U.S. patent application number 11/357014 was filed with the patent office on 2006-06-29 for jacketed led assemblies and light strings containing same.
Invention is credited to David Allen.
Application Number | 20060139920 11/357014 |
Document ID | / |
Family ID | 34435871 |
Filed Date | 2006-06-29 |
United States Patent
Application |
20060139920 |
Kind Code |
A1 |
Allen; David |
June 29, 2006 |
Jacketed LED assemblies and light strings containing same
Abstract
A jacketed light emitting diode assembly is provided, which
includes a light emitting diode including a set of positive and
negative contacts, and a lens body containing a semiconductor chip
and end portions of the contacts. An electrical wire set of first
and second electrical wires are connected to the positive contact
and the negative contact, respectively. A light transmissive cover
receives the lens body, and has an opening through which at least
one of the contact set and the electrical wire set passes. An
integrally molded plastic jacket at the opening of the light
transmissive cover provides a seal at the opening against moisture
and airborne contaminants. A waterproof light string including one
or more of the jacketed light emitting diode assemblies is also
provided, as are related methods.
Inventors: |
Allen; David; (Yardley,
PA) |
Correspondence
Address: |
BERENATO, WHITE & STAVISH;SUITE 240
6550 ROCK SPRING DRIVE
BETHESDA
MD
20817
US
|
Family ID: |
34435871 |
Appl. No.: |
11/357014 |
Filed: |
February 21, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10755463 |
Jan 13, 2004 |
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11357014 |
Feb 21, 2006 |
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10243835 |
Sep 16, 2002 |
6830358 |
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10755463 |
Jan 13, 2004 |
|
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09819736 |
Mar 29, 2001 |
6461019 |
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10243835 |
Sep 16, 2002 |
|
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Current U.S.
Class: |
362/249.01 ;
257/E33.073 |
Current CPC
Class: |
F21V 31/04 20130101;
H01L 2924/30107 20130101; H01L 2924/3011 20130101; F21S 4/10
20160101; H01L 33/58 20130101; H05B 45/37 20200101; H01L 2924/181
20130101; H01L 33/56 20130101; F21Y 2115/10 20160801; F21V 5/04
20130101; Y02B 20/30 20130101; F21V 15/01 20130101; F21V 31/005
20130101; H05B 45/42 20200101; F21W 2121/04 20130101; H01L 33/62
20130101; F21V 23/001 20130101; Y10S 362/80 20130101; F21V 19/0005
20130101; H01L 2224/48247 20130101; H05B 45/40 20200101; F21W
2121/00 20130101; H01L 2224/48091 20130101; H01L 2924/00014
20130101; H01L 2924/3011 20130101; H01L 2924/00 20130101; H01L
2924/30107 20130101; H01L 2924/00 20130101; H01L 2924/181 20130101;
H01L 2924/00012 20130101 |
Class at
Publication: |
362/249 |
International
Class: |
F21V 21/00 20060101
F21V021/00 |
Claims
1. A jacketed light emitting diode assembly, comprising: a light
emitting diode comprising a contact set comprising a positive
contact and a negative contact, each of the contacts having a first
end portion and a second end portion; and a lens body containing a
semiconductor chip and the first end portions of the positive and
negative contacts; an electrical wire set comprising a first
electrical wire and a second electrical wire electrically connected
to the second end portions of the positive contact and the negative
contact, respectively; a light transmissive cover having a cavity
with an opening, the cavity receiving the lens body, the opening
having at least one of the contact set and the electrical wire set
passing therethrough; and an injection molded thermoplastic jacket
sealing and encasing the opening of the light transmissive cover to
provide a seal at the opening against moisture and airborne
contaminants; wherein the jacket is formed in a single molding
operation; and wherein the light transmissive cover is at least
partially encased by the injection molded thermoplastic jacket.
2. A jacketed light emitting diode assembly according to claim 1,
wherein electrically connected portions of the contact set and the
electrical wire set are directly encased by the injection molded
thermoplastic jacket to provide a seal against moisture and
airborne contaminants.
3. A jacketed light emitting diode assembly according to claim 1,
wherein the electrical wire set passes through the opening, and
wherein the injection molded plastic jacket encases respective
regions of the electrical wire set passing through the opening.
4. A jacketed light emitting diode assembly according to claim 1,
wherein the contact set passes through the opening, and wherein the
injection molded thermoplastic jacket encases electrical
connections between the contact set and the electrical wire
set.
5. A jacketed light emitting diode assembly according to claim 1,
wherein the injection molded thermoplastic jacket comprises at
least one of polycarbonate, polystyrene, and other moldable
thermoplastic material.
6. A jacketed light emitting diode assembly according to claim 1,
wherein the injection molded thermoplastic jacket comprises a
thermoplastic selected from poly(vinyl chloride).
7. A jacketed light emitting diode assembly according to claim 1,
wherein the injection molded thermoplastic jacket comprises
polypropylene.
8. A jacketed light emitting diode assembly according to claim 1,
wherein the contact set and/or the electrical connections and/or a
portion of the electrical wire set are separated by a contact
separator to isolate them during the molding operation.
9. A method for making a jacketed light emitting diode assembly,
comprising: providing a light emitting diode comprising a positive
contact and a negative contact of a contact set, each of the
contacts having a first end portion and a second end portion, and a
lens body containing a semiconductor chip and the first end
portions of the positive and negative contacts; electrically
connecting a first electrical wire and a second electrical wire of
an electrical wire set to the second end portions of the positive
contact and the negative contact, respectively; inserting the light
emitting diode through an opening and into a cavity of a light
transmissive cover, the opening having at least one of the contact
set and the electrical wire set passing therethrough; and injection
molding a thermoplastic jacket integrally at the opening of the
light transmissive cover to provide a seal at the opening against
moisture and airborne contaminants.
10. A method according to claim 9, wherein electrically connected
portions of the contact set and the electrical wire set are encased
by the injection molded plastic jacket to provide a seal against
moisture and airborne contaminants.
11. A method according to claim 9, wherein the electrical wire set
passes through the opening, and wherein the plastic jacket encases
respective regions of the electrical wire set passing through the
opening.
12. A method according to claim 9, wherein the contact set passes
through the opening, and wherein the plastic jacket encases
electrical connections between the contact set and the electrical
wire set.
13. A method according to claim 9, wherein the plastic jacket
comprises at least one of polycarbonate, polystyrene, or other
moldable thermoplastic material.
14. A method according to claim 9, wherein the plastic jacket
comprises a thermoplastic selected from poly(vinyl chloride).
15. A method according to claim 9, wherein the thermoplastic jacket
comprises polypropylene.
16. A method according to claim 9, wherein the light transmissive
cover is at least partially encased by the integrally molded
plastic jacket.
17. A method according to claim 9, wherein the light transmissive
cover is not a portion of the thermoplastic jacket seal.
18. A light string comprising a plurality of light emitting diode
assemblies connected to one another, the light emitting diode
assemblies comprising a plurality of jacketed light emitting diode
assemblies, comprising: a light emitting diode comprising a contact
set comprising a positive contact and a negative contact, each of
the contacts having a first end portion and a second end portion;
and a lens body containing a semiconductor chip and the first end
portions of the positive and negative contacts; an electrical wire
set comprising a first electrical wire and a second electrical wire
electrically connected to the second end portions of the positive
contact and the negative contact, respectively; a light
transmissive cover having a cavity with an opening, the cavity
receiving the lens body, the cavity having at least one of the
contact set and the electrical wire set passing therethrough; and
an injection molded thermoplastic jacket at the opening of the
light transmissive cover to provide a seal at the opening against
moisture and airborne contaminants along a length of the light
string. wherein the jacket is formed in a single molding operation;
and wherein the light transmissive cover is at least partially
encased by the injection molded thermoplastic jacket.
19. A light string according to claim 18, wherein electrically
connected portions of the contact set and the electrical wire set
are encased by the injection molded thermoplastic jacket to provide
a seal against moisture and airborne contaminants.
20. A light string according to claim 18, wherein the electrical
wire set passes through the opening, and wherein the injection
molded thermoplastic jacket encases respective regions of the
electrical wire set passing through the opening.
21. A light string according to claim 18, wherein the contact set
passes through the opening, and wherein the injection molded
thermoplastic jacket encases electrical connections between the
contact set and the electrical wire set.
22. A light string according to claim 18, wherein the injection
molded plastic jacket comprises at least one of polycarbonate,
polystyrene, or other moldable thermoplastic material.
23. A light string according to claim 18, wherein the injection
molded plastic jacket comprises a thermoplastic selected from
poly(vinyl chloride).
24. A light string according to claim 18, wherein the injection
molded thermoplastic jacket comprises polypropylene.
25. A light string according to claim 18, wherein the contact set
and/or the electrical connections and/or a portion of the
electrical wire set are separated by a contact separator to isolate
them during the molding operation.
26. A method for moisture sealing a light-emitting diode elements
of a light string, comprising: providing a light string comprising
a plurality of light emitting diodes, the plurality of light
emitting diodes comprising a positive contact and a negative
contact of a contact set, each of the contacts having a first end
portion and a second end portion, and a lens body containing a
semiconductor chip and the first end portions of the positive and
negative contacts; electrically connecting a first electrical wire
and a second electrical wire of an electrical wire set to the
second end portions of the positive contact and the negative
contact, respectively; inserting the light emitting diode through
an opening and into a cavity of a light transmissive cover, the
opening having at least one of the contact set and the electrical
wire set passing therethrough; and injection molding a
thermoplastic jacket integrally at the opening of the light
transmissive cover to provide a seal at the opening against
moisture and airborne contaminants.
27. A method according to claim 26, wherein electrically connected
portions of the contact set and the electrical wire set are encased
by the injection molded thermoplastic jacket to provide a seal
against moisture and airborne contaminants.
28. A method according to claim 26, wherein the plastic jacket
comprises at least one of polycarbonate, polystyrene, or other
moldable thermoplastic material.
