Abstract:
A modular luminaire comprises a luminaire base having a heat sink and a primary LED module, one of a plurality of interchangeable decorative elements disposed against the luminaire base, the plurality of decorative elements having a central aperture for light output, one of a plurality of interchangeable collar assemblies connected to the base and compressing the one of a plurality of decorative elements, the collar having a central collar aperture coaxial with the central opening of any of the decorative elements.

Description:
CROSS-REFERENCE TO RELATED DOCUMENTS 
       [0001]    None 
       TECHNICAL FIELD 
       [0002]    This invention pertains to a modular LED luminaire. More specifically, the invention pertains to a modular LED luminaire capable of varying appearance by interchanging of the decorative element and/or a collar. 
       BACKGROUND 
       [0003]    Recessed luminaires are extremely popular for a variety of reasons. In some instances however, recessed luminaires may not be utilized due to environmental conditions in the area of the ceiling where the luminaire is to be positioned. For example, a recessed luminaire may not be utilized where a joist is positioned in the ceiling or where plenum is too small to allow positioning of the luminaire fixture elements. Alternatively, a recessed luminaire may not be 
         [0004]    Additionally, it is desirable to utilize lighting components which may be interchangeable by merely changing one or two elements in order to change the appearance of the light without necessitating removal of the entire fixture and replacement thereof. Such interchangeability allows the end user increased options in changing the appearance of the room and lighting therein without requiring changing of the entire fixture. 
         [0005]    It is desirable to overcome these and other deficiencies in order to provide a light which has a similar appearance and light output to a recessed luminaire, while also allowing interchangeability of one or more components in order to change the appearance of the light output there from. 
       SUMMARY 
       [0006]    A modular luminaire comprises a luminaire base having a heat sink and a primary LED module, one of a plurality of interchangeable decorative elements disposed against the luminaire base, the plurality of decorative elements having a central aperture for light output, one of a plurality of interchangeable collar assemblies connected to the base and compressing the one of a plurality of decorative elements, the collar having a central collar aperture coaxial with the central opening of any of the decorative elements. The modular luminaire wherein the plurality of decorative elements is three elements. The modular luminaire wherein the plurality of decorative elements each has differing depths. The modular luminaire wherein the luminaire base has a depending threaded wall. The modular luminaire further comprising a threaded portion of the collar engaging the threaded wall of the luminaire base. The modular luminaire wherein the depending threaded wall having a thread on a radially inward facing surface. The modular luminaire wherein the collar has a thread on a radially outward facing surface. The modular luminaire wherein the decorative element is captured between an upper surface of a flange of the threaded collar and the luminaire base. The modular luminaire further comprising a reflector positioned within the threaded collar. The modular luminaire further comprising a lens over the LED module. The modular luminaire further comprising a secondary LED module for effect lighting. 
         [0007]    A modular luminaire comprises a luminaire base, a heat sink disposed adjacent to the base and a primary LED array in thermal communication with the heat sink, a light mixing chamber extending below the primary LED array, a lens disposed within the lens frame, a connection wall depending from the luminaire base, a collar connected to the connection wall, the collar having a flange extending about a lower end of the collar, the collar capturing one of a plurality of decorative elements between the luminaire base and the flange. The modular luminaire wherein the threaded wall depends from the luminaire base. The modular luminaire wherein the threaded collar and the decorative element opening each having co-axial central apertures. The modular luminaire wherein the threaded collar is disposed radially inwardly of the decorative element. The modular luminaire further comprising a secondary LED array disposed against the luminaire base. The modular luminaire wherein the luminaire base has a locating rib to properly position the decorative element on the base. The modular luminaire wherein the plurality of decorative elements have different depths. 
         [0008]    A modular luminaire comprises a lower collar flange, a decorative element seated on the lower collar flange and extending around a collar, a base having a plurality of LEDs and a heat sink positioned adjacent the plurality of LEDs, the plurality of LEDs positioned centrally within an opening of the decorative element, the collar connected to the base, the lower collar flange extending from the collar, the collar compressing the decorative element against the base. The modular luminaire wherein the decorative element is distinct from the collar. The modular luminaire wherein the decorative element is integral with the collar. The modular luminaire further comprising a plurality of secondary LEDs. 
