GB2614227A

GB2614227A - LED profiles

Info

Publication number: GB2614227A
Application number: GB2113394.7A
Authority: GB
Inventors: Daniel Charles
Original assignee: DELTECH UK Ltd
Current assignee: DELTECH UK Ltd
Priority date: 2021-09-20
Filing date: 2021-09-20
Publication date: 2023-07-05

Abstract

LED strip profile 1 comprising a flexible LED profile body with a channel for receiving an LED lighting strip 4, with a flexible diffuser 7 mountable on the channel, whereby light emitted from LEDs within the channel exits the channel through the diffuser, the LED profile body and the diffuser both being greater than three metres in length. The channel may comprise a base having a sidewall on either side, an open mouth opposite the base, and be configured to retain the LED lighting strip at the base. The profile may comprise a second diffuser 8 mountable on the profile body, a first of the diffusers being mounted adjacent the mouth and the second between the base and the first diffuser. Also claimed is a clip 11 for mounting an LED strip profile on a suspended or dropped ceiling structure and comprising an upper portion for engaging a T-grid frame member 10 of the ceiling structure and a lower portion for engaging sides of the profile. The upper portion of the clip may comprise a flat portion having flaps on each of its edges for wrapping round opposite edges of the frame. The lower portion of the clip may comprise an inwardly sprung leg on each side of the clip which press against opposite sides of the profile.

Description

LED Profiles

Field of the invention

This invention relates to LED Profiles/Channels of the type generally used house / mount LED lighting strips.

Background

LED Strip Profiles/Channels allow LED strips to be fitted and accessed inside so that you can just see neat Profiles or/and the bright glow of the light as opposed to the individual LEDs on the strip itself. The profiles generally have the form of a channel in which the LED lighting strip is mounted, along with a diffuser covering the mouth of the channel, so that the light from the LEDs is emitted into the surrounding environment through the diffuser.

The profiles are available in various forms, including Surface mounted, Recessed, Angle/Corner and Straight mounting types to allow a variety of usages and placements.

The profiles are typically made of aluminium with optional accessories, including diffusers, mounting brackets and end caps, often supplied all together in Kit form.

The profiles are generally rigid and typically supplied in 1 metre, 2 metre or 3 metre lengths. Where lengths longer than 3 metres are required, or lengths intermediate the standard lengths (for example 2.3 metres) are required, it is often necessary to join two profile sections. The joint between two profiles can create an unpleasant visual distortion to the otherwise clean lines of the profiles. This is especially noticeable in brand new installations.

There are some bendable/flexible profiles available on the market but their degree of flexibility is limited and their length is limited to a maximum of 3 metres.

LED lighting strips are generally fixed within the profiles with double sided adhesive tape. However, with time and the heat generated by the LEDs the tape often loses its adhesive qualities resulting in the strip becoming lose and sagging. This causes uneven light distribution which is visually unpleasant as you begin to see the individual LEDs through the diffuser. This is especially prominent when the profiles are mounted on a ceiling and facing downwards. This sagging could also create uneven visible light curves when the LED strip profiles are mounted against a wall.

Summary

An overall aim of embodiments of this invention is to create a convenient, cost effective, highly bendable, flexible LED profile of continuous long length that can be transported in a rolled-up form which has similar features and looks to standard profiles.

In particular, preferred embodiments of the invention relate to long ultra-flexible LED strip profiles for general use instead of solid fixed lengths profiles.

Some embodiments of the LED profile of this invention have a flexible body with the advantage of being available in extra-long continuous length, for example at least 5 metres or, more preferably, 10 metres or more. In some embodiments, the length of the flexible body of the LED profile is 15 metres, 20 metres or even 25 metres or longer. In some embodiments, the flexible profile body is manufactured from strong yet flexible materials such as silicon, nylon, PMMA, etc. These and other suitable materials can be easily cut on sites (e.g. in a building in which the LED profiles are being installed) to any length, e.g. to closely match the required installation length, so as to keep the profile as a single piece and avoid any visibly disturbing joints.

The LED profiles are preferably fire-resistant and/or recyclable, for example made from materials (e.g. plastics) that satisfy one or both of these criteria.

In some embodiments the LED profile also has a continuous length of diffuser that can be cut to the required length in the same way that the profile body is cut to length. This avoids any unsightly intermediate joints on the diffuser (another problem seen in know LED profiles).

By using a flexible LED profile (body and diffuser) in accordance with embodiments of the invention, it also becomes possible to allow the profile and diffuser combination to bend sideways, for example to form non-linear shapes such as '5' shapes.