29. A method according to claim 26, wherein the plastic jacket
comprises a thermoplastic selected from poly(vinyl chloride).
30. A method according to claim 26, wherein the thermoplastic
jacket comprises polypropylene.
31. A method according to claim 26, wherein the light transmissive
cover is at least partially encased by the injection molded
thermoplastic jacket.
32. A method according to claim 26, wherein said molding comprises
injection molding the thermoplastic jacket in a mold cavity.
33. A jacketed light emitting diode assembly, comprising: a light
emitting diode comprising a contact set comprising a positive
contact and a negative contact, each of the contacts having a first
end portion and a second end portion; and a lens body containing a
semiconductor chip and the first end portions of the positive and
negative contacts; an electrical wire set comprising a first
electrical wire and a second electrical wire electrically connected
to the second end portions of the positive contact and the negative
contact, respectively and, an injection molded thermoplastic jacket
directly molded onto at least one of the lens body, contact set,
electrical connections and a portion of the electrical wire set to
seal and encase against moisture and airborne contaminants.
34. A jacketed light emitting diode assembly according to claim 33,
wherein the contact set and/or the electrical connections and/or a
portion of the electrical wire set are separated by a contact
separator to isolate them during the direct molding process.
Description
[0001] This application is a continuation of U.S. application Ser.
No. 10/755,463 filed Jan. 13, 2004, now abandoned, which is hereby
incorporate by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to light emitting diode
assemblies, light strings comprising a plurality of light emitting
diode assemblies, and related methods.
[0004] 2. Description of Related Art
[0005] Light emitting diodes (LEDs) are increasingly employed as a
basic lighting source in a variety of forms, including decorative
lighting, for reasons among the following. First, as part of an
assembly, LEDs have a very long lifespan, compared with common
incandescent and fluorescent sources. For example, a typical LED
lifespan is at least 100,000 hours. Second, LEDs have several
favorable physical properties, including ruggedness, cool
operation, and ability to operate under wide temperature
variations. Third, LEDs are currently available in all primary and
several secondary colors, as well as in a "white" form employing a
blue source and phosphors. Fourth, with newer doping techniques,
LEDs are becoming increasingly efficient, and colored LED sources
currently available may consume an order of magnitude less power
than incandescent bulbs of equivalent light output. Moreover, with
expanding applications and resulting larger volume demand, as well
as with new manufacturing techniques, LEDs are increasingly cost
effective.
[0006] Conventional LEDs are typically constructed using steel or
coated steal contacts or frames. LED contacts are also available in
copper or copper-alloys, although these materials generally are
considered undesirable because of their higher cost and
incompatibility with some automated LED manufacturing equipment and
certain types of LED die material.
[0007] LED-containing holiday and decorative light sets, such as
used for decorative purposes such as for Christmas lighting,
typically use copper-alloy contacts to transfer electricity from
the lead wires to the LED lamps. Although manufacturers take
efforts to seal the contacts and connections against moisture and
airborne contaminants, it is difficult if not impossible to achieve
completely and consistently a moisture and contaminant seal.
[0008] LED-based light strings also present other drawbacks. For
example, U.S. Pat. No. 5,495,147 entitled LED LIGHT STRING SYSTEM
to Lanzisera ("Lanzisera") and U.S. Pat. No. 4,984,999 entitled
STRING OF LIGHTS SPECIFICATION to Leake ("Leake") describe
different forms of LED-based light strings. In both Lanzisera and
Leake, exemplary light strings are described employing purely
parallel wiring of discrete LED lamps using a step-down transformer
and rectifier power conversion scheme. These and all other LED
light string descriptions found in the prior art convert input
electrical power, usually assumed to be the common U.S. household
power of 110 VAC to a low voltage, nearly DC input.
SUMMARY OF THE INVENTION
[0009] It is an object of this invention to provide an LED assembly
capable of addressing one or more of the above-mentioned
drawbacks.
[0010] It is another object of this invention to provide an LED
assembly possessing a complete and permanent barrier, especially
for the metal contacts and associated electrical connections,
against moisture and corrosive contaminants.
[0011] It is still another object of this invention to provide an
LED assembly having improved durability and longevity.
[0012] It is another object of the invention to provide a light
string comprising a series of LED assemblies of the invention.
[0013] It is still another object of the invention to provide a
method for manufacturing the assemblies and light-strings of this
invention.
[0014] To achieve one or more of the foregoing objects, and in
accordance with the purposes of the invention as embodied and
broadly described in this document, according to a first aspect of
this invention there is provided a jacketed light emitting diode
assembly, comprising a light emitting diode, an electrical wire
set, a light transmissive cover, and an integrally molded plastic
jacket. The light emitting diode comprises a contact set comprising
a positive contact and a negative contact, each of the contacts
having a first end portion and a second end portion, and a lens
body containing a semiconductor chip and the first end portions of
the positive and negative contacts. The electrical wire set
comprises a first electrical wire and a second electrical wire
electrically connected to the second end portions of the positive
contact and the negative contact, respectively. The light
transmissive cover has a cavity receiving the lens body, and an
opening having at least one of the contact set and the electrical
wire set passing therethrough. The integrally molded plastic jacket
is positioned at the opening of the light transmissive cover to
provide a seal at the opening against moisture and airborne
contaminants.
[0015] According to a second aspect of the invention a method is
provided for making a jacketed light emitting diode assembly. The
method comprises providing a light emitting diode comprising a
positive contact and a negative contact of a contact set, each of
the contacts having a first end portion and a second end portion,
and a lens body containing a semiconductor chip and the first end
portions of the positive and negative contacts. A first electrical
wire and a second electrical wire of an electrical wire set are
electrically connected to the second end portions of the positive
contact and the negative contact, respectively. The light emitting
diode is inserted through an opening and into a cavity of a light
transmissive cover, so that the contact set and/or the electrical
wire set passes through the opening. A plastic jacket is molded
integrally at the opening of the light transmissive cover to
provide a seal at the opening against moisture and airborne
contaminants.
[0016] A third aspect of the invention provides a light string
comprising a plurality of light emitting diode assemblies connected
to one another, the light emitting diode assemblies comprising a
plurality of jacketed light emitting diode assemblies, comprising a
light emitting diode, an electrical wire set, a light transmissive
cover, and an integrally molded plastic jacket. The contact set
comprises a positive contact and a negative contact, each of the
contacts having a first end portion and a second end portion, and a
lens body containing a semiconductor chip and the first end
portions of the positive and negative contacts. The electrical wire
set comprises a first electrical wire and a second electrical wire
electrically connected to the second end portions of the positive
contact and the negative contact, respectively. The light
transmissive cover has a cavity with an opening, the cavity
receiving the lens body, the opening having the contact set and/or
the electrical wire set passing therethrough. The integrally molded
plastic jacket, which is at the opening of the light transmissive
cover, provides a seal at the opening against moisture and airborne
contaminants along a length of the light string.
[0017] In accordance with a fourth embodiment of the invention, a
method is provided for moisture sealing a light-emitting diode
elements of a light string. The method comprises providing a light
string comprising a plurality of light emitting diodes, the
plurality of light emitting diodes comprising a positive contact
and a negative contact of a contact set, each of the contacts
having a first end portion and a second end portion, and a lens
body containing a semiconductor chip and the first end portions of
the positive and negative contacts. First and second electrical
wires of an electrical wire set are electrically connected to the
second end portions of the positive contact and the negative
contact, respectively. The light emitting diode is inserted through
an opening and into a cavity of a light transmissive cover, the
opening having at least one of the contact set and the electrical
wire set passing therethrough. A plastic jacket is molded
integrally at the opening of the light transmissive cover to
provide a seal at the opening against moisture and airborne
contaminants.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings are incorporated in and constitute
a part of the specification. The drawings, together with the
general description given above and the detailed description of the
certain preferred embodiments and methods given below, serve to
explain the principles of the invention. In such drawings:
[0019] FIGS. 1A and 1B show two example block diagrams of the light
string in its embodiment preferred primarily, with one diagram for
a 110 VAC common household input electrical source (e.g., 60 Hz)
and one diagram for a 220 VAC common household (e.g., 50 Hz) input
electrical source.
[0020] FIG. 2A shows a schematic diagrams of an embodiment of this
invention in which the diodes of the 50 LEDs (series) blocks 102 of
FIG. 1 are connected in the same direction.
[0021] FIG. 2B Shows a schematic diagrams of an embodiment of this
invention in which the diodes of the 50 LEDs (series) blocks 102 of
FIG. 1 are connected in the reverse direction.
[0022] FIGS. 3A and 3B show two example block diagrams of the light
string in its embodiment preferred alternatively, with one diagram
for a 110 VAC common household input electrical source (e. g., 60
Hz) and one diagram for a 220 VAC common household (e.g., 50 Hz)
input electrical source.
[0023] FIG. 4 shows an example schematic diagram of the AC-to-DC
power supply corresponding to the two block diagrams in FIG. 3 for
either the 110 VAC or the 220 VAC input electrical source.
[0024] FIGS. 5A and 5B show example pictorial diagrams of the
manufactured light string in either its "straight" or "curtain"
form (either form may be manufactured for 110 VAC or 220 VAC
input).
[0025] FIG. 6 shows an example pictorial diagram of a fiber optic
"icicle" attached to an LED and its housing in the light string.,
where the "icicle" diffuses the LED light in a predetermined
manner.
[0026] FIG. 7 is a graph of current versus voltage for diodes and
resistors.
[0027] FIGS. 8A and 8B are a schematic and block diagrams of direct
drive embodiments.
[0028] FIG. 9 is a plot showing the alternating current time
response of a diode.
[0029] FIG. 10 is a graph showing measured diode average current
response for alternating current and direct current.
[0030] FIG. 11 is a graph showing measured AlInGaP LED average and
maximum AC current responses.
[0031] FIG. 12 is a graph showing measured light output power as a
function of LED current.
