicular to the first segment of the lighting device to form a T-branch lighting connector when the upper and lower housings are coupled.
In another aspect, the upper and lower housings are shaped to facilitate coupling of the connector with the ends of two lighting devices in parallel to each other to form a U-shaped branched lighting connector when the upper and lower housings are coupled.
In another aspect, each of the connector pins is made of a conductive material.
In another aspect, the embedded portion of each connector pin is insert molded into the upper shell.
In another aspect, the protruding part of each of the connector pins includes: barbed points, inverted V-shaped points, or U-shaped points.
In another aspect, the upper and lower shells are made of a thermoplastic.
In yet another aspect, the present invention relates to a method of electrically and mechanically connecting at least two segments of a lighting device using a connector, wherein each segment has at least one electrically conductive bus bar, the connector having: an upper housing having one or more interlocking grooves, a lower housing having one or more interlocking tongue members, connector pins embedded within the upper housing, and one or more holes and/or slots formed in the lower housing, the method comprising: coupling an end of a first of the at least two segments of the lighting device into at least one of the one or more apertures and/or slots; coupling a second section of the at least two sections of lighting devices into at least one of the one or more holes and/or slots; and pressing the upper and lower housings to couple the corresponding interlocking grooves of the upper housing into the interlocking tongue features of the lower housing to pass the connector pins into at least two segments of the lighting fixture to contact the conductive bus bars of the respective lighting fixtures.
In another aspect, the at least two segments of the lighting device comprise an encapsulant and the connector pins penetrate into the encapsulant during the pressing step.
In another aspect, the penetration of each of the at least two lengths of lighting apparatus creates an electrical connection between at least one conductive bus of the at least two lengths of lighting apparatus.
In yet another aspect, the present invention relates to a lighting connector comprising: (a) first and second upper cases, each having: a plurality of connector pins, and one or more interlocking grooves; (b) first and second lower shells, each lower shell having a plurality of connector pin guide holes and one or more interlocking tongue members; and (c) a flexible connector electrically connecting an inner side of the first lower housing with an inner side of the second lower housing, the first lower housing being connectable with the first upper housing and the second lower housing being connectable with the second upper housing to form the lighting connector by: coupling at least one of the one or more interlocking grooves with at least one of the one or more interlocking tongue members and coupling at least one of the plurality of connector pins with at least one of the connector pin guide holes.
In another aspect, each of the plurality of connector pins includes an embedded portion located within one of the first and second upper cases and a plurality of protruding portions, at least one of the protruding portions being configured to couple with a respective corresponding one of the at least one connector pin guide holes.
In another aspect, each of the first and second upper and lower housings is shaped to facilitate engagement with an end of a segment of the lighting device to mechanically or electrically connect the at least two segments of the lighting device to each other when the upper and lower housings are coupled to form the lighting connector.
In another aspect, each of the at least two segments of the lighting device coupled to the connector includes an encapsulant and at least one conductive bus embedded in the encapsulant, and when the upper housing is coupled to the lower housing, the raised portion of each connector pin passes through the encapsulant of at least one segment of the lighting device such that the raised portion contacts the at least one conductive bus and creates an electrical coupling between the at least two segments of the lighting device.
In yet another aspect, a lighting system includes at least one lighting connector as recited in claim 1.
Detailed Description
According to various embodiments, the lighting connector is formed with upper and lower shells and connector pins. According to the disclosed embodiments, connector pins formed in the upper housing are located inside the upper housing such that when the upper housing is coupled to the lower housing, segments or portions of a plurality of rigid and/or flexible lighting connectors (such as LED light wires, cables, banks, or tubes) are disposed therebetween, with electrical and mechanical connections being made between portions of the lighting device by the connector pins.
As shown in fig. 1-7, according to a first preferred embodiment, a T-branch lighting connector 10 is formed of an upper housing 12 and a lower housing 14. The upper shell 12 has connector pins 16 and pins 17. The connector pin 16 includes a protruding portion extending from the upper case and an embedded portion 16a, the embedded portion 16a being indicated by a dotted line, formed in the case perpendicular to and connecting the protruding portion. Similarly, the connector pin 17 includes a protruding portion and an embedded portion 17 a. As will be described in more detail below, each connector pin forms a connection between a first lighting device 31 connected to the connector from a first direction and a second lighting device 32 connected to the connector from a second direction.