     
    
     
       BRIEF DESCRIPTION OF THE ILLUSTRATIONS 
         [0009]    Embodiments of the invention are illustrated in the following illustrations. 
           [0010]      FIG. 1  depicts a perspective view of a first exemplary embodiment of a LED luminaire; 
           [0011]      FIG. 2  depicts a side view of the modular LED luminaire of  FIG. 1 ; 
           [0012]      FIG. 3  depicts a bottom view of the modular LED luminaire of  FIG. 1 ; 
           [0013]      FIG. 4  depicts an exploded perspective view of the modular LED luminaire of  FIG. 1 ; 
           [0014]      FIG. 5  depicts a side-section view of the modular LED luminaire of  FIG. 1 ; 
           [0015]      FIG. 6  depicts a perspective view of a second exemplary embodiment of a modular LED luminaire; 
           [0016]      FIG. 7  depicts a side view of the modular LED luminaire of  FIG. 6 ; 
           [0017]      FIG. 8  depicts a bottom view of the modular LED luminaire of  FIG. 6 ; 
           [0018]      FIG. 9  depicts an exploded perspective view of the modular LED luminaire of  FIG. 6 ; 
           [0019]      FIG. 10  depicts a side-section view of the modular LED luminaire of  FIG. 6 ; 
           [0020]      FIG. 11  depicts a perspective view of a third exemplary embodiment of the modular LED luminaire; 
           [0021]      FIG. 12  depicts a side view of the modular LED luminaire of  FIG. 11 ; 
           [0022]      FIG. 13  depicts a bottom view of the modular LED luminaire of  FIG. 11 ; 
           [0023]      FIG. 14  depicts an exploded perspective view of the modular LED luminaire of  FIG. 11 ; and, 
           [0024]      FIG. 15  depicts a side section view of the modular LED luminaire of  FIG. 11 . 
       
    
    
     DETAILED DESCRIPTION 
       [0025]    It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings. 
         [0026]    A modular light emitting diode (LED), luminaire is shown in the various  FIGS. 1-15 . The modular LED luminaire utilizes a modular design wherein a single base may be utilized and combined with various interchangeable decorative elements and one or more interchangeable collars to provide a light fixture capable of various appearances. Additionally, the modular luminaire may be positioned on a ceiling surface and provide a comparable light output and a similar appearance to a partially recessed light. 
         [0027]    Referring initially to  FIG. 1 , a first embodiment of a modular LED luminaire  10  is depicted in perspective view. The luminaire  10  may be recessed with a ceiling or wall as shown in the exemplary embodiments. The luminaire  10  includes a base  12 , at least one collar  14  and at least one decorative element captured between the base  12  and the collar  14 . The decorative element may be integral with the collar  14  as shown or may be a distinct element from the collar as in further embodiments. The luminaire  10  may utilize various decorative elements and collars which are interchangeable in order to provide different appearances for the luminaire  10  as will be described further herein. Additionally, although the term collar is utilized throughout this description, one skilled in the art should realize that where alternate non-circular shapes are utilized for the instant luminaire, the collar need not be circular and should not be limited to such definition. For example, where a square shaped luminaire is utilize the collar may also be square in shape. 
         [0028]    Referring now to  FIG. 2 , a side view of the luminaire  10  is depicted. The side view depicts the base  12  and the collar  14  having slightly tapered sides so that the luminaire has a frusto-conical appearance. However, the frusto-conical design of the base  12  and the threaded collar  14  is merely exemplary and should not be considered limiting as a straight sidewall may be utilized or as a further alternative embodiment an opposite taper as well, for example. Extending from the upper portion of the base is a heat sink  20  which transfers the heat from the LED lamps within the luminaire  10  out of the fixture and to ambient atmosphere in order to reduce the operating temperature of the LED lamps. The heat sink  20  is defined by a plurality of die cast aluminum fins which may or may not be integrally formed with base  12 . An upper cover with plate  22  extends across a portion of the heat sink  20  in order to protect the inner elements of the luminaire  10  from contaminants. Additionally, due to the convective movement of air upward through the luminaire  10 , the upper plate  22  limits the amount of contaminants which would otherwise be dispersed on the ceiling surface and which would be aesthetically unpleasing. 