[0032] FIG. 13 is a graph showing measured GaAlAs LED average and
maximum AC current responses.
[0033] FIG. 14 shows an unjacketed LED assembly having crimp
connectors.
[0034] FIG. 15 shows an unjacketed LED assembly having solder
connections.
[0035] FIG. 16 shows another embodiment of an unjacketed LED
assembly containing a contact separator.
[0036] FIG. 17 shows an unjacketed LED assembly inserted into a
light-transmissive cover.
[0037] FIG. 18 shows a partially sectioned view of a jacketed LED
assembly according to an embodiment of the invention.
[0038] FIG. 19 shows a partially sectioned view of a jacketed LED
assembly according to another embodiment of the invention.
[0039] FIG. 20 shows a non-sectioned view of the jacketed LED
assembly of FIG. 18 or 19.
[0040] FIG. 21 shows a step involved in the manufacture of a
jacketed LED assembly according to another embodiment of the
invention.
DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS AND CERTAIN
PREFERRED METHODS OF THE INVENTION
[0041] Reference will now be made in detail to the presently
preferred embodiments and methods of the invention as illustrated
in the accompanying drawings, in which like reference characters
designate like or corresponding parts throughout the drawings. It
should be noted, however, that the invention in its broader aspects
is not limited to the specific details, representative assemblies
and methods, and illustrative examples shown and described in this
section in connection with the preferred embodiments and methods.
The invention according to its various aspects is particularly
pointed out and distinctly claimed in the attached claims read in
view of this specification, and appropriate equivalents.
[0042] It is to be noted that, as used in the specification and the
appended claims, the singular forms "a," "an," and "the" include
plural referents unless the context clearly dictates otherwise.
[0043] According to an embodiment of the present invention, a
jacketed light emitting diode assembly is provided, comprising a
light emitting diode, an electrical wire set, a light transmissive
cover, and an integrally molded plastic jacket. The light emitting
diode comprises a contact set comprising a positive contact and a
negative contact, each of the contacts having a first end portion
and a second end portion, and a lens body containing a
semiconductor chip and the first end portions of the positive and
negative contacts. The electrical wire set comprises a first
electrical wire and a second electrical wire electrically connected
to the second end portions of the positive contact and the negative
contact, respectively. The light transmissive cover has a cavity
receiving the lens body, and an opening through which the contact
set and/or the electrical wire set passes. The integrally molded
plastic jacket is provided at the opening of the light transparent
cover to provide a seal at the opening against moisture and
airborne contaminants. The internal circuitry of the light emitting
diode assembly may include internal resistance elements as known by
those of skill in the art.
[0044] An example of a light emitting diode is depicted in FIG. 14
and generally designated by reference numeral 1000. The light
emitting diode 1000 comprises an LED lens (also referred to as a
lamp) 1002, and contacts 1006, 1008. In the illustrated embodiment,
the lamp 1002 is depicted as a dome-shaped member. The lens 1002
may undertake various other shapes, many of which are known and
practiced in the art, e.g., oblong, cylindrical, pointed,
polygonal. The lens 1002 may be made of various materials, such as
glass, plastic, or epoxy and may be clear, clear-colored, and/or
diffuse-colored. It should be noted that LED lenses are normally
encapsulated in epoxy. Light-emitting elements (e.g.,
semiconductors, 1003a in FIGS. 17-19) and internal circuitry (e.g.,
wire 1003b in FIGS. 17-19) are housed in the lens 1002. The
conventional LED structure shown in FIGS. 17-19 is for discussion
purposes only. It is to be understood that other structures,
arrangements, and configurations suitable for use or known in the
LED art may be used. These elements and circuitry are well known in
the art and, therefore, not described herein in detail. It is
noted, however, that the internal circuitry may provide for
emission of a continuous light signal, intermittent on-off
blinking, and/or intermittent LED sub-die color changes.
[0045] A flanged lens base 1004 is optionally formed at an end of
the lens 1002, and may form part of a seal of the lens chamber.
This lens base 1004 can be formed with a "flange" (as illustrated),
or without a flange. Protruding through the lens base 1004 are a
contact set comprising a negative contact 1006 and a positive
contact 1008 (also referred to in the art as frames or leads)
extending parallel to one another. Thus, the contacts 1006 and 1008
have first end portions (unnumbered) contained in the lens 1002,
and second end portions (unnumbered) outside of the lens 1002. The
contacts 1006 and 1008 are preferably made of a metal or alloy,
such as steel, coated steel, copper, or a copper alloy.
[0046] The light emitting diode 1000 is assembled to a set of
electrical wires 1010 and 1012, e.g., drive wires, discussed below.
Various mechanical and chemical mechanisms and means may be
employed for attaching the light emitting diode 1000 to the
electrical wires 1010 and 1012. For example, FIG. 14 illustrates
conventional crimp connectors 1014 and 1016 for making the
respective connections. Another example is shown in FIG. 15, which
is substantially identical to the assembly of FIG. 14 but includes
solder connections 1018 and 1020 in place of the crimp connectors
1014 and 1016, respectively.
[0047] As shown in FIG. 16, the light emitting diode assembly may
optionally further comprise a contact separator 1022. The contact
separator 1022 is placed between the contacts 1006 and 1008 to
prevent accidental contact and resultant shorting thereof. The
contact separator 1022 is made of a non-conductive material, such
as a plastic. Although FIG. 16 illustrates the contact separator
1022 used in combination with the crimp connectors 1014 and 1016,
it is to be understood that other connection means, including, for
example, solder, may be used.
[0048] The LED assembly further comprises a light transmissive
cover 1024. As shown in FIGS. 17-20, the light transmissive cover
1024 may have a generally spherical shape with a cylindrical base,
although other shapes (e.g., bulb-like, cylindrical,
frustum-conical, conical, polygonal, etc.) may be selected. The
light-transmissive cover 1024 permits for the full or partial
passage of light emitted from the LED 1000. The light transmissive
cover 1024 may be made of a transparent material, such as one
selected from the group consisting of glass and plastic, such as
polycarbonates. The cover 1024 may be optically clear, tainted
colored, frosted, semi-transparent or translucent, and the like for
providing the desired illumination effect. The light-transmissive
cover 1024 may include prisms, facets, or other designs or
patterns.
[0049] The light emitting diode 1000 is inserted through an opening
of the light transmissive cover 1024 base, so that a portion and
more preferably all of the LED lens 1002 is situated in the chamber
of the light transparent cover 1024. Preferably, the opening of the
light transmissive cover 1024 is sized to be relatively tight yet
slidable relative to the LED lens base 1004. In this manner, the
LED 1000 may be retained in the opening of the light transmissive
cover, yet permit for insertion and removal with firm force.
Alternatively, a bonding or mechanical securing (e.g., clamping)
means may be used to retain the light emitting diode 1000 relative
to the light transmissive cover 1024.
[0050] In accordance with embodiments of the present invention, a
plastic jacket is integrally molded onto the light emitting diode
assembly at the opening of the light transparent cover to provide a
seal at the opening against moisture and airborne contaminants.
[0051] An embodiment of a plastic jacket is illustrated in FIGS.
18-20 and designated by reference numeral 1030 and 1030A. The
jacket 1030, 1030A may comprise one or more plastic materials, used
alone or in combination with non-plastics. Preferably but not
necessarily, the jacket 1030, 1030A consists of one or more plastic
materials. Suitable plastics include, for example and not
necessarily limitation, polycarbonate (PC), poly(vinyl chloride)
(PVC), polypropylene (PP), and any combination thereof. The plastic
material may be optically transparent or non-transparent, clear or
colored.
[0052] The plastic jacket 1030, 1030A is integrally molded on the
base of the light transparent cover 1024 to intimately contact
electrical wires 1010 and 1012. The plastic jacket 1030, 1030A
preferably yet optionally contacts less than the entire surfaces of
the light transmissive cover 1024, e.g., in FIG. 20 jacket 1030
contacts the base of the cover 1024. The plastic jacket 1030, 1030A
may enter into the opening of the light transmissive cover 1024,
for example, to contact a portion of the interior of the cover 1024
base. It should be understood that the portion of the light
transmissive cover 1024 that the plastic jacket 1030, 1030A
contacts need not be light transmissive.
[0053] In the embodiment illustrated in FIG. 18, the electrical
wires 1010 and 1012 pass through the opening of the light
transmissive cover 1024, and the plastic jacket 1030 encases (at
least) respective regions of the electrical wire set passing
through the opening. Another embodiment is illustrated in FIG. 19,
in which the first and second contacts 1006 and 1008 pass through
the opening of the light transmissive cover 1024. In the embodiment
illustrated in FIG. 19, the plastic jacket 1030A encases the
contacts 1006 and 1008, the distal end portions of the electrical
wires 1010 and 1012, and the second end portions of the
corresponding connectors 1014 and 1016. (In the event the
connectors 1014 and 1016 pass through at the opening of the cover
1024, the connectors 1014 and 1016 may be considered to be part of
the contacts 1006, 1008 or the electrical wires 1010, 1012.)
[0054] Although not shown, the plastic jacket 1030 or 1030A may
optionally encase other components of the LED 1000, including the
lamp base 1004, a greater or lesser portion or all of the contacts
1006, 1008, a greater or lesser portion or all of the cover 1024,
as well as a greater or lesser portion of the electrical wires 1010
and 1012.
[0055] In preferred embodiments of the invention, the plastic
jacket 1030 (or 1030A) provides a permanent, waterproof (or at
least moisture resistant), and corrosion resistant encapsulation
for at least the contacts 1006 and 1008, the connectors 1014 and
1016, and the distal portion of the electrical wires 1010 and 1012.
The invention provides an arrangement where a series of LEDs are
interconnected in a sealed, waterproof assembly.
[0056] As used herein, "integrally molded" jacket refers to a
plastic jacket that has been molded onto, as opposed to pre-molded
and subsequently applied to, another member or device, such as a
light transmissive cover 1024.