The upper shell includes interlocking grooves 20 and a gasket 22. The interlocking grooves 20 mate with interlocking tabs 21 in the lower housing 14 to form a secure connection (e.g., a snap fit) between the upper and lower housings when the connectors are assembled. The spacer 22 is used to ensure a tight fit of the housing and the lighting device when the connector is assembled. Although shown in combination with the upper shell 12 in the drawings, the spacer may be provided separately and located between the upper and lower shells when the connector is assembled, for example as shown in fig. 5A.
The lower shell 14 includes a plurality of connector pin guide holes 24, slots 26 formed by walls 27, and openings 58. In the T-branch embodiment, the end of the first segment lighting device 31 is inserted into the opening 28 to connect to a second segment lighting device 32, the second segment lighting device 32 being located in the slot 26 perpendicular to the first segment lighting device, as shown in detail in fig. 6A, 6B and 7. For example, as shown in fig. 4B, 4C, 5B, and 6B, an opening gasket 29 fills the opening 28 in the lower case. The lower shell 14 also includes a gasket groove 30. For example, the opening gasket 29 prevents water leakage between the lower case 14 and the lighting device inserted into the opening 28.
To assemble the connector 10, the upper shell 12 is coupled with the lower shell 14 by the corresponding interlocking grooves 20 and locking tongues 21. When the upper and lower shells 12 and 14 are pressed together, one end of each of the connector pins 16 and 17 in the upper shell is fitted into the corresponding connector pin guide holes 24 in the lower shell. The connector pins/connector pin guide holes guide the upper and lower cases in a manner allowing corresponding interlocking grooves and locking tongues to be easily coupled. The other end of each connector pin penetrates into the lighting device 32.
Preferably, the tip of each connector pin is configured to increase the contact area between the connector pin and a conductive bus bar of the lighting device, such as the conductive bus bar 31a or 32a shown in fig. 6. To accomplish this function, the tip may be in the shape of an inverted "V" or an inverted "U".
When the connector 10 is assembled, the pressure created by the coupling of the interlocking grooves 20 and the locking tongues 21 and the connector pins 16 and 17 penetrate through the open gasket 29 into the enclosure, protective sleeve, boot or protective layer of the lighting device (e.g., LED light wire, cable, bank light or tube) to form a waterproof seal between the upper and lower housings 12 and 14, 29 and 31, 12 and 32 (in the case of the T-branch lighting connector apparatus of the first embodiment). Specifically, the upper shell gasket 22 is pressed tightly against the corresponding gasket groove 30 and/or lighting device, thereby forming a tight pressure seal. In addition, the opening gasket 29 is tightly pressed against the lighting device via the pressure insertion of the lighting device into the opening 28 and the penetration of the connector pins 16 and 17 into the lighting device.
As shown in fig. 6A, 6B and 7, when the connector is assembled, the connector pins 16 and 17 pass through the encapsulant of the lighting devices 31 and 32 to make contact with the conductive bus bars 31a and 32a, respectively, resulting in an electrical connection between the conductive bus bars 31a and 32a, allowing electrical signals and/or power to pass between the lighting devices 31 and 32 and securely connect the lighting devices together.
As shown in fig. 8-13, according to a second preferred embodiment, a U-shaped branch lighting connector 40 is formed from an upper shell 42 and a lower shell 44.
The U-branch connector according to the second embodiment operates in a manner generally similar to the T-branch connector 10 described above, except that the U-branch connector is configured to electrically and mechanically connect the ends of the first and second sections 61, 62 of the lighting device to form a U-connection. As in the first embodiment, the connector pins 46 and 47 are located in the upper case 42. The connector pins 46 and 47 have embedded portions 46a and 47a formed on the upper case, respectively.
The upper shell includes interlocking grooves 50 and spacers 52. The interlocking grooves 50 mate with interlocking tabs 51 in the lower housing 44 to form a secure connection (e.g., a snap fit) between the upper and lower housings when the connectors are assembled. The spacer 52 serves to ensure a tight fit of the housing when the connector is fully assembled. Although shown in combination with the upper shell 42 in the figures, the spacer may be provided separately and located between the upper and lower shells when the connector is installed.