In embodiments of the invention in which the LED Profile has a separate, removable diffuser, beneficially, the LED strip can be accessed at any time.

Some embodiments of the invention include one or more of the following features and benefits: a) The Profile can be supplied in long lengths, e.g., 10 metres and due to its flexible nature supplied on a roll for easy transportation.

b) The Profile can have a plurality of continuous side protuberances as part of the same moulding/extrusion of the body which will hold the LED lighting tape (strip) in place without the need for adhesive tape. This allows the use of adhesive-less LED tapes which could be manufactured at a lower cost. This prevents the problematic issue of sagging LED tapes. In some embodiments, however, double-sided adhesive tape could be used in addition to the protuberances to more firmly hold the LED lighting strip in place or adhesive tape could be used to secure the LED strip in place in embodiments of the invention that do not include protuberances to secure the LED strip.

c) These protuberances could also allow for the use of a secondary, intermediate diffuser which would rest between them. This secondary diffuser would be sandwiched between the LEDs and the underside of the main diffuser with an air gap in between the two diffusers. This should further enhance the light distribution and reduce the visual effect of seeing LED dots shining through the diffuser. A single diffuser could be used in embodiments of the invention that do not include protuberances to secure an inner second diffuser.

d) A brand-new T-Grid LED Profile design of similar width to T-Grids used on dropped ceilings (also known as 'suspended ceilings') can be constructed by adding flaps on the base of the Profile as part of the same body which due to their flexible nature can be wrapped around the T-Grids allowing it to be attached as a neat continuous Profile.

e) A brand-new T-Grid Clip design that can attach to any standard Profiles being of standard or flexible type, allowing these Profiles to be attached to T-Grids.

f) A brand-new easy align design with a ledge as part of the profile which can easily align itself to back of wall cabinets whereby a gap is present between the wall and the back of cabinets such as Kitchen cabinets.

g) The Profile can have a slit in each vertical edge running parallel to its length which will allow standard diffusers to be attached.

Brief description of figures

Embodiments of the invention are described below, by way of example, with reference to the accompanying figures, in which: Figure 1 shows the detail of the Flexible LED Profile with 4 protuberances, LED strip and slits; Figure 2 shows an embodiment of the Flexible LED Profile rolled up; Figure 3 shows the standard LED Profile shapes; Figure 4 shows an embodiment of the Flexible LED Profile with 2 diffusers attached; Figure 5 shows an embodiment of the Flexible LED Profile with flaps for attachment to a T-Grid; Figure 6 shows the detail of the T-Grid Clip; Figure 7 Shows the detail of an 'easy align' profile; and Figure 8 Shows a new type of Secure Fix Recess Profile.

Description of Embodiments

Figure 1-Showing an embodiment of the Flexible LED Profile with 4 protuberances, LED strip and slits Figure 1 shows an embodiment of the invention that aims to provide maximum flexibility for the installer to add up to 2 diffusers, 1 LED strip and use standard mounting clips. The form is produced by extruding a flexible polymer plastic in the profile shown [1] with 4 protuberances [2] that will hold down the LED strip [4] and provide slots [5] to hold an intermediate diffuser. These protuberances provide a snug fit to the LED strip so adhesive backing is not necessary. This means the LED strip can be easily removed if it becomes faulty without having to remove the whole profile from its installed location. As you will not be relying on adhesive in any case, LED sagging is also eliminated. 2 slits [3] are cut in the top to allow for the attachment of a standard off-the-shelf diffuser strip. These narrow slits will conform to whatever shape mounts are on the diffuser. Scallops [6] on each side allow offthe-shelf clips of various designs to clamp onto the side of the profile allowing it to be easily mounted to various surfaces.

Figure 2-Showing an embodiment of the Flexible LED Profile rolled up for transport Figure 2 shows an embodiment of the Flexible LED Profile rolled up for transport. Its narrow profile and flexible nature mean it will take up a lot less space than standard linear rigid LED Profiles. Also, lengths of 10m should be able to be accommodated with ease.

Figure 3a -3e -Showing various standard LED Profile shapes Figure 3a -3e -shows standard LED Profile shapes that are currently on the market. This invention can be produced in many shapes to replace these current designs.

Figure 3a shows standard surface profile.

Figure 3b shows standard recess profile.

Figure 3c shows standard deep profile.

Figure 3d shows standard Angle / Come( profile.

Figure 3e shows standard plaster over recess profile.