[0057] A method for making the jacketed LED assembly will now be
explained with reference to FIG. 20. Molding is performed with mold
die 1050 and a counterpart mold die (not shown). The mold die 1050
includes a cavity 1052, an upper opening 1054, and a lower opening
1056. The LED 1000 and the base of cover 1024 are placed on the
mold die 1050 and positioned so that the end portions of the
electrical wires 1010 and 1012, the exposed portions of the
contacts 1006 and 1008, the connectors 1014 and 1016, and the
contact separator 1022 are disposed in the mold cavity 1052. The
lens 1004 extends through the upper opening 1054 of the mold die
1050 to situate the lens 1002 outside the mold die 1050. Likewise,
the majority of the light transmissive cover 1024 is situated
outside of the mold die 1050. The electrical wires 1010 and 1012
extend through the lower opening 1056 of the mold die 1050.
[0058] The mold process and techniques will now be described.
Vertical injection molding equipment is preferred as the easiest
and most efficient for machine operators to align the assembled LED
lens, contact wire, and light transmissive cover base inside the
injection mold cavity (cavities).
[0059] Significant to this waterproof, molded process is selecting
a molding temperature compatible with LED lens encapsulating
material. LED lenses 1002 are normally formed using an optical
grade epoxy. The encapsulating epoxy properties will vary between
manufacturers. Further variations in epoxy material are found when
flame retardant compounds are added to the epoxy. At certain
temperature thresholds epoxy material will begin to soften,
transitioning back into liquid form. This is known in the art as
TG, or Glass Transition temperature. Exceeding the TG temperature
of the LED epoxy material during the molding, or jacketing process
will soften the LED lens material, damaging the internal structure
of the LED lamp. This is particularly true of this jacketing, or
molding process as heat from molding is first conducted by the LED
contacts (1006 and 1008). This causes softening of the epoxy
surrounding the LED "wire bond" (electrical connection inside the
LED lamp completing the circuit from the LED chip to the wire frame
or contacts) and causing disruption of wire bond contact.
[0060] Mold temperature is not of concern when jacketing, or
"over-molding" conventional, incandescent lamps as the melting
point of the glass "bulb" material is considerably higher than that
of the jacketing plastic material.
[0061] For jacketing, or over-molding LED lamps one first
determines the TG temperature of the encapsulating epoxy used.
Second, the mold temperature and duration of the injection
(jacketing) process are adjusted so the TG temperature is not
exceeded. Pre-warming the injection material (PVC, PP, PS, etc.) in
its raw granular, or pellet form will greatly assist material flow,
reduce air pockets, or voids in the finished jackets, as well as
reduce molding duration and temperature.
[0062] According to another embodiment of the invention, a light
string comprising a plurality of LED assemblies is provided, in
which at least one of the LED assemblies comprises a jacketed LED
assembly. More preferably, a plurality or all of the LED assemblies
are jacketed. The jacketed LED assemblies may have constructions as
described above and as illustrated in FIGS. 18 and 19.
[0063] In the event that LED assemblies of a light string are to be
individually jacketed, the jacketing process may be conducted
simultaneously on two or more LED assemblies by use of a
corresponding number of molds, or one or more molds containing
multiple cavities for simultaneous jacketing of multiple LED lamp
and contact wire assemblies. Concurrent practice of this molding
technique will improve process efficiency.
[0064] The jacketed LED assembly of this invention may be used in
various systems and light strings. Preferred light string systems
with which the jacketed LED assembly of aspects of this invention
may be used are described in detail below. It should be understood
that the following description and attached drawings of preferred
devices, apparatuses, assemblies, methods, and the like are
exemplary, but not exhaustive as to the scope of environments in
which the jacketed LED assemblies and light strings of the present
invention may be used.
[0065] The term "alternating current voltage", sometimes
abbreviated as "VAC", as used herein occasionally refers to a
numerical amount of volts, for example, "220 VAC". It is to be
understood that the stated number of alternating current volts is
the nominal voltage which cycles continuously in forward and
reverse bias and that the actual instantaneous voltage at a given
point in time can differ from the nominal voltage number.
[0066] In accordance with an embodiment of the present invention,
an LED light string employs a plurality of LEDs wired in
series-parallel form, containing at least one series block of
multiple LEDs. The series block size is determined by the ratio of
the standard input voltage (e.g., either 110 VAC or 220 VAC) to the
drive voltage(s) of the LEDs to be employed (e.g., 2 VAC). Further,
multiple series blocks, if employed, are each of the same LED
configuration (same number and kinds of LEDs), and are wired
together along the string in parallel. LEDs of the light string may
comprise either a single color LED or an LED including multiple
sub-dies each of a different color. The LED lenses may be of any
shape, and may be clear, clear-color, or diffuse-color. Moreover,
each LED may have internal circuitry to provide for intermittent
on-off blinking and/or intermittent LED sub-die color changes.
Individual LEDs of the light string may be arranged continuously
(using the same color), or periodically (using multiple,
alternating CIP colors), or pseudo-randomly (any order of multiple
colors). The LED light string may provide an electrical interface
to couple multiple light strings together in parallel, and
physically from end to end. Fiber optic bundles or strands may also
be coupled to individual LEDs to diffuse LED light output in a
predetermined manner.
[0067] An LED light string of embodiments of the present invention
may have the following advantages. The LED light string may last
far longer and require less power consumption than light strings of
incandescent lamps, and the light string may be safer to operate
since less heat is generated. The LED light string may have reduced
cost of manufacture by employing series-parallel blocks to allow
operation directly from a standard household 110 VAC or 220 VAC
source, either without any additional circuitry (AC drive), or with
only minimal circuitry (DC drive). In addition, the LED light
string may allow multiple strings to be conveniently connected
together, using standard 110 VAC or 220 VAC plugs and sockets,
desirably from end-to-end.
[0068] Direct AC drive of LED light string avoids any power
conversion circuitry and additional wires; both of these items add
cost to the light string. The additional wires impose additional
mechanical constraint and they may also detract aesthetically from
the decorative string. However, direct AC drive results in pulsed
lighting. Although this pulsed lighting cannot be seen at typical
AC drive frequencies (e.g. 50 or 60 Hz), the pulsing apparently may
not be the most efficient use of each LED device because less
overall light is produced than if the LEDs were continuously driven
using DC. However, this effect may be compensated for by using
higher LED current during each pulse, depending on the pulse duty
factor. During "off" times, the LED has time to cool. It is shown
that this method can actually result in a higher efficiency than DC
drive, depending on the choice of AC current.
[0069] FIG. 1 shows the embodiment of an LED light string in
accordance with the present invention, and as preferred primarily
through AC drive. In FIG. 1, the two block diagrams correspond to
an exemplary string employing 100 LEDs, for either 110 VAC (top
diagram) or 220 VAC (bottom diagram) standard household current
input (e.g., 50 or 60 Hz). In the top block diagram of FIG. 1A, the
input electrical interface consists merely of a standard 110 VAC
household plug 101 attached to a pair of drive wires.
[0070] With the average LED drive voltage assumed to be
approximately 2.2 VAC in FIG. 1A, the basic series block size for
the top block diagram, corresponding to 110 VAC input, is
approximately 50 LEDs. Thus, for the 110 VAC version, two series
blocks of 50 LEDs 102 are coupled in parallel to the drive wires
along the light string. The two drive wires for the 110 VAC light
string terminate in a standard 110 VAC household socket 103 to
enable multiple strings to be connected in parallel electrically
from end-to-end.
[0071] In the bottom block diagram of FIG. 1B, the input electrical
interface likewise consists of a standard 220 VAC household plug
104 attached to a pair of drive wires. With again the average LED
drive voltage assumed to be approximately 2.2 VAC in FIG. 1B, the
basic series block size for the bottom diagram, corresponding to
220 VAC input, is 100 LEDs. Thus, for the 220 VAC version, only one
series block of 100 LEDs 105 is coupled to the drive wires along
the light string. The two drive wires for the 220 VAC light string
terminate in a standard 220 VAC household socket 106 to enable
multiple strings to be connected in parallel from end-to-end. Note
that for either the 110 VAC or the 220 VAC light string, the
standard plug and socket employed in the string varies in
accordance to the country in which the light string is intended to
be used.
[0072] Whenever AC drive is used and two or more series are
incorporated in the light string, the series blocks may each be
driven by either the positive or negative half of the AC voltage
cycle. The only requirement of this embodiment is that, in each
series block, the LEDs are wired with the same polarity; however
the series block itself, since driven in parallel with the other
series blocks, may be wired in either direction, using either the
positive or the negative half of the symmetric AC electrical power
cycle.
[0073] FIGS. 2A and 2B show two schematic diagram implementations
of the top diagram of FIG. 1A, where the simplest example of AC
drive is shown that uses two series blocks of 50 LEDs, connected in
parallel and powered by 110 VAC. In the top schematic diagram of
FIG. 2A both of these LED series blocks are wired in parallel with
the polarity of both blocks in the same direction (or,
equivalently, if both blocks were reversed). With this block
alignment, both series blocks flash on simultaneously, using
electrical power from the positive (or negative, if both blocks
were reversed) portion of the symmetric AC power cycle. A possible
advantage of this configuration is that, since the LEDs all flash
on together at the cycle rate (60 Hz for this example), when the
light string flashes on periodically, it is as bright as
possible.
[0074] The disadvantage of this configuration is that, since both
blocks flash on simultaneously, they both draw power at the same
time, and the maximum current draw during this time is as large as
possible. However, when each flash occurs, at the cycle rate, the
amount of light flashed is maximal. The flash rate, at 50-60 Hz,
cannot be seen directly by human eye and is instead integrated into
a continuous light stream.