The lower shell 44 includes a plurality of connector pin guide holes 54 and openings 58. In the U-branch embodiment, the end of the first segment of lighting device 61 is inserted into one of the openings 58 and the end of the second segment of lighting device 62 is inserted into the other of the openings 58, as particularly shown in fig. 12 and 13. An opening gasket 59 fills the opening 58 in the lower shell. The lower shell 44 preferably includes a gasket groove 60. The opening gasket 59 prevents water leakage between the lower case 44 and the lighting device inserted into the opening 58.
To assemble the connector 40, the upper shell 42 is coupled with the lower shell 44 by the corresponding interlocking grooves 50 and locking tongues 51. When the upper and lower shells 42 and 44 are pressed together, the connector pins 46 and 47 in the upper shell mate with corresponding connector pin guide holes in the lower shell. The connector pins/connector pin guide holes guide the upper and lower cases in a manner allowing corresponding interlocking grooves and locking tongues to be easily coupled.
Preferably, the tip of each connector pin is configured to increase the contact area between the connector pin and a conductive bus bar of the lighting device, such as conductive bus bar 61a or 62a shown in fig. 13. To accomplish this function, the tip may be in the shape of an inverted "V" or an inverted "U".
When the connector 40 is assembled, the pressure created by the coupling of the interlocking grooves 50 and the locking tabs 51 and the connector pins 46 and 47 penetrate the enclosure, protective sleeve, protective cover, or protective layer of the lighting device (e.g., LED light wire, cable, bank light, or tube) through the opening gasket 59 to form a waterproof seal between the upper and lower shells 42 and 44, and between the opening gasket 59 and the lighting device. Specifically, the upper shell gasket 52 tightly presses against the corresponding gasket groove 60, thereby forming a tight pressure seal. In addition, the opening gasket 59 is tightly pressed against the lighting device via the pressure insertion of the lighting device into the opening 58 and the penetration of the connector pins 46 and 47 into the lighting device.
As shown in fig. 12 and 13, when the connector is assembled, the connector pins 46 and 47 pass through the encapsulant of the lighting devices 61 and 62 to contact the conductive bus bars 61a and 62a, respectively, resulting in an electrical connection between the conductive bus bars 61a and 62a, thereby allowing electrical signals and/or power to pass between the lighting devices 61 and 62 and securely connect the lighting devices together.
As shown in fig. 14-18B, according to a third preferred embodiment, an L-shaped branch illumination connector 70 is formed from an upper housing 72 and a lower housing 74.
The L-branch connector 70 according to the third embodiment operates in a manner generally similar to the U-branch connector 40 described above, except that the L-branch connector 70 is configured to electrically and mechanically connect the ends of the first and second segments 90, 92 of the lighting device to form a right angle connection. As in the first to second embodiments, the connector pins 76 and 77 are located in the upper case 72. The pins 76 and 77 have embedded portions 76a and 77a, respectively, formed in the upper case.
The upper shell includes interlocking grooves 80, and the interlocking grooves 80 mate with interlocking tabs 81 in the lower shell 74 to form a secure connection (e.g., a snap fit) between the upper and lower shells when the connectors are assembled. A spacer 82 is located between the upper and lower shells to ensure a tight fit of the shells when the connector is fully assembled.
The lower shell 74 includes a plurality of connector pin guide holes 84 and openings 88. In the L-branch embodiment, the end of the first segment of lighting device 91 is inserted into one of the openings 88 and the end of the second segment of lighting device 92 is inserted into the other of the openings 88, as particularly shown in fig. 17, 18A and 18B. An opening gasket 89 fills the opening 88 in the lower shell. The opening gasket 89 prevents water leakage between the lower case 74 and the lighting device inserted into the opening 88.
To assemble the connector 70, the upper shell 72 is coupled to the lower shell 74 by the corresponding interlocking grooves 80 and locking tabs 81. When the upper and lower shells 72 and 74 are pressed together, the connector pins 76 and 77 in the upper shell mate with the corresponding connector pin guide holes 84 in the lower shell. The connector pins/connector pin guide holes guide the upper and lower cases in a manner allowing corresponding interlocking grooves and locking tongues to be easily coupled.
Preferably, the tip of each connector pin is configured to increase the contact area between the connector pin and a conductive bus bar of the lighting device, such as conductive bus bar 91a or 92a shown in fig. 18A and 18B. To accomplish this function, the tip may be in the shape of an inverted "V" or an inverted "U".