         [0029]    As shown also in  FIG. 2 , a gap  17  is defined between the collar  14  and the base portion  10 . The gap  17  is visible due to the lack of a distinct decorative element in the first embodiment and as opposed to the subsequent embodiments. The gap  17  also functions as a secondary light output for LEDs positioned within the base  12  and radially outward of lens  30  ( FIG. 3 ). The secondary LEDs provide a halo effect, or effect lighting which may include alternate shapes, about the luminaire  10  through the gap  17 . According to the instant embodiment, the collar  14  is formed of a polished metallic material and the base  12  is also found with a metallic material so that the collar  14  functions as an integrated decorative element when the collar  14  and base  12  are threadably or otherwise connected. Additionally, the exemplary threaded connection between base  12  and collar  14  is not visible to a person passing beneath the down light luminaire  10  as viewed in  FIG. 3 . The depth of luminaire  10  is more shallow than subsequent embodiments as viewed from the upper plate  22  the lower flange surface  24  of the collar  14 . The connection between the collar  14  and the base  12  is a threaded connection, however such connection is merely exemplary and various other mechanisms may be utilized to connect the base  12  and collar  14 . The connection is hidden to improve the aesthetic appearance of the luminaire  10 . Additionally, the collar and decorative element are shown as being circular in cross-section. However, alternative shapes may be utilized. For example, the luminaire  10  may have a square or rectangular shape. 
         [0030]    Referring now to  FIG. 3 , the base  12  and the collar  14  of the first embodiment are both formed of metallic material. Accordingly, the base  12  may be formed of a polished aluminum or other polished, highly reflective material providing an aesthetically pleasing appearance. The collar  14  has a wide flange  24  and a radial inner edge  26  defining an opening through which light output from the LED lamps passes. Additionally, the heat sinks  20  are shown extending about the lamp socket region, as indicated by lens  30 , and aid heat transfer to atmosphere. 
         [0031]    The luminaire  10  may further comprise a lens  30  positioned within the base  12  and beneath the central LED lamps. The lens  30  may be formed of polycarbonate or acrylic and may provide an aesthetically pleasing color to the light output. The lens  30  also inhibits touching of or access to the lamps  54  as well as inhibiting contaminants from reaching the lamps  54 . 
         [0032]    Referring now to  FIG. 4 , an exploded perspective view of the luminaire  10  is depicted. The upper plate  22  is ring shaped and is positioned over a power supply cover  40  and power supply  42  therein. A plurality of leads  44  extend from the power supply  42  for electrical connection with primary and secondary LED boards  50 ,  60 . The power supply  42  may be fastened or alternatively potted in the cover  40  to position therein and eliminate loosening or movement thereof. 
         [0033]    Beneath the cover  40  is the base  12  which is, according to the exemplary embodiment, formed of die-cast aluminum. From the depicted view, the fins of the heat sink  20  are also shown. The heat sink  20  of the instant embodiment is integral with the base  12  and is also formed of die-cast aluminum although the heat sink  20  may be formed independently and later connected to the base  12 . Within the central portion of the base  12  is thermal transfer surface  21 . 
         [0034]    Positioned on a lower surface of the base  12  and radially outward of the heat sink  20  is a secondary LED array  60 . The secondary array  60  includes a circuit board  62  and a plurality of LED lamps  64 . The circuit board  62  is ring shaped and includes a plurality of lamps  64  along the lower surface. The secondary LED array  60  is electrically connected to the power supply  42  to power the lamps  64 . The secondary LED lamps  64  provide illumination from gap  17  ( FIG. 2 ) to provide the previously described halo effect. 
         [0035]    Beneath the LED array  60  is a thermal pad  68  which has an adhesive on an upper side. The thermal pad  68  is positioned on base surface  21  to eliminate gaps between the primary LED array  50  and the base  12 . This, in turn, maximizes heat transfer from the LED array  50  to the heat sink  20 . In short, any imperfections in the surface  21  or the LED array  50  are compensated for by the thermal pad  68 . The LED array  50  is formed by an LED circuit board  52  and a plurality of LEDs  54  thereon. The LED array  50  is electrically connected to the power supply  42  allowing powering of the LED lamps  54 . 