[0075] The bottom schematic diagram FIG. 2B shows the alternative
implementation for the top diagram of FIG. 1A, where again, two
series blocks of 50 LEDS are connected in parallel and powered by
110 VAC.
[0076] In this alignment, the two series blocks are reversed,
relative to each other, in polarity with respect to the input AC
power. Thus, the two blocks flash alternatively, with one block
flashing on during the negative portion of each AC cycle. The
symmetry, or "sine-wave" nature of AC allows this possibility. The
advantage is that, since each block flashes alternatively, drawing
power during opposite phases of the AC power, the maximum current
draw during each flash is only half of that previously (i.e.,
compared when both blocks flash simultaneously). However, when each
flash occurs, at twice the cycle rate here, the amount of light
flashed is reduced (i.e., half the light than if two blocks were
flashing at once as previously illustrated). The flash rate, at
100-120 Hz, cannot be seen directly by the human eye and is instead
integrated into a continuous light stream.
[0077] The trade-off between reversing series blocks when two or
more exist in an AC driven circuit is influenced primarily by the
desire to minimize peak current draw. A secondary influence has to
do with the properties of the human eye in integrating periodic
light flashes. It is well known that the human eye is extremely
efficient in integrating light pulses rapid enough to appear
continuous. Therefore, the second form of the light string is
preferred from a power draw standpoint because the effect on human
perception is insignificant.
[0078] For AC drive with non-standard input (e.g., three-phase AC)
the series blocks may similarly be arranged in polarity to divide
power among the individual cycles of the multiple phase AC. This
may result in multiple polarities employed for the LED series
blocks, say three polarities for each of the three positive or
negative cycles.
[0079] As an alternative preference to AC drive, FIG. 3 shows two
block diagrams that correspond to an exemplary string employing 100
LEDs and DC drive, for either 110 VAC (top diagram) or 220 VAC
(bottom diagram) standard household current input (e.g., 50 or 60
Hz). In the top block diagram of FIG. 3A, the input electrical
interface consists of a standard 110 VAC household plug 301
attached to a pair of drive wires, followed by an AC-to-DC
converter circuit 302. As in FIG. 1, with the average LED drive
voltage assumed to be approximately 2.2 VAC in FIG. 3A, the basic
series block size for the top block diagram, corresponding to 110
VAC input, is approximately 50 LEDs. Thus, for the 110 VAC version,
two series blocks of 50 LEDs 303 are coupled in parallel to the
output of the AC-to-DC converter 302 using additional feed wires
along the light string. The two drive wires for the 110 VAC light
string terminate in a standard 110 VAC household socket 304 to
enable multiple strings to be connected in parallel electrically
from end-to-end.
[0080] In the bottom block diagram of FIG. 3B, the input electrical
interface likewise consists of a standard 220 VAC household plug
305 attached to a pair of drive wires, followed by an AC-to-DC
converter circuit 306. With again the average LED drive voltage
assumed to be approximately 2.2 VAC in FIG. 3B, the basic series
block size for the bottom diagram, corresponding to 220 VAC input,
is 100 LEDs. Thus, for the 220 VAC version, only one series block
of 100 LEDs 307 is coupled to the output of the AC-to-DC converter
306 using additional feed wires along the light string. The two
drive wires for the 220 VAC light string terminate in a standard
220 VAC household socket 308 to enable multiple strings to be
connected in parallel from end-to-end. Note that for either the 110
VAC or the 220 VAC light string, the standard plug and socket
employed in the string varies in accordance to the country in which
the light string is intended to be used.
[0081] FIG. 4 shows an example schematic electrical diagram for the
AC-to-DC converter employed in both diagrams of FIG. 3. The AC
input to the circuit in FIG. 1 is indicated by the symbol for an AC
source 401. A varistor 402 or similar fusing device may optionally
be used to ensure that voltage is limited during large power
surges. The actual AC to DC rectification is performed by use of a
full-wave bridge rectifier 403. This bridge rectifier 403 results
in a rippled DC current and therefore serves as an example circuit
only. A different rectification scheme may be employed, depending
on cost considerations. For example, one or more capacitors or
inductors may be added to reduce ripple at only minor cost
increase. Because of the many possibilities, and because of their
insignificance, these and similar additional circuit features have
been purposely omitted from FIG. 4.
[0082] For either the 110 VAC or the 220 VAC version of the LED
light string, and whether or not an AC to-DC power converter is
used, the final manufacturing may be a variation of either the
basic "straight" string form or the basic "curtain" string form, as
shown in the top and bottom pictorial diagrams in FIGS. 5A and 5B.
In the basic "straight" form of the light string, the standard (110
VAC or 220 VAC) plug 501 is attached to the drive wires which
provide power to the LEDs 502 via the series-parallel feeding
described previously. The two drive and other feed wires 503 are
twisted together along the length of the light string for
compactness and the LEDs 502 in the "straight" form are aligned
with these twisted wires 503, with the LEDs 502 spaced uniformly
along the string length (note drawing is not to scale). The two
drive wires in the "straight" form of the light string terminate in
the standard (correspondingly, 110 VAC or 220 VAC) socket 504.
Typically, the LEDs are spaced uniformly every four inches.
[0083] In the basic "curtain" form of the light string, as shown
pictorially in the bottom diagram of FIGS. 5A and 5B, the standard
(110 VAC or 220 VAC) plug 501 again is attached to the drive wires
which provide power to the LEDs 502 via the series-parallel feeding
described previously. The two drive and other feed wires 503 are
again twisted together along the length of the light string for
compactness. However, the feed wires to the LEDs are now twisted
and arranged such that the LEDs are offset from the light string
axis in small groups (groups of 3 to 5 are shown as an example).
The length of these groups of offset LEDs may remain the same along
the string or they may vary in either a periodic or pseudo-random
fashion.
[0084] Within each group of offset LEDs, the LEDs 502 may be spaced
uniformly as shown or they may be spaced nonuniformly, in either a
periodic or pseudo-random fashion (note drawing is not to scale).
The two drive wires in the "curtain" form of the light string also
terminate in a standard (correspondingly 110 VAC or 220 VAC) socket
504. Typically, the LED offset groups are spaced uniformly every
six inches along the string axis and, within each group, the LEDs
are spaced uniformly every four inches.
[0085] In any above version of the preferred embodiment to the LED
light string, blinking may be obtained using a number of techniques
requiring additional circuitry, or by simply replacing one of the
LEDs in each series block with a blinking LED. Blinking LEDs are
already available on the market at comparable prices with their
continuous counterparts, and thus the light string may be sold with
the necessary (e.g., one or two) additional blinkers included in
the few extra LEDs.
[0086] Typically, the LEDs in the light string will incorporate a
lens for wide-angle viewing. However, it is also possible to attach
fiber optic bundles or strands to the LEDs to spatially diffuse the
LED light in a predetermined way for a desirable visual effect. In
such case, the LED lens is designed to create a narrow-angle light
beam (e.g., 20 degree beamwidth or less) along its axis, to enable
the LED light to flow through the fiber optics with high coupling
efficiency. An example of the use of fiber optics is shown in FIG.
6, where a very lossy fiber optic rod is employed with intention
for the fiber optic rod to glow like an illuminated "icicle." In
FIG. 6, the LED 801 and its housing 802 may be attached to the
fiber optic rod 803 using a short piece of tubing 804 that fits
over both the LED lens and the end of the fiber optic rod (note
that the drawing is not to scale). An example design uses a
cylindrical LED lens with a narrow-angle end beam, where the
diameter of the LED lens and the diameter of the fiber optic rod
are the same (e.g., 5 mm or 3/16 inches). The fiber optic rod 803
is typically between three to eight inches in length and may be
either uniform in length throughout the light string, or the fiber
optic rod length may vary in either a periodic or pseudo-random
fashion.
[0087] Although the fiber optic rod 803 in FIG. 6 could be
constructed using a variety of plastic or glass materials, it may
be preferred that the rod is made in either a rigid form using
clear Acrylic plastic or clear crystal styrene plastic, or in a
highly flexible form using highly plasticized Polyvinyl Chloride
(PVC). These plastics are preferred for safety, durability, light
transmittance, and cost reasons. It may be desirable to add into
the plastic rod material either air bubbles or other constituents,
such as tiny metallic reflectors, to achieve the designed measure
of lossiness for off-axis glowing (loss) versus on-axis light
conductance. Moreover, it is likely to be desirable to add UV
inhibiting chemicals for longer outdoor life, such as a combination
of hindered amine light stabilizer (HALS) chemicals. The tubing 804
that connects the fiber optic rod 803 to its LED lens 801 may also
made from a variety of materials, and be specified in a variety of
ways according to opacity, inner diameter, wall thickness, and
flexibility. From safety, durability, light transmittance, and cost
reasons, it may be preferred that the connection tubing 804 be a
short piece (e.g., 10 mm in length) of standard clear flexible PVC
tubing (containing UV inhibiting chemicals) whose diameter is such
that the tubing fits snugly over both the LED lens and the fiber
optic rod (e.g., standard wall tubing with 1/4 inch outer
diameter). An adhesive may be used to hold this assembly more
securely.
[0088] The method of determining and calculating the preferred LED
network that provides stable and functioning operation will now be
described.
[0089] Many current-limiting designs use a single impedance element
in series between the LED network and the power supply.
Current-saturated transistors are a less common method of current
limiting. A resistor is often used for the impedance element due to
low cost, high reliability and ease of manufacture from
semiconductors. For pulsed-DC or AC power, however, a capacitor or
inductor may instead be used for the impedance element. With AC
power, even though the waveform shape may be changed by capacitors
or inductors, the overall effect of these reactive elements is
basically the same as a resistor, in adding constant impedance to
the circuit due to the single AC frequency involved (e.g., 60 Hz).
In any case, the fundamental effect of current-limiting circuitry
is to partially linearize or limit the highly nonlinear current
versus voltage characteristic response curve of the diode, as shown
in FIG. 7 for a single resistor element.