When the connector 70 is assembled, the pressure created by the coupling of the interlocking grooves 80 and the latches 81 and the connector pins 76 and 77 penetrate through the open gasket 89 into the enclosure, protective sleeve, boot, or protective layer of the lighting device (e.g., LED light wire, cable, bank light, or tube) to form a waterproof seal between the upper and lower shells 72 and 74, 89 and the lighting device. Specifically, the upper housing gasket 82 is tightly pressed against the lower housing, thereby forming a tight pressure seal. In addition, the opening gasket 89 is tightly pressed against the lighting device via the pressure insertion of the lighting device into the opening 88 and the penetration of the connector pins 76 and 77 into the lighting device.
As shown in fig. 18A and 18B, when the connector is assembled, the connector pins 76 and 77 pass through the encapsulant of the lighting devices 91 and 92 to make contact with the conductive bus bars 91a and 92a, respectively, resulting in an electrical connection between the conductive bus bars 91a and 92a, allowing electrical signals and/or power to be transferred between the lighting devices 91 and 92 and securely connect the lighting devices together.
As shown in fig. 19A-23B, according to the fourth preferred embodiment, an X-shaped branched illumination connector 100 is formed of an upper housing 102 and a lower housing 104.
The X-branch connector 100 according to the fourth embodiment operates in a manner generally similar to the L-branch connector 70 described above, except that the X-branch connector 100 is configured to electrically and mechanically connect the first segment of lighting device 121 with the end of the second segment of lighting device 122 and the end of the third segment of lighting device 123 to form an X-connection. As in the first to third embodiments, the connector pins 106 and 107 are located in the upper case 102. The connector pins 106 and 107 have embedded portions 106a and 107a formed in the upper case, respectively.
The upper shell includes interlocking grooves 110. The interlocking grooves 110 mate with interlocking tabs 111 in the lower housing 104 to form a secure connection (e.g., a snap fit) between the upper and lower housings when the connectors are assembled. A gasket 112 is located between the upper and lower shells to ensure a tight fit of the shells when the connector is assembled.
The lower shell 104 includes a plurality of connector pin guide holes 114, openings 118 and slots 116. In the X-branch embodiment, the first segment of the illumination device 121 is positioned in the slot 116 completely through the connector 100. The end of the second segment of lighting device 122 is inserted into one of the openings 118 and the end of the third segment of lighting device 123 is inserted into the other of the openings 118, as shown in detail in fig. 22 and 23. An opening gasket 119 fills the opening 118 in the lower shell. The opening gasket 119 prevents water leakage between the lower case 104 and the lighting device inserted into the opening 118.
To assemble the connector 100, the upper housing 102 is coupled with the lower housing 104 via the corresponding interlocking grooves 110 and locking tongues 11. When the upper and lower shells 102 and 104 are pressed together, the outer ones of the connector pins 106 and 107 in the upper shell mate with corresponding connector pin guide holes 114 in the lower shell. The inner prongs are positioned above the lighting device 121 to facilitate penetration of the lighting device during assembly. The connector pins/connector pin guide holes guide the upper and lower cases in a manner allowing corresponding interlocking grooves and locking tongues to be easily coupled.
Preferably, the tip of each connector pin is configured to increase the contact area between the connector pin and a conductive bus bar of the lighting device, such as conductive bus bars 121a, 122a, and 123A shown in fig. 23A and 23B. To accomplish this function, the tip may be in the shape of an inverted "V" or an inverted "U".
When the connector 100 is assembled, the pressure created by the coupling of the interlocking grooves 110 and the latches 111 and the connector pins 106 and 107 penetrate the enclosure, protective sleeve, protective cover, or protective layer of the lighting device (e.g., LED light wire, cable, bank light, or tube) through the opening gasket 119 to form a waterproof seal between the upper and lower housings 102 and 104, and between the opening gasket 119 and the lighting device. Specifically, the gasket 112 is tightly pressed against the lower case and the lighting device 121, thereby forming a tight pressure seal. In addition, the opening gasket 119 is tightly pressed against the lighting device via the pressure insertion of the lighting device into the opening 118 and the penetration of the outer one of the connector pins 106 and 107 into the lighting devices 122 and 123. The inner one of the connector pins will penetrate into the lighting device 121.
