Flexible LED Light Pad For Phototherapy

Abstract

In a flexible LED pad for use in phototherapy treatment of humans or animals, the PCBs in the pad are securely linked together with electrical connectors and ribbon cables to prevent the connections from being broken as the flexible pad is bent or otherwise deformed during the treatment. In one embodiment, low-profile socket connectors are mounted to the PCBs and mate with plug connectors at the ends of the ribbon cables. For similar reasons, the LED pad may be connected to an LED control unit by means of an electrical connector (e.g. a USB socket) mounted to a PCB in the LED pad. The PCBs, on which the LEDs are mounted, are fitted into a downset in the flexible pad to prevent the LEDs from becoming misaligned with openings in the flexible pad.

We claim: 
     
         1 . A flexible LED pad for use in phototherapy comprising a plurality of rigid printed circuit boards (PCBs) arranged in a row across the pad, an array of LEDs being attached to each PCB, each of the PCBs having an electrical connection to an adjacent one of the PCBs, the PCBs and the electrical connections being enclosed in a flexible material. 
     
     
         2 . The flexible LED pad of  claim 1  wherein the plurality of rigid PCBs comprise a first PCB and a second PCB, a first external electrical connector for linking the flexible LED pad to a second flexible LED pad being mounted on an edge of the first PCB. 
     
     
         3 . The flexible LED pad of  claim 2  wherein the first external electrical connector comprises a USB socket. 
     
     
         4 . The flexible LED pad of  claim 3  wherein the flexible material comprises a top piece and a bottom piece, the bottom piece comprising a downset for each of the first and second PCBs, each PCB being fitted into a corresponding downset in the bottom piece. 
     
     
         5 . The flexible LED pad of  claim 3  wherein the bottom piece comprises a plurality of openings, each of the openings being aligned with one of the LEDs. 
     
     
         6 . The flexible LED pad of  claim 5  wherein each of the first and second PCBs comprises at least one hole, a post extending from one of the top and bottom pieces through the at least one hole to assist in anchoring the PCB at a selected position within the flexible material. 
     
     
         7 . The flexible LED pad of  claim 6  wherein the post extends into a hole formed in the other of the top and bottom pieces. 
     
     
         8 . The flexible LED pad of  claim 5  wherein the top piece and the bottom piece are glued together so as to enclose the first and second PCBs. 
     
     
         9 . The flexible LED pad of  claim 2  further comprising a second external electrical connector mounted on an edge of the second PCB, the second external electrical connector being for linking the flexible LED pad to an LED control unit. 
     
     
         10 . The flexible LED pad of  claim 9  wherein the second external electrical connector comprises a USB socket. 
     
     
         11 . The flexible LED pad of  claim 1  wherein the flexible material comprises a strain relief formed along an edge of the flexible LED pad, a feature being formed in the strain relief for mating with a corresponding feature on a cable linking the LED pad with a control unit. 
     
     
         12 . An arrangement for use in phototherapy comprising:
 a plurality of flexible LED pads for use in phototherapy, each of the flexible LED pads comprising a plurality of rigid printed circuit boards (PCBs) arranged in a row across the pad, an array of LEDs being attached to each PCB, each of the PCBs having an electrical connection to an adjacent one of the PCBs, the electrical connections being enclosed in a flexible material;   an LED control unit; and   a control cable linking one of the flexible LED pads to the LED control unit, said one of the flexible LED pads comprising an electrical connector mated to a corresponding electrical connector at an end of the control cable.   
     
     
         13 . The arrangement of  claim 12  wherein the electrical connector comprised in said one of the flexible LED pads comprises a USB socket and the electrical connector at the end of the control cable comprises a USB plug. 
     
     
         14 . The arrangement of  claim 13  wherein the control cable further comprises an adapter cable connected to the LED control unit. 
     
     
         15 . The arrangement of  claim 14  wherein the adapter cable comprises a USB connector at one end of the adapter cable and a RJ45 plug at the opposite end of the adapter cable. 
     
     
         16 . The arrangement of  claim 12  wherein the control cable is shielded. 
     
     
         17 . The arrangement of  claim 12  wherein each of the flexible LED pads has a rectangular shape and each of the flexible LED pads comprises second and third electrical connectors positioned along a single edge of the rectangular shape, at least one of the second and third connectors in each flexible LED pad being connected to a cable extending to an adjacent flexible LED pad in the arrangement. 
     
     
         18 . The arrangement of  claim 17  wherein the flexible LED pads and the LED control unit are arranged in a T configuration. 
     
     
         19 . The arrangement of  claim 17  wherein the flexible LED pads and the LED control unit are arranged in an L configuration. 
     
     
         20 . A process for fabricating a flexible LED pad for use in phototherapy, said process comprising:
 forming a rigid PCB;   mounting and electrically connecting components to the PCB, said components comprising LEDs;   forming a first flexible covering, said first flexible covering having an array of openings therein;   positioning the first flexible covering adjacent the PCB such that the openings are aligned with the LEDs;   forming a second flexible covering; and   attaching the first and second flexible coverings together so as to enclose the PCB.