[0090] FIGS. 8A and 8B show the preferred embodiment of the
inventions wherein a network of diodes, consisting of LEDs, is
directly driven by the AC source without any current-limiting
circuitry. FIG. 8A is a general schematic diagram showing M series
blocks of LEDs directly connected in parallel to the AC source
where, for the m-th series block, there are N.sub.m
{1.ltoreq.m.ltoreq.M} LEDs directly connected to each other in
series. Also shown is a reversal of polarity between some series
blocks, placing these blocks in opposite AC phase, in order to
minimize peak current in the overall AC circuit. FIG. 8B is a block
diagram of the above schematic, where a combination plug/socket is
drawn explicitly to show how multiple devices can be directly
connected either on the same end or in an end-to-end fashion,
without additional power supply wires in between. This end-to-end
connection feature is particularly convenient for decorative LED
light strings.
[0091] The invention in FIGS. 8A and 8B may have additional
circuitry, not explicitly drawn, to perform functions other than
current-limiting. For example, logic circuits may be added to
provide various types of decorative on-off blinking. A full-wave
rectifier may also be used to obtain higher duty factor for the
diodes which, without the rectifier, would turn on and off during
each AC cycle at an invisibly high rate (e.g., 50 or 60 Hz). The
LEDs themselves may be a mixture of any type, including any size,
shape, material, color or lens. The only vital feature of the diode
network is that all diodes are directly driven from the AC power
source, without any form of current-limiting circuitry external to
the diode.
[0092] In order to directly drive a network of diodes without
current-limiting circuitry, the voltage of each series block of
diodes must be matched to the input source voltage. This voltage
matching requirement for direct AC drive places fundamental
restrictions on the number of diodes on each diode series block,
depending on the types of diodes used. For the voltage to be
"matched," in each series block, the peak input voltage,
V.sub.peak, must be less than or equal to the sum of the maximum
diode voltages for each series block. Mathematically, let
V.sub.peak be the peak voltage of the input source and let
V.sub.max(n,m) be the maximum voltage for the n-th diode
{1.ltoreq.n.ltoreq.N.sub.m} of the m-th series block
{1.ltoreq.m.ltoreq.M}. Then, for each m, the peak voltage must be
less than or equal to the m-th series block voltage sum,
V.sub.peak.ltoreq..SIGMA..sub.nV.sub.max(n,m) (1) where
{1.ltoreq.n.ltoreq.N.sub.m} in the sum over n. For simpler cases
where all N.sub.m diodes in the m-th series block are of the same
type, each with V.sub.max, then V.sub.peak.ltoreq.N.sub.m
V.sub.max.
[0093] The maximum voltage V.sub.max of each diode is normally
defined by the voltage which produces diode maximum current,
I.sub.max. However, when diodes of different types are used in a
series block, the series block value of I.sub.max is the minimum of
all individual diode values for I.sub.max in the series block.
Thus, if the m-th series block has N.sub.m diodes, with the n-th
diode in the m-th series block having maximum current
I.sub.max(n,m), then the value of I.sub.max for the m-th series
block, I.sub.max(m), is determined by the minimum of these N.sub.m
individual diode values, I.sub.max(m)=min[I.sub.max(n,m);
{1.ltoreq.n.ltoreq.N.sub.m}]. (2)
[0094] The maximum voltage V.sub.max of each diode in the m-th
series block is thus defined as the voltage which produces the m-th
series block maximum current I.sub.max(m). For simpler cases where
all diodes in a series block are of the same type, each with
maximum current I.sub.max, then I.sub.max(m)=I.sub.max.
[0095] For AC or any other regularly varying input voltage, there
is an additional requirement to direct drive voltage matching.
Here, in a similar way to peak voltage above, the average, or RMS,
voltage of the source, V.sub.rms, must also be less than or equal
to the sum of the average diode voltages, V.sub.avg, for each
series block. Mathematically, let V.sub.rms be the RMS voltage of
the input source and let V.sub.avg(n,m) be the average forward
voltage for the n-th diode {1.ltoreq.n.ltoreq.N.sub.m} of the m-th
series block {1.ltoreq.m.ltoreq.M}. Then, for each m, the RMS
voltage must be less than or equal to the m-th series block voltage
sum, V.sub.rms.ltoreq..SIGMA..sub.n V.sub.avg(n,m) (3) where
{1.ltoreq.n.ltoreq.N.sub.m} in the sum over n. For simpler cases
where all N.sub.m diodes in the m-th series block are of the same
type, each with V.sub.rms, then V.sub.rms.ltoreq.N.sub.m
V.sub.avg.
[0096] In a similar way to the peak voltage above, the average
voltage of each diode, V.sub.avg is normally defined by the voltage
which produces diode average current, I.sub.avg. However, when
diodes of different types are used in a series block, the series
block value of I.sub.avg is the minimum of all individual diode
values for I.sub.avg in the series block. Thus, if the m-th series
block has N.sub.m diodes, each with average current I.sub.avg(n,m)
then the value of I.sub.avg for the M-th series block,
I.sub.avg(m), is determined by the minimum of these N.sub.m values,
I.sub.avg(m)=min[I.sub.avg(n,m); {1.ltoreq.n.ltoreq.N.sub.m}].
(4)
[0097] The average voltage V.sub.avg of each diode in the m-th
series block is thus defined as the voltage which produces the m-th
series block average current I.sub.avg(m). For simpler cases where
all diodes in a series block are of the same type, each with
average current I.sub.avg, then I.sub.avg(m)=I.sub.avg.
[0098] Note that the term "average", rather than "RMS," is used to
distinguish RMS diode values from RMS input voltage values because
diode values are always positive (nonnegative) for all positive or
negative input voltages considered, so that diode RMS values are
equal to their simple averages. Note also that in past LED designs,
the specified DC value for I.sub.nom is equated to the average
diode value, I.sub.avg. LEDs are always specified in DC, and the
specified DC value for I.sub.nom results from a tradeoff between
LED brightness and LED longevity. In the direct AC drive analysis
below, this tradeoff between brightness and longevity results in
values for I.sub.avg that are generally different than I.sub.nom.
The direct AC drive value for V.sub.avg is thus also generally
different than the LED specified DC value V.sub.nom.
[0099] LEDs are specified in terms of DC values, V.sub.nom and
I.sub.nom. For AC power, since V.sub.avg is an AC quantity and
V.sub.nom is a DC quantity, they are fundamentally different from
each other. This basic difference between AC and DC values arises
from the nonlinear relationship between diode voltage and diode
current. Consider AC voltage input to a diode as shown for one
period in FIG. 9, where the peak voltage shown, V.sub.pk, is less
than or equal to the diode maximum voltage, V.sub.max. For AC
voltages below the diode voltage threshold, V.sub.th, the current
is zero. As the voltage increases above V.sub.th to its peak value,
V.sub.pk, and then falls back down again, the diode current rises
sharply in a nonlinear fashion, in accordance to its current versus
voltage characteristic response curve, to a peak value, l.sub.pk,
and then the diode current falls back down again to zero current in
a symmetric fashion. Since the voltage was chosen such that
V.sub.pk.ltoreq.V.sub.max, then the peak diode current satisfies
I.sub.pk.ltoreq.I.sub.max. The average diode current, I.sub.avg, is
obtained by integrating the area under the current spike over one
full period.
[0100] The central problem of AC voltage matching in equations (1)
through (4) for direct drive of diodes is to first determine peak
AC diode current, I.sub.peak and average AC diode current,
I.sub.avg as a function of V.sub.rms or, equivalently, the peak AC
voltage V.sub.peak= 2 V.sub.rms. Since the nonlinear relationship
for diode current versus voltage is not known in closed form, these
diode AC current versus input AC voltage relationships cannot be
obtained in closed form. Moreover, the nonlinear diode AC current
versus input AC voltage relationships vary for different diode
types and materials. In all cases, since the diode current versus
voltage characteristic curve, near the practical operating point
V.sub.nom, is a convex-increasing function, i.e., its slope is
positive and increases with voltage, the average diode current
I.sub.avg that results from a given RMS value of AC voltage is
always higher than the diode current that would be achieved for a
DC voltage input having the same value. Because of this, specified
DC values for diode voltage cannot be directly substituted for AC
diode voltage values. Instead, the characteristic diode AC current
versus input AC voltage relationships must be found for the AC
waveform of interest.
[0101] The characteristic diode AC current versus voltage
relationships may be found by measuring diode current values
I.sub.avg and I.sub.peak as a function of RMS voltage, V.sub.rms,
using variable voltage AC source. A number of alike diodes are used
in these measurements to obtain good statistics. If different diode
types or materials are considered, then each measurement procedure
is repeated accordingly. FIG. 10 shows a typical measurement result
for average current, I.sub.avg, where the diode used has specified
nominal values of V.sub.nom=2 VDC and I.sub.nom=20 mA.
[0102] The average AC current curve is always to left of the DC
current curve in FIG. 10. Thus, FIG. 10 shows that if one used DC
voltages for the diode in an AC circuit, the resulting average AC
diode current would be much higher than the DC current expected.
Recall that in the prior art, where a number of alike 2 VDC LEDs
are connected in series with a current-limiting resistor, a maximum
number N of LEDs is defined by summing the individual LED voltages
and equating to the RMS input voltage. For a 120 VAC source, this
maximum number is N=60 LEDs. The prior art then subtracts five or
ten LEDs from this maximum to obtain a design number, and computes
the resistor value using the difference between the AC input RMS
voltage and the sum of these DC LED voltages. This design is
marginally stable, and then becomes unstable, as the number of LEDs
subtracted becomes smaller. Instability is proven in FIG. 10, by
considering the limit case where a maximum number N=60 of LEDs are
used and hence no LEDs are subtracted. In this limit case, one
might argue that a resistor must be used anyway, but according to
this design formula, presented for five or ten LEDs subtracted, the
resistor value in this case would equal zero. As FIG. 10 shows, if
the resistor value were zero, i.e., the resistor is omitted,
instead of the DC design value of I.sub.nom=20 mA for LED current
(the rightmost, DC, curve at 2.0 VDC), the LED average AC current
will be off the scale, higher than the maximum diode current
I.sub.max=100 mA (the leftmost, AC, curve at 1.87 VAC), and the
device will fail immediately or almost immediately.