As shown in fig. 23A and 23B, when the connector is assembled, the connector pins 106 and 107 pass through the encapsulant of the lighting devices 121, 122, and 123 to make contact with the conductive bus bars 121a, 122a, and 123A, respectively, resulting in an electrical connection between the conductive bus bars 121a, 122a, and 123A (e.g., two outer ones of the lighting devices 121, 122, and 123, as shown in fig. 23A), thereby allowing electrical signals and/or power to pass between and safely connect the lighting devices 121, 122, and 123 together.
As shown in fig. 24A-28, according to a fifth preferred embodiment, an I-branch lighting connector 130 is formed of an upper shell 132 and a lower shell 134.
The I-branch connector 130 according to the fifth embodiment operates in a manner substantially similar to the L-branch connector 70 described above, except that the I-branch connector is configured to electrically and mechanically connect the end of the first segment of lighting device 151 and the end of the second segment of lighting device 152 to form a straight line connection. As in the first to fourth embodiments, the connector pins 136 and 137 are located in the upper case 132. The connector pins 136 and 137 have embedded portions 136a and 137a formed on the upper case, respectively.
The upper shell includes interlocking grooves 140, and the interlocking grooves 140 mate with interlocking catches 141 in the lower shell 134 to form a secure connection (e.g., a snap fit) between the upper and lower shells when the connectors are assembled. A spacer 142 is located between the upper and lower shells to ensure a tight fit of the shells when the connector is fully assembled.
The lower shell 134 includes a plurality of connector pin guide holes 144 and openings 148. In the I-branch embodiment, the end of the first segment of the lighting device 151 is inserted into one of the openings 148 and the end of the second segment of the lighting device 152 is inserted into the other of the openings 148, as particularly shown in fig. 27 and 28. An opening gasket 149 fills the opening 148 in the lower housing. The opening gasket 149 prevents water leakage between the lower case 134 and the lighting device inserted into the opening 148.
To assemble the connector 130, the upper shell 132 is coupled with the lower shell 134 by the corresponding interlocking grooves 140 and locking tongues 141. When the upper and lower shells 132 and 134 are pressed together, the connector pins 136 and 137 in the upper shell are mated with the corresponding connector pin guide holes 144 in the lower shell. The connector pins/connector pin guide holes guide the upper and lower cases in a manner allowing corresponding interlocking grooves and locking tongues to be easily coupled.
Preferably, the tip of each connector pin is configured to increase the contact area between the connector pin and a conductive bus bar of the lighting device, such as conductive bus bar 151a or 152a shown in fig. 28. To accomplish this function, the tip may be in the shape of an inverted "V" or an inverted "U".
When the connector 130 is assembled, the pressure created by the coupling of the interlocking grooves 140 and the latches 141 and the connector pins 136 and 137 penetrate the enclosure, protective sleeve, protective cover, or protective layer of the lighting device (e.g., LED light wire, cable, bank light, or tube) through the opening gasket 149 to form a waterproof seal between the upper shell 132 and the lower shell 134, and between the opening gasket 149 and the lighting device. Specifically, the gasket 142 is tightly pressed against the lower case, thereby forming a tight pressure seal. In addition, the opening gasket 149 is pressed tightly against the lighting fixture via pressure insertion of the lighting fixture into the opening 148 and penetration of the connector pins 136 and 137 into the lighting fixture.
As shown in fig. 28, when the connector is assembled, the connector pins 136 and 137 pass through the encapsulant of the lighting devices 151 and 152 to make contact with the conductive bus bars 151a and 152a, respectively, resulting in an electrical connection between the conductive bus bars 151a and 152a (e.g., the two outer conductive bus bars 151a and 152a, as shown in fig. 28), thereby allowing electrical signals and/or power to pass between the lighting devices 151 and 152 and securely connect the lighting devices together.
As shown in fig. 29-33, according to a sixth preferred embodiment, the I-shaped extension illuminating connector 160 is formed from upper shells 162a and 162b, lower shells 164a and 164b, and preferably a flexible connector extension 163, the flexible connector extension 163 being used to electrically connect the lower shells together.