         [0036]    Beneath the primary LED array  50  is a light mixing chamber  70 . The chamber  70  is formed of a plurality of reflectors  72  which surround each of the LED lamps  54  and direct the light output downwardly and out of the chamber  70 . The light mixing chamber  70  may also function to provide the appearance of a single light output rather than a plurality of single LED outputs. 
         [0037]    Beneath the mixing chamber  70  is the lens  30  which is formed of acrylic or polycarbonate. The lens  30  may be tinted for a color effect if desired by the light designer. The lens  30  inhibits contact with the lamps  54  and prevents contaminants from reaching the lamps  54 . Beneath the lens  30  is the threaded collar  14 . 
         [0038]    Referring now to  FIG. 5 , the luminaire  10  is shown in an assembled side-section view. The base  12  includes a depending connection wall  13  and a threaded portion on a radially inwardly facing surface. Although a threaded connection is shown, alternate mechanisms may be utilized to connect the base and  12  and collar  14 . In the depicted embodiment, the collar  14  includes a threaded surface  15  which is radially outwardly facing. The threaded connection is therefore hidden from view from beneath the luminaire  10 . The threaded surfaces may be reversed while keeping with the desired goal of inhibiting viewing of this threaded connection of the base  12  and collar  14 . Also shown in  FIG. 5  is the position of the second array  60  relative to the collar  14 . The plurality of LEDs  64  on the second array  60  are directed downward to an upper surface of the collar  14 . The light from the second array  60  is reflected upwardly and out of the luminaire through gap  17 . This provides the previously described halo effect or effect lighting around the fixture, although the light halo need not be circular if an alternate shaped luminaire is utilized and therefore such term should not be considered limiting. 
         [0039]    Referring now to  FIG. 6 , a perspective view of an alternate embodiment of a LED luminaire  110  is depicted. As shown in this embodiment, the luminaire  110  includes an at least semi-translucent decorative element  116  extending about the outer surface of the luminaire. Along a bottom or lower surface  117  is a collar  114 . As in the previous embodiment, the collar  114  may be threaded, however alternate means of connection a base  112  and collar  114 . As opposed to the threaded collar  14  of the previous embodiment, the collar  114  includes a lower flange  124  which is substantially more narrow than the flange  24  of the previous embodiment. The lower flange  124  provides a lower support for a distant decorative element  116 , whereas the previous embodiment utilized a collar  14  which was a polished material and functioned additionally as an integrated decorative element. Within the opening of the collar  114  is a lens  130 . 
         [0040]    As previously described, the lens  130  may be formed of polycarbonate or acrylic and may or may not be tinted. Also shown spaced about the lens  130  are heat sink elements  120  which transfer thermal energy from the LED&#39;s to atmosphere and cause convection currents through the luminaire. As with the previous embodiment, the heat sink  120  is defined by a plurality of fins formed of die-cast aluminum. 
         [0041]    Referring now to  FIG. 7 , a side view of the luminaire  110  is depicted. The side view of the luminaire  110  shows the heat sink  120  extending above the upper surface of the decorative element  116 . First and second fasteners extend above the upper plate  122  for connection of the luminaire to the ceiling. As previously described, the instant embodiment may be flush mounted to a ceiling, although the fixture may alternatively be partially recessed if the ceiling and space above the luminaire allows for such mounting technique. According to the instant embodiment, the decorative element  116  is formed of an acrylic material which is also either translucent or semi-translucent and may or may not be tinted to a pre-selected color in order to add lighting effect to the light output. The at least semi-translucent decorative element  16  provides visual indication of the internal components within the luminaire  110 . For example, the base  112  and collar  114  may be seen through the decorative element  116 . The decorative element  116  extends from the upper edge of a base  112  downward to the lower edge of the luminaire. The decorative element  116  has a radially inwardly extending shoulder or ledge  140  which is seated upon an upper surface of the flange  124 . In the view shown in  FIG. 7 , various lines are depicted in a distorted manner as would appear when viewed through the decorative element material  116 . As one skilled in the art will understand, such distortion occurs when light passes from one medium such as air to a second medium, in this case the exemplary acrylic decorative material. For example, the vertical lines depicting the interface between the base  112  and the decorative element  116  shown closer to the outermost edges of the luminaire than this actual dimension due to the distortion which would be seen when looking at a side view of the luminaire  110 . 