Figure 4 -Showing an embodiment of the Flexible LED Profile with 2 diffusers attached Figure 4 shows an embodiment of the Flexible LED Profile [1] with 2 diffusers attached. The main diffuser [7] slots into the slits at the top that hold it firmly in place. An additional diffuser [8] softens the light even more from the LED strip [4], hiding the individual LEDs so the light output is smooth and continuous.

One example of an installation process for the LED strip profile is as follows: a) Profile (1) can be attached to surface by screws mounted internally and screwed directly to surfaces such as walls or cabinets or by having metal clips mounted fixed on surfaces clipped on to profile (1) similar to figure 6. Profiles can be also mounted directly onto surfaces by means of adhesive such as double-sided tapes, mastics or silicones. Figure 8 shows external new features for recess typed profiles for extra reassured fixings.

b) Once profile (1) tape (4) (i.e. the LED strip) is pushed through the protuberances (2) to stay in place.

c) Diffuser (7) is pushed into the slots (3) to stay in place. Optionally Secondary diffuser (8) is pushed through the protuberances (2) to stay in place prior of fixing diffuser 7.

Figure 5 -Showing an embodiment of the Flexible LED Profile with flaps for attachment to a 1-Grid Figure 5 shows an embodiment of the Flexible LED Profile [1] with flaps [9] for attachment to a T-Grid [10] dropped-ceiling bracket. The LED strip [4] now points downwards to light the room below. This allows the LED Profile to be mounted without additional clips.

Figure 6-Showing the detail of the T-Grid Clip.

Figure 6 shows the detail of the T-Grid Clip. This single piece metal clip [11] allows the attachment of standard size LED Profiles [1] to a T-Grid [10] dropped-ceiling bracket. The clips have a small top to allow the clip to be installed or removed without having to slide them off the end. A larger scalloped bottom gives a large holding area for the LED Profile. The LED strip [4] now points downwards to light the room below.

Figure 7 -Showing the detail of Easy Align Profile Figure 7 shows the detail of Easy Align Profile. The profile [1] has an extra ledge [12] that allows the profile to be aligned to the back of the cabinet [13] and neatly fixed underneath the cabinet. This is feasible on cabinets which are fixed with brackets slightly away from the wall [14] such as kitchen wall cabinets. The profile can be aligned to the back of the cabinet according to the cabinet shape being of standard straight, curved or other cabinet shapes. Because of its flexible nature, the ledge [12] could be cut where obstacles are present.

Figure 8 Figures 8a and 8b show two examples of a recess profile (1) being of standard or plaster over type with new additional features, having external protuberances of winglets or wedge type similar to type used in wall\ Rawl plugs which will prevent Recess profiles from easily coming out of its placement once pushed into place. This feature is especially useful for ceiling mounted plaster over type recess profiles The LED strip profiles and diffusers can be formed by any suitable manufacturing process. One example of a suitable process is a plastics extrusion process, with an appropriately shaped die corresponding to the desired cross-section for the LED strip profile body and for the diffuser respectively.

The skilled person will appreciate that various changes, omissions and additions can be made to the embodiments described above without departing from the scope of the invention. The LED profiles can, for example be formed without the described protuberances or with additional or different protuberances to those described above. The profile bodies, diffusers, protuberances, and diffuser mounting slots / slits are not limited to the particular forms and shapes described and illustrated herein; they may be of any suitable form and shape.