The I-shaped extension connector according to the sixth embodiment operates in a manner substantially similar to the I-branch connector 130 described above, except that the I-shaped extension connector is configured to electrically or mechanically connect the ends of the first and second sections 181, 182 of the lighting device together. However, by providing the flexible connector extension 163 between the lower shells 164a and 164b, a flexible connection can be achieved, which is not limited to a straight connection. As in the first to fifth embodiments, each upper case has connector pins 166 and 167 therein. However, the I-shaped extension connector 160 includes two upper shells, 162a and 162b, each of which is attached to a corresponding one of the lower shells 164a and 164 b. The connector pins 166 and 167 have embedded portions 166a and 167a formed on the upper case, respectively.
Each top shell includes an interlocking groove 170, and the interlocking groove 170 mates with an interlocking tongue 171 in the corresponding bottom shell 174a or 174b to form a secure connection (e.g., a snap fit) between the top shell and the corresponding bottom shell when the connector is assembled. As shown in fig. 30B, a spacer 172 may be positioned between the upper and lower shells (in a manner similar to that shown in the other embodiments) to ensure a tight fit of the shells when the connector 160 is assembled.
Each of the lower shells 164a and 164b includes a plurality of connector pin guide holes 174 and openings 178. In the I-shaped extension embodiment, the end of the first segment of lighting device 181 is inserted into one of the openings 178 and the end of the second segment of lighting device 182 is inserted into the other of the openings 178, as particularly shown in fig. 32 and 33. An opening gasket 179 may be used to fill opening 188 in the lower shell. The opening gasket 179 prevents water leakage between the lower cases 164a and 164b and the lighting device inserted into the opening 178.
To assemble the connector 160, the upper shells 162a and 162b are coupled with the corresponding lower shells 164a and 164b through the corresponding interlocking grooves 170 and locking tongues 171. When the upper and lower shells 162a and 162b and 164a and 164b are pressed together, the connector pins 166 and 167 in the upper shell are fitted with the corresponding connector pin guide holes 174 in the lower shell. The connector pins/connector pin guide holes guide the upper and lower cases in a manner allowing corresponding interlocking grooves and locking tongues to be easily coupled.
Preferably, the tip of each connector pin is configured to increase the contact area between the connector pin and a conductive bus bar of the lighting device, such as conductive bus bar 151a or 152a shown in fig. 33. To accomplish this function, the tip may be in the shape of an inverted "V" or an inverted "U".
When the connector 160 is assembled, the pressure created by the coupling of the interlocking grooves 170 and the latches 171 and the connector pins 166 and 167 are threaded through the opening gasket 149 into the enclosure, protective sleeve, boot, or protective layer of the lighting device (e.g., LED light wire, cable, bank light, or tube) to form a waterproof seal between the upper and lower shells 162a and 162b and 164a and 164b, and the opening gasket 179 and the lighting device. Specifically, a gasket 172 is located between the upper and lower shells to provide a tight pressure seal. In addition, opening gasket 179 presses tightly against the lighting fixture via pressure insertion of the lighting fixture into opening 178 and penetration of connector pins 166 and 167 into the lighting fixture.
As shown in fig. 32 and 33, when the connector is assembled, the outermost of the connector pins 166 and 167 passes through the encapsulant of the lighting devices 181 and 182. The innermost of the connector pins 166 and 167 penetrates into the interior of the lower shell to make contact with: (a) conductive pins electrically connected to wires in the flexible connector extension 163; (b) wires coming out of the flexible connector extension 163; or (c) a wire within the flexible connector extension 163 (by passing through the flexible connector extension 163 and contacting the wire within the flexible connector extension 163). The flexible connector extension 163 may have one or more wires that electrically connect with conductive pins on the interior of each lower housing. Each of the possible connections described above allows an electrical connection to be made between the conductive bus bars 181a and 182a by electrically connecting the lower cases to each other, thereby allowing electrical signals and/or power to be transmitted between the lighting devices 181 and 182 and securely connecting the lighting devices together. In an alternative embodiment, the tips of the connector pins that connect directly or indirectly to the wires in the flexible connector extension 163 are U-shaped.
As shown in figures 34-37, according to a seventh preferred embodiment, the power extension connector 190 is formed from an upper shell 192, a lower shell 194, a power plug 195, and preferably a flexible connector extension 193, the flexible connector extension 193 being formed for electrically connecting the lower shell and the power plug 195 together.
As in the first to sixth embodiments, the connector pins 196 and 197 are located on the upper case 192. The connector pins 196 and 197 have embedded portions 196a and 197a formed on the upper case, respectively.