         [0042]    Referring now to  FIG. 8 , a bottom view of a luminaire  110  is depicted. The translucent decorative element  116  is shown with an outer radial line indicating an outer edge of the base  112 . The flange  124  is also shown, as well as the opening defined at the radially inner edge of the flange  124  so that light output from the LED lamps passes through the lower portion of the assembly. 
         [0043]    Referring now to  FIG. 9 , an exploded perspective view of the luminaire  110  is depicted. At the top of the assembly is an upper plate  122  which is ring-shaped and positioned over a power supply cover  140 . The cover  140  serves as a housing for a power supply  142 . The power supply  142  includes leads  144  for electrical connection with at least one LED array. The power supply  142  is potted within the cover  140  to inhibit movement or loosing of one relative to the other. However, alternative means of connection may be utilized if desired. 
         [0044]    Beneath the cover  140  and the power supply  142  is a base  112  which, according to the exemplary embodiment, is formed of die-cast aluminum. From the depicted view, the heat sink  120  is shown extending about the center portion of the base  112 . As previously described, the base  112  is formed integrally with the heat sink  120 , and therefore is also formed of die-cast aluminum, although the heat sink  120  may be formed independently of the base  112  and connected later in the manufacturing process. Also, within the central portion of the base  112  is a thermal transfer surface  121  which receives heat from at least one LED array and transfers the thermal energy to the heat sink  120 . Although the base  112  is described with differing numbers than the first embodiment, it should be understood by one skilled in the art that the base  112  is the same as the base  12  and defines a structure from which various other interchangeable elements may be built upon in order to utilize a single fixture structure, yet provide various appearances for the fixture utilizing the decorative elements  116 ,  216  and collars  14 ,  114 ,  214 . 
         [0045]    Positioned beneath the base  112  and radially outward from the heat sink  120  is a secondary LED array  160 . As previously described with the first embodiment, the secondary array  160  includes a circuit board  162  and a plurality of LED lamps  64  connected thereto. The circuit board  162  is generally ring-shaped and is electrically connected to the power supply  142  in order to power the LED lamps  164 . 
         [0046]    Beneath the LED array  160  is a thermal pad  168  having an adhesive on an upper side for adhering the pad  168  to the thermal transfer system  121 . As previously indicated, the thermal pad illuminates gaps between the primary LED array  150  and the base  112  by compensating for imperfections in the surface  121  or the LED array  150 . Such construction maximizes heat transfer between the components. 
         [0047]    Beneath the thermal pad is the LED array  150  which is comprised of an LED circuit board  52  and a plurality of LEDs  154  thereon. The LED array  150  is electrically connected to the power supply  152 , allowing powering of the LED lamps  154 . 
         [0048]    Beneath the primary LED array  150  is a light mixing chamber  170 . The light mixing chamber comprises a plurality of reflectors which surround each of the LED lamps  154  and direct light output downwardly from the chamber  170 . The light mixing chamber  170  provides the appearance of a single output rather than a plurality of single light outputs, thus mixing the light of the individual lamps  154 . 
         [0049]    Beneath the mixing chamber  170  is a lens  130  which may be formed of polycarbonate, acrylic or the like. The lens  130  is same structure as previously described. Likewise, the mixing chamber  170 , LED array  150 , thermal pad  168  and secondary LED array  160  are all the same structures as described in the first embodiment. 
         [0050]    Beneath the lens  130  is the decorative element  116 . As previously described, the decorative element  116  differs from the first embodiment which did not comprise a distinct decorative element. The decorative element  116  of the instant embodiment is formed of a polycarbonate, acrylic or the like, transparent, translucent, or at least semi-translucent, material allowing light to pass there from. The decorative element  116  has a central aperture through which light passes from the primary LED array  150 . The secondary LED array  160  shines light outwardly and through the sidewalls of the decorative element  116 . 