Claims

Claims: 1. An LED strip profile, comprising: a flexible LED profile body, the body including a channel for receiving an LED lighting strip; and a flexible diffuser, mountable on the channel, whereby light emitted from LEDs within the channel exits the channel through the diffuser; wherein the LED profile body and the diffuser are both greater than 3 metres in length.
2. An LED strip profile according to claim 1, wherein the channel extends longitudinally along the profile body and, in cross-section, has a base, two sidewalls, one either side of the base, and an open mouth opposite the base.
3. An LED strip profile according to claim 2, wherein the diffuser, when mounted on the channel, covers the mouth of the channel.
4. An LED strip profile according to claim 2 or claim 3, wherein a base portion of the channel is configured to retain an LED lighting strip at the base of the channel.
5. An LED strip profile according to claim 4, wherein the sidewalls each comprise a protuberance extending laterally into the channel, each protuberance defining a longitudinal slot between the protuberance and the channel base into which respective edge portions of the LED lighting strip can be engaged, thereby to retain the LED lighting strip at the base of the channel.
6. An LED strip profile according to any one of claims 2 to 5, wherein a mouth portion of the channel is configured to retain the diffuser in place over the mouth of the channel.
7. An LED strip profile according to claim 6, wherein an outwardly facing edge of each channel side wall includes a slit into which respective opposite edges of the diffuser can be received to secure the diffuser in place over the mouth of the channel.
8. An LED strip profile according to claim 6 or claim 7, wherein the sidewalls of the channel each comprise two protuberances extending laterally into the channel to define longitudinal slots between the protuberances, one slot on each side of the channel, into which opposite edge portion of a diffuser can be engaged to retain the diffuser in place.
9. An LED strip profile according to any one of claims 2 to 8, comprising a second diffuser mountable on the profile body, wherein the profile body is configured to mount a first one of the diffusers adjacent a mouth of the channel and the second of the diffusers in the channel between the base of the channel and first diffuser.
10. An LED strip profile according to any one of claims 2 to 9, wherein an outer wall of a base portion of the profile body, opposite the channel, is configured to mount the profile body on a ceiling structure with the channel mouth facing away from the ceiling.
11. An LED strip profile according to claim 10, for mounting on suspended-or dropped-ceiling structure, wherein the outer wall portion is configured to mount the profile body on a T-grid frame member of the ceiling structure.
12. An LED strip profile according to claim 11, wherein the outer wall portion comprises inwardly facing flexible flaps that define a longitudinally extending horizontal slot between the flaps and an outer surface of the channel base into which the T-grid frame member is received through an opening between inner ends of the flaps.
13. An LED strip profile according to any one of claims 2 to 9, further comprising one or more ceiling mounting clips for mounting the profile body on a ceiling structure with the channel mouth facing away from the ceiling.
14. An LED strip profile according to claim 13, wherein the or each ceiling mounting clip comprises is adapted for mounting the profile body on suspended-or dropped-ceiling structure, wherein clip comprises an upper portion configured to engage with a T-grid frame member of the ceiling structure and a lower portion configured to engage outwardly facing surfaces of the channel side walls of the profile body.
15. An LED strip profile according to claim 14, wherein the upper portion of the or each ceiling clip comprises a generally flat portion that extends below the T-grid frame member and, at each edge of the flat portion, flap portions configured to wrap around opposite edges of the T-grid frame member.
16. An LED strip profile according to claim 14 or claim 15, wherein the lower portion of the clip comprises inwardly sprung legs, one to either side of the clip, whereby in use the legs press against opposite sides of the profile body.
17. An LED strip profile according to claim 16, wherein the legs are convexly curved towards the sides of the profile body and the sides of the profile body have concave indents with which the legs of the clip engage.
18. An LED strip profile according to any one of the preceding claims, comprising an alignment guide protruding from extending longitudinally along the profile body, whereby the profile body can be aligned with another object by butting the alignment guide against the object.
19. An LED strip profile according to any one of the preceding claims, wherein the LED profile body and the diffuser are both greater than 10 metres in length.
20. An LED strip profile according to any one of the preceding claims, wherein the LED profile body is sufficiently flexible to be wound multiple times around a reel.
21. An LED strip profile according to any one of the preceding claims, wherein the diffuser is removable from the profile body.
22. An LED strip profile according to any one of the preceding claims, wherein the profile body is adapted for mounting a plurality of LED lighting strips.
23. An LED strip profile according to any one of the preceding claims, wherein with the diffuser mounted on the profile body the LED strip profile is water resistant.
24. An LED strip profile according to any one of the preceding claims, wherein the profile body and the diffuser are formed from a fire-resistant plastic.
25. An LED strip profile according to any one of the preceding claims, wherein side walls of the profile body comprise one or more external anchor formations configured to resist removal of the profile body from a recess once installed.
26. A clip for mounting an LED strip profile on suspended-or dropped-ceiling structure, wherein clip comprises an upper portion configured to engage with a T-grid frame member of the ceiling structure and a lower portion configured to engage sides of the LED strip profile.
27. A clip according to claim 26, wherein the upper portion of the or each ceiling clip comprises a generally flat portion that extends below the T-grid frame member and, at each edge of the flat portion, flap portions configured to wrap around opposite edges of the 1-grid frame member.
28. A clip according to claim 26 or claim 27, wherein the lower portion of the clip comprises inwardly sprung legs, one to either side of the clip, whereby in use the legs press against opposite sides of LED strip profile.
29. A clip according to claim 28, wherein the legs are convexly curved towards the sides of the LED strip profile and the sides of the LED strip profile have concave indents with which the legs of the clip engage.
30. A clip according to any one of claims 26 to 29, in combination with a rigid LED strip profile.