The superior and inferior shells 192, 194 are substantially identical to the superior and inferior shells 162b, 164b described in connection with the I-shaped extension embodiment. Power extension connector 190 differs from the I-shaped extension embodiment in that: the flexible connector extension 193 does not terminate in another set of upper and lower housings for connection to another length of lighting device, and in the seventh embodiment, the flexible connector extension 193 terminates in a power plug 195 that supplies power to the lighting device to which the power extension connector 190 is connected. Therefore, in the seventh embodiment, there is only a single pair of the upper and lower cases, instead of the two pairs in the sixth embodiment. The power plug 195 preferably includes a female connector 220 that can mate with any conventional power source to provide power to the lighting device. Of course, the connector is not limited to a female connector, and any known electrical connection may be employed, depending on the configuration of the power supply line, for example.
The upper housing includes interlocking grooves 200, and the interlocking grooves 200 mate with interlocking catches 201 in the lower housing 194 to form a secure connection (e.g., a snap fit) between the upper and lower housings when the connectors are assembled. A gasket 202 is located between the upper and lower shells to ensure a tight fit of the shells when the connector is assembled.
The lower shell 194 includes a plurality of connector pin guide holes 204 and openings 208. The end of the first section of the lighting device 211 is inserted into one of the openings 208, as shown in detail in fig. 36 and 37. An opening gasket 209 fills the opening 208 in the lower shell. The opening gasket 209 prevents water leakage between the lower case 194 and the lighting device inserted into the opening 208.
To assemble the connector 190, the upper housing 192 is coupled to the lower housing 194 via the corresponding interlocking grooves 200 and locking tabs 201. When the upper and lower shells 192 and 194 are pressed together, the connector pins 196 and 197 in the upper shell mate with corresponding connector pin guide holes 204 in the lower shell. The connector pins/connector pin guide holes guide the upper and lower cases in a manner allowing corresponding interlocking grooves and locking tongues to be easily coupled.
Preferably, the tip of each connector pin is configured to increase the contact area between the connector pin and a conductive bus bar of the lighting device, such as conductive bus bar 211a shown in fig. 36. To accomplish this function, the tip may be in the shape of an inverted "V" or an inverted "U".
As in the I-shaped extension embodiment, for example, when the connector 190 (specifically, the upper and lower housings) is assembled, the pressure created by the coupling of the interlocking grooves 200 and the locking tabs 201 and the connector pins 196 and 197 penetrate through the opening gasket 209 into the enclosure, protective sleeve, boot, or protective layer of the lighting device (e.g., LED light wire, cable, bank light, or tube) to form a waterproof seal between the upper and lower housings 192 and 194, and between the opening gasket 209 and the lighting device. A gasket 202 is located between the upper and lower shells to provide a tight pressure seal. In addition, the opening gasket 209 is pressed tightly against the lighting fixture via pressure insertion of the lighting fixture into the opening 208 and penetration of the connector pins 196 and 197 into the lighting fixture.
As shown in fig. 36, when the connector is assembled, one end (leftmost end in fig. 36) of each of the connector pins 196 and 197 passes through the package of the lighting device 211 to be in contact with the conductive bus bar 211 a. The innermost connector pins 196 and 197 penetrate into the interior of the lower shell to make contact with: (a) conductive pins electrically connected to wires in the flexible connector extension 193; (b) wires coming out of the flexible connector extension 193; or (c) wires within the flexible connector extension 193 (by passing through the flexible connector extension 193 and contacting wires within the flexible connector extension 193). The flexible connector extension 193 may have one or more wires that connect to conductive pins on the interior of the lower housing. Each of the possible connections described above results in an electrical connection between the conductive bus bar 211a and the power source, allowing electrical signals and/or power to be transferred from the power plug 195 to the lighting device 211. In an alternative embodiment, the tips of the connector pins that connect directly or indirectly to the wires in the flexible connector extension 193 are U-shaped.
When forming a lighting system using one or more lighting connector devices, at least two lengths of lighting apparatus (e.g., LED light wires, cables, banks, or tubes) are inserted into respective openings or slots in the lower housing, and then the upper housing is pressed onto the lower housing. The connector pins penetrate through a section of packaging material, a protective sleeve, a protective cover or a protective layer of the lighting device and are electrically connected with the conductive bus of the lighting device; thereby electrically connecting the segments.