         [0051]    Beneath the decorative element  116  is a threaded collar  114  which passes upwardly through the decorative element  116  and threadably fastens to the base  112 . 
         [0052]    Referring now to  FIG. 10 , a section view of the LED luminaire  110  is depicted. The base  112  includes the heat sinks  120  which extend from the inner surface of the decorative element  116  radially inward. The heat sink  120  is defined by a plurality of fins which are in thermal communication with the LEDs and circuit board operatively connected to the LEDs. The base  112  is connected to the collar  114  by a threaded portion  115  and a depending connection wall  113  having threads for threadable connection to the collar  114 . 
         [0053]    Referring now to  FIG. 11 , a third embodiment of the luminaire  210  is depicted in perspective view. The luminaire  210  differs from the first and second embodiments due to the deeper depth of the luminaire as measured from the top surface or plate of the fixture  210  to the lower most surface  224 . According to this embodiment, the LED luminaire  210  includes a base portion, a decorative element  216  and a threaded collar  214 . The luminaire  210  differs from the first and second embodiments additionally due to type of collar  214  utilized. For example, the collar  214  has a lower flange  224  which is positioned in a more radially outward location and the second embodiment of the LED luminaire  110 . Additionally, the LED luminaire  210  differs from the first embodiment in that the luminaire utilizes separable or a distinct decorative element  216  formed of an acrylic, polycarbonate or like material which is transparent, translucent or at least semi-translucent. The base structure  212  may be the same as the base  12 ,  112  and the modular or interchangeable decorative element  216  may be utilized rather than the collar  14  alone for the decorative element  116  and collar  114  of the second embodiment. Thus, the luminaire is modular in the sense that it may have various appearances based on the user&#39;s desire by simply changing the decorative element and/or the collar structure. Additionally, the collar  214  may be a threaded collar but various other connection mechanisms may be utilized. Additionally, as with the first and second embodiments, the exemplary luminaire  210  is shown as having a round shape but various shapes may be utilized, such as square, rectangular or other polygons. 
         [0054]    Referring now to  FIG. 12 , a side view of the luminaire  210  is depicted. The base portion  212  includes a heat sink  220  extending from an upper portion thereof and an upper plate  222  generally covering the uppermost edges of the heat sink  220 . As previously described, the base  212  is the same as the first and second bases  12 ,  112 . This allows for varied luminaire appearance by merely changing the decorative element and or threaded collar. As shown, the luminaire of  FIG. 12  has a depth which is greater than the first and second embodiments of the luminaire. The increased depth is due to the depth of the collar  214  and decorative element  216 . 
         [0055]    Referring to  FIG. 13 , a bottom view of the luminaire  210  is depicted. The flange  224  is shown defining the lower portion of the collar  214 . Radially inward of the flange  224  is a surface  218  which is vertically offset from the heat sink  220 . The step surface  218  differs from the second embodiment of the decorative element  116 . 
         [0056]    Referring now to  FIG. 14 , an exploded perspective view of the luminaire  210  is depicted. The elements of the luminaire  210  are the same as previously described with numbers changed only to depict a differing embodiment. However, the decorative element  216  and collar  214  differ from the embodiments previously described. As shown, the decorative element  216  has a depth which is greater than the depth of the decorative element  116  and additionally includes a stepped-in area near an upper elevation of the decorative element  216 . 
         [0057]    As shown clearly in  FIG. 15 , the decorative element  216  is threadably connected to the base  212 . Additionally, the side section view of  FIG. 15  clearly depicts the stepped area  218  of the threaded collar of  214 . 
         [0058]    Accordingly, the base  12 ,  112 ,  212  may be utilized with various separable and distinct decorative elements  116 ,  216  as well as various threaded collars  14 ,  114 ,  214  which may or may not be integrated with the decorative finish in order to illuminate the need for a distinct decorative element. 
         [0059]    The foregoing description of several embodiments of the invention has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise steps and/or forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention and all equivalents be defined by the claims appended hereto.