[0103] In order to properly perform matching in an direct AC drive
design, the characteristic diode AC current versus input AC voltage
relationships must be measured and used to specify the AC values
for equations (1) through (4). DC specifications and DC diode
measurements cannot directly be used in the direct AC drive design,
and they are useful only as a guide for theoretical inference,
discussed further below. Along with the diode average AC current,
the diode peak AC current must also be measured as a function of
RMS (or equivalently, peak) input AC voltage. FIG. 11 shows a
typical measurement result, where the diode used has specified DC
nominal values of V.sub.nom=2 VDC and I.sub.nom=20 mA.
[0104] As stated previously, for an AC design, the LED average AC
current, I.sub.avg, is generally different from the specified LED
nominal DC current, I.sub.nom. Likewise, the LED maximum AC
current, I.sub.max, is also generally different from the specified
LED maximum DC current. Choice of these values represent a tradeoff
between LED brightness and electrical efficiency versus LED
longevity. In general for pulsed-DC or AC input, the LED is off at
least part of the time and is therefore has time to cool during
off-time while heating during on-time. In order to increase light
output and hence electrical efficiency, both the average and the
peak diode current values can be raised somewhat above specified DC
values and maintain the same longevity, which is defined as the
total on-time until, say, 30% loss of light output is
incurred--typically at about 100,000 on-time hours. Moreover, these
LED average and peak current values can be raised further to
increase light output and electrical efficiency at some expense in
LED longevity, depending on the on-time duty factor. Higher ambient
temperatures are accounted for by lowering, or "derating" these
values somewhat.
[0105] In a publication by Hewlett Packard, a number of curves are
presented of projected long term light output degradation, for
various pulsed-DC duty factors and various average and peak current
values, at ambient temperature T.sub.A=55.degree. C. The AlInGaP
LEDs used in this data represents the material commonly used in an
LED with specified DC nominal voltage V.sub.nom=2 VDC. While
results vary somewhat for other LED materials, it can be inferred
from this data that, for most LEDs specified at I.sub.nom=20 mA,
the AC design choice for I.sub.avg is approximately in the
interval, 30 mA.ltoreq.I.sub.avg.ltoreq.50 mA (5) where the
specific value chosen, I.sub.avg=36 mA, is indicated in FIG.
13.
[0106] Similarly, from the Hewlett Packard data it can be inferred
that, for most LEDs with maximum DC current specified at 100 mA,
and the AC design choice for I.sub.max is approximately,
I.sub.max.ltoreq.120 mA (6) where a specific value chosen of
I.sub.max=95 mA satisfying this, that corresponds to V.sub.avg=1.6
VAC and I.sub.avg=36 mA, is also indicated in FIG. 11.
[0107] To clarify the direct AC drive design, consider again the
simpler case where all N LEDs in a series block are of the same
type, with each LED specified as before at V.sub.nom=2 VDC and
I.sub.nom=20 mA. Moreover, let the input AC power be the U.S.
standard value and assume V.sub.rms=120 VAC for voltage matching.
With the above values for I.sub.max and I.sub.avg, the maximum and
average LED voltages, V.sub.max and V.sub.avg, are determined using
AC current versus voltage measurements in FIG. 11 and simplified
versions of equations (2) and (4), respectively. The minimum number
N of LEDs is determined from these voltages using the input voltage
V.sub.peak=42 V.sub.rms and equations (1) and (3), for maximum and
average voltage respectively. Since the value for I.sub.max=95 mA
was chosen as a lower value than possible by equation (6),
corresponding to V.sub.avg=1.6 VAC and I.sub.avg=36 mA, the maximum
voltage becomes V.sub.max= 2 V.sub.avg and equation (1) is
automatically satisfied by satisfying equation (3). Solving
equation (3) results in the minimum number of N LEDs as,
V.sub.rms.ltoreq.N V.sub.avg 120.ltoreq.N (1.6) N.gtoreq.75 (7)
[0108] Although the value of N=75 is a convenient number to use for
manufacturing and sale of a decorative LED light string, if a
different, less convenient, minimum number N of LEDs were computed,
the result can be rounded up or down slightly for convenience,
provided that the subsequent changes in LED brightness or longevity
are acceptable. For example, if the RMS voltage were assumed to be
110 VAC, then the resulting minimum number of LEDs in equation (7)
would be N.gtoreq.69, and this value may be rounded to a final
value of N=70 for convenience, with only slight impact on LED
brightness.
[0109] Efficiency of the above direct AC drive design example can
be estimated by first noting that the average power, P.sub.avg,
consumed by a single LED in the series block is the product of the
average voltage and the average current, P.sub.avg=V.sub.avg
I.sub.avg. This is compared against the optimal DC baseline that
uses the specified DC nominal LED power consumption, P.sub.nom,
defined as the product of the nominal voltage and the nominal
current, P.sub.nom=V.sub.nom I.sub.nom. Using the values given in
the above direct AC drive example, there results,
P.sub.avg.apprxeq.1.44 P.sub.nom, so that the direct AC drive
design consumes 44% more power per LED than the DC baseline.
However, to examine efficiency, first let L.sub.avg be the average
light output power for the direct AC drive design and L.sub.DC be
the optimal light output power using the DC baseline. This light
output power L represents LED efficiency as a device, i.e., how
much light the LED can be made to produce. Defining relative device
efficiency as the quotient .epsilon..sub.D=L.sub.avg/L.sub.DC
enables the amount of light produced by each LED in direct AC drive
design to be compared with the optimal DC baseline. Using an
approximation that the LED light output power, L, is proportional
to the LED current, I, this LED device efficiency, .epsilon..sub.D,
is approximately,
.epsilon..sub.D=L.sub.avg/L.sub.DC.apprxeq.I.sub.avg/I.sub.nom=36/20=1.8
(8) so that the direct AC design example makes about 80% more use
of each LED as a light producing device than the optimal DC
baseline. In other words, for each LED used, the direct AC drive
design produces about 80% more light than the maximum possible by a
DC design based on nominal LED values. Although this factor of 80%
light increase appears to be large, its effect is diminished by
human perception. According to the well known law by Stevens, human
perceptions follow a continuum given by the power relationship,
B.varies.L.sup..rho. (9) where L is the stimulus power, B is the
perceived brightness intensity, and exponent .rho. is a parameter
that depends on the type of stimulus. For light stimuli, L is the
light power in Watts, B is the perceived photopic brightness in
lumens, and the exponent is approximately .rho..apprxeq.1/3. With
this exponent, the 80% increase in light output power offered by
the direct AC design example translates into about 22% increase in
perceived brightness. Although a smaller realized effect, the
direct AC design example does offer an increase, rather than a
decrease, in brightness relative to the optimal DC baseline.
[0110] LED electrical efficiency, E, is defined by dividing light
output power by electrical power used, E=L/P. Defining relative
electrical efficiency as the quotient
.epsilon..sub.E=E.sub.avg/E.sub.DC enables the electrical
efficiency in direct AC drive design to be compared with the
optimal DC baseline. Using again an approximation that the LED
light output power, L, is proportional to the LED current, I, there
follows,
.epsilon..sub.E.apprxeq.(I.sub.avg/P.sub.avg)/(I.sub.nom/P.sub.nom)=V.sub-
.nom/V.sub.avg=2.0/1.6=1.25 (10) so that the AC direct drive design
is about 25% more electrically efficient than the optimal DC
baseline. In other words, for a fixed amount of input power, the
direct AC design examples produces about 25% more light than the
maximum possible by DC based on nominal LED values.
[0111] There are two basic reasons for the results in equations (8)
and (10). First, the direct drive design does not have
current-limiting circuitry to consume power. If this were the only
factor involved, the direct AC design efficiency would be 100%,
relative to the optimal DC baseline, because the optimal DC
baseline is computed without current-limiting circuitry loss. The
second basic reason stems from the nonlinear relationship between
LED current and voltage. Because this relationship is a
convex-increasing function, i.e., its slope is positive and
increases with voltage, average AC diode current I.sub.avg is
always higher than DC current for the same voltage value. This
higher AC average current in turn leads to higher average light
output, with an approximation showing a proportional relationship.
This is a fundamental advantage to the pulsed waveforms over DC
that others fail to recognize for AC and instead try to avoid. The
nonlinear current versus voltage relationship is further taken
advantage of in the direct AC drive design by increasing the
average current to a more optimal value, using the fact that the
LED has time to cool during the off-time interval in each AC
cycle.
[0112] An approximation that LED light output is proportional to
LED current is very close for most operating values of LED current,
but the approximation usually overestimates light output at high
current values. A typical curve for AlInGaP LEDs, the common
material type for LEDs with a 2 VDC specification, is shown in FIG.
12. With this measured result, the relative direct AC drive
efficiencies computed in equations (8) and (10) are lowered
somewhat, but they are still well above unity. A numerical
integration using FIG. 12 indicates that equations (8) and (10)
overestimate efficiency of the direct AC design in the example
presented by about 15%, and closer estimates for the above relative
efficiencies are .epsilon..sub.D.apprxeq.1.53 and
.epsilon..sub.E.apprxeq.1.06.
[0113] Diminishing light output power at high LED current places
the optimal value for RMS and peak LED current values, I.sub.avg
and I.sub.max, at a slightly lower value than the average and peak
current constraints in equations (5) and (6) allow. For example,
FIG. 11 shows that the largest value allowed by equations (5) and
(6) for V.sub.avg is 1.65 VAC, rather than the value of 1.60 VAC
used above. This larger value of V.sub.avg=1.65 VAC, achieved by
N=72 LEDs in a 120 VAC series block, is slightly less efficient, as
well as slightly less reliable, than the value of V.sub.avg=1.60
VAC and N=75 LEDs. However, the value of N=72 LEDs in the series
block would cost less to produce per unit. Using 110 VAC instead of
120 VAC to obtain a lower number N=69 LEDs in the series block
yields yet slightly lower efficiency and reliability still. For
decorative LED light strings, this final direct AC drive tradeoff
between, say, 70 versus 75 LEDs in the series block exemplified is
a matter of practical judgment to provide the highest quality
product at the lowest unit cost.