Thus, as will be appreciated by those skilled in the art, a lighting system may be formed by connecting multiple segments of lighting devices together using one or more of the connectors of the above embodiments. For example, fig. 38 shows a plurality of segments of a lighting device connected to each other with the L-shaped branch connector 202, the I-shaped branch connector 203, the X-shaped branch connector 204, the T-shaped branch connector 205, and the U-shaped branch connector 206 according to the above-described embodiments, thereby forming a lighting system. Power for the entire device may be provided by a power connector device 207, such as a power connector according to the seventh embodiment.
Each of the connector pins of the above-described embodiments is arranged in any given upper case in parallel with each other, and the connector pins may instead be formed in the upper case so as to be staggered with each other as long as the gap between the pins can prevent, for example, a short circuit of connection. Preferably, in such a staggered configuration, there should be a gap of about 1-2mm between the embedded portions of the pins within the upper shell, as shown in FIG. 39.
It is an object of the present invention according to the above exemplary embodiments to provide an easily assembled connector device, which electrically and mechanically connects segments of rigid and/or flexible lighting means, such as LED light wires, cables, banks or tubes. The connector device may be used indoors as well as outdoors.
The present invention relates to a lighting connector device having a housing comprising: an upper housing having a plurality of connector pins, an upper housing gasket, and at least one receiving interlock groove; a lower housing coupled with the upper housing by connecting at least one interlocking groove in the upper housing with at least one interlocking tongue in the lower housing, the lower housing including a plurality of connector pin guide holes, at least one gasket groove, at least one opening gasket within the at least one opening, and at least one interlocking tongue. The position of the interlocking grooves and locking tongues are interchangeable, for example, the interlocking grooves and locking tongues may be located on the upper and lower shells, respectively, or a combination thereof.
Preferably, the upper case and the lower case in the above embodiment are made of a thermoplastic material, for example: polypropylene (PP), Polyethylene (PE), acrylonitrile-butadiene-styrene copolymer (ABS) or the like.
The gasket between the housing and the opening gasket is preferably made of waterproof rubber (e.g. silicone or the like), plastic, foam or any other known waterproof material. A preferred water resistant material for the top case gasket and the split gasket is silicone. The upper shell gasket or opening gasket may be a separate part or molded with the upper shell or opening using methods known in the art, such as dual injection with the upper shell or lower shell. As for the opening pad, it may cover the entire inside or a part of the opening. The upper shell may have a groove that receives the upper shell gasket.
The opening gasket may be optional because the openings of the present invention (e.g., openings 28, 58, 88, 118, 148, 178, 208) may be made to form a tight fit with the lighting device.
The connector pins are made of a conductive material, such as copper, steel or copper clad steel. The conductive material may be electroplated with tin to provide conductivity and prevent oxidation. For example, the connector pins may be barbed to better penetrate into any encapsulant, protective sleeve, protective cover, or protective layer of the lighting device (e.g., LED light wire, cable, bank light, or tube) and prevent the connector pins from sliding out of their corresponding penetration points, thereby allowing the connector pins to maintain electrical contact with the conductive bus of the lighting device while protecting the coupling of the upper and lower shells. The connector pins may be injection molded into the upper shell to maximize durability.
For example, the lighting devices connected together by the connectors in the disclosed embodiments may be light wires, cables, banks, or tubes, such as, but not limited to:
CabLED from OptiLED Lighting International LtdTM(http://cabled.optiled.com/；http://cabled.optiled.com/MyImage/image/Web/CabLED％20brochure％20final.pdf)；
Rigid Light Strip from Light Engine LtdTM(http://www.lightengine-tech.com/en/generallighting3_detail.aspID＝38&CATID 38; http:// www.lightengine-tech.com/upload/PRODUCTG _ PL38. pdf); and
flexible Light Strip from Light Engine LtdTM(http://www.lightengine-tech.com/en/generallighting3_detail.aspID＝40&CATID＝40；http://www.lightengine-tech.com/upload/PRODUCTG_PL40.pdf)。
The lighting device may be a solid state lighting device, including but not limited to an LED lighting device.
Although preferred embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the embodiments shown and described without departing from the scope of the present invention. This disclosure is intended to cover any adaptations or variations of the specific embodiments discussed herein. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.