[0114] Although it has been shown above that LED specified DC
values cannot be directly used in for direct AC drive, these values
do have some theoretical utility for using a smaller measurement
set to estimate the AC design values. The theoretical basis of this
estimation procedure results from applying statistical inference on
the LED specifications, using these specifications in a different
way than they are obtained or intended.
[0115] LEDs are specified by two voltage parameters, a typical, or
"nominal" voltage, V.sub.nom, and a largest, or "supremum" (usually
called "maximum" by LED manufacturers) voltage, V.sub.sup. These
specifications are obtained as ensemble estimates, for a large
ensemble of alike LEDs, of "typical" and "largest" DC voltages to
expect, from variations due to manufacturing, that produce the
chosen nominal value of DC current, I.sub.nom. The nominal DC
voltage, V.sub.nom, is intended as a "typical" value for the LED,
obtained either by averaging measurements or by taking the most
likely, or modal, value in a measurement histogram. The maximal DC
voltage, V.sub.sup, is intended as a largest, or "supremum," value
for the LED, obtained by sorting the largest voltage value measured
that produces the chosen nominal value of DC current,
I.sub.nom.
[0116] The theoretical problem of interest is to obtain values for
average AC voltage, V.sub.avg, and maximum AC voltage, V.sub.max,
that produce average AC current, I.sub.avg and maximum AC current,
I.sub.max, respectively. These voltage values V.sub.avg and
V.sub.max do not consider LED ensemble variations due to
manufacturing but instead rely on a large enough number N of LEDs
in each AC series block for manufacturing variations to be averaged
over. Otherwise, voltage equations (1) and (3) above must be
altered slightly to account for expected LED manufacturing
variations. Such an alteration would rely on a statistical model
obtained by measuring variations of the characteristic AC current
versus AC voltage curve, from LED to LED in a large ensemble of
alike LEDs. In any event, the voltages V.sub.avg and V.sub.max are
fundamentally defined to represent characteristic estimates of
voltage for varying values of LED current, obtained by averaging
over the ensemble, rather than ensemble estimates, using individual
LEDs within the ensemble, of voltages that produce a fixed, say,
nominal, value of LED current.
[0117] In order to make theoretical inferences from LED
specifications, it must be assumed that the specified ensemble
random variables representing "nominal" and "supremum" voltages can
be interchanged with equivalent characteristic random variables
representing corresponding voltages that produce corresponding LED
current over time. This assumption is similar to a commonly assumed
form of ergodicity in random process theory that interchanges
ensemble random variables with corresponding time-series random
variables.
[0118] With this ergodicity assumption, the AC average and maximum
voltage values of interest, V.sub.avg and V.sub.max, can be
inferred from the specified diode values for DC nominal and maximum
voltage, V.sub.nom and V.sub.sup, respectively, using appropriate
DC-to-AC scaling between them. It is desired to obtain a single
scale factor .alpha. for all LED materials, colors, and LED
manufacturers. In trying to find this single value for scale factor
.alpha., difficulty arises in that the specified voltages,
V.sub.nom and V.sub.sup, are fundamentally different for different
LED dopant materials. However, given a specific LED dopant material
"M", such as AlInGaP or GaAlAs, the variations in V.sub.nom and
V.sub.sup across applicable colors and manufacturers are small
enough to be considered fairly insignificant.
[0119] Recall that V.sub.max is equated with peak input voltage
V.sub.peak in equation (1), and V.sub.avg is equated with RMS input
voltage V.sub.rms in equation (3). For AC power, the quotient
V.sub.peak/V.sub.rms= 2. It would thus be desirable if the quotient
V.sub.sup/V.sub.nom were also always a constant, preferably equal
to 2, so that a single scale factor .alpha..sub.M could be used for
each LED material, "M." Unfortunately, this ratio also varies
significantly for different LED materials. As a result, two
distinct scale factors .alpha..sub.M and .beta..sub.M are required
for each LED material composition, "M." With these
material-dependent scale factors, .alpha..sub.M and .beta..sub.M,
the AC voltages of interests are estimated from DC specified values
using, V.sub.avg.apprxeq..alpha..sub.M V.sub.nom,
V.sub.max.apprxeq..beta..sub.M V.sub.sup. (11) where the scale
factors .alpha..sub.M and .beta..sub.M are determined by
measurement. The advantage provided by this theoretical estimation
procedure is that the set of measurements determining
characteristic curves for peak and average AC current versus AC
voltage need only be obtained for each LED dopant material,
independent of LED color and LED manufacturer. Of course, the
disadvantage to this procedure is that it is approximate when
compared to making full measurement sets for all specific types of
LEDs considered, and hence some experimentation with the exact
number of LEDs is required.
[0120] For AlInGaP LEDs, V.sub.nom=2.0 VDC and V.sub.sup=2.4 VDC
represent the centroids of specified values across applicable
colors and from various manufacturers. The characteristic curves
presented in FIG. 7 were obtained from AlInGaP LEDs. From FIG. 11,
and the criteria for average and maximum AC current defined in
equations (5) and (6), respectively, AC current values I.sub.avg=36
mA and I.sub.max=95 mA were chosen previously, with V.sub.max=42
V.sub.avg and V.sub.avg=1.6 VAC. Equations (11), then, lead to
.alpha..sub.AlInGaP=0.80 and .beta..sub.AlInGaP=0.94. These values
may be used theoretically in equations (11) to estimate approximate
AC average and maximum voltages, V.sub.avg and V.sub.max, for other
AlInGaP LEDs.
[0121] FIG. 13 shows measured characteristic curves for a different
set of alike LEDs, where the dopant material is GaAlAs, rather than
AlInGaP. For GaAlAs LEDs, V.sub.nom=1.7 VDC and V.sub.sup=2.2 VDC
represent the centroids of specified values across applicable
colors and from various manufacturers. From FIG. 13, and the
criteria for average and maximum AC current defined in equations
(5) and (6), respectively, AC current values I.sub.avg=38 mA and
I.sub.max=95 mA are chosen, with again V.sub.max= 2 V.sub.avg, but
now V.sub.avg=1.45 VAC. Equations (11), then, lead to
.alpha..sub.GaAlAs=0.85 and .beta..sub.GaAlAs=0.93. These values
may be used theoretically in equations (11) to estimate approximate
AC average and maximum voltages, V.sub.avg and V.sub.max, for other
GaAlAs LEDs. Note that, with 120 VAC assumed for the RMS input
voltage, this value V.sub.avg=1.45 VAC leads to N=83 LEDs per
series block. Similarly, with 110 VAC assumed for the RMS input
voltage, N=76 LEDs per series block. Rounding these values leads to
either 75, 80, or 85 LEDs per series block in a manufactured
product, with N=75 being most desirable for a decorative LED light
string from a cost basis, if it is sufficiently reliable.
[0122] The above direct AC drive design procedure has been verified
by building numerous decorative LED light string prototypes using a
variety of dopant materials, colors, and manufacturers. Many of
these prototypes were built as long as two years ago, and all
prototypes have remained operating continuously without any sign of
impending failure. Moreover, a number of these prototypes were
subjected to harsh voltage surge and voltage spike conditions.
Voltage surge conditions were produced using high power appliances
in the same circuit, all of which failed to produce anything other
than at most some flickering. In about half of these experiments
the voltage surges created caused circuit breakers to trip.
[0123] Voltage spikes, simulating lightning discharges, were
produced by injecting 1000 V, 10 A pulses of up to 10 ms duration
and one second apart into a 100 A main circuit of a small home
using a pulse generator and 10 kW power amplifier. The amplifier
was powered from the main electrical input of an adjacent home.
During these tests, all decorative LED light string prototypes
merely flickered in periodic succession at one second intervals. In
the meantime during these tests, the protective circuitry of
adjoining electronic equipment shut off without any ensuing damage.
All these tests verified conclusively that the decorative LED light
strings were designed to be highly reliable by the direct AC drive
method, without the use of any current-limit circuitry.
[0124] It is to be understood, however, that current-limit
circuitry may be omitted in accordance with embodiments of the
invention, omission of the current-limit circuitry is not required.
Instead, current-limit circuitry, such as a resistor, may be
included in the circuit as an independent element or as part of an
LED. For example, one or more LED in a series of LEDs may be
equipped with a known drop-down resistor integrally formed as part
of the LED.
[0125] It will be understood that various changes in the details,
materials and arrangements of the parts which have been described
and illustrated in order to explain the nature of this invention
may be made by those skilled in the art without departing from the
principle and scope of the invention as expressed in the following
claims.
[0126] This application incorporates the following disclosures by
reference: U.S. Pat. No. 6,461,019, U.S. Pat. No. 6,072,280; U.S.
Pat. No. 6,830,358; application Ser. No. 09/378,631 filed Aug. 20,
1999 titled Preferred Embodiment to Led Light String, now
abandoned; and application Ser. No. 09/339,616 filed Jun. 24, 1999,
titled Preferred Embodiment to Led Light String; U.S. application
Ser. No. 10/657,256; U.S application Ser. No. 10/755,463 filed Jan.
13, 2004; and U.S. provisional application No. 60/119,804, filed
Feb. 12, 1999.
[0127] The foregoing detailed description of the preferred
embodiments of the invention has been provided for the purpose of
explaining the principles of the invention and its practical
application, thereby enabling others skilled in the art to
understand the invention for various embodiments and with various
modifications as are suited to the particular use contemplated.
This description is not intended to be exhaustive or to limit the
invention to the precise embodiments disclosed. Modifications and
equivalents will be apparent to practitioners skilled in this art
and are encompassed within the spirit and scope of the appended
claims.
* * * * *