Cassette light, powering unit therefore, multi-dynamic smart magnetic structure and method

A cassette light retrofit adapted to be received in a housing portion of an existing lighting fixture from which the light tubes and door frame with diffuser have been removed comprises an open cassette enclosure having a door frame and diffuser closing the enclosure; a lightable tubing array in the cassette enclosure; a power converter in the enclosure connected to energize the lightable array; and, said cassette door frame being attachable to the fixture housing portion to replace said fixture door frame with the cassette enclosure being in said housing. The power converter uses 8 windings with isolation to improve the tracking efficiency of the sensing windings for accurate high frequency power application for the load. Also, an A.C. winding permits dimming of the lamp load by filling in chunks of voltage deleted by the dimmer.

BACKGROUND OF THE INVENTION 
(1) Field of the Invention 
The invention is a retrofit sealed lighting device cassette for use in 
existing light housings, a unique powering unit for each cassette, a 
magnetic structure for use in the unit, combinations thereof, and methods. 
(2) Prior Art 
Many commercial area task lighting fixtures comprise a housing for the 
light and an openable door carrying a light diffuser element. The diffuser 
element is normally a thin plastic diffuser element embossed with a 
multiplicity of small lenses designed to scatter or concentrate the light. 
The commercial light normally comprises a multiplicity of standard 
flourescent tubes, powered by one or more ballasts, in turn energized from 
a 120 volt main. 
The prior art cold cathode systems consists of inefficient 60 cycle, high 
voltage generating core and coil sets. Our related prior art cold cathode 
systems employed 24 D.C. or A.C. and 10000 volts or more. 
All prior art is characterized by low power factors. 
SUMMARY OF THE INVENTION 
The present invention preferably replaces the conventional flourescent 
tubes, ballast, diffuser and door frame and then utilizes the remaining 
housing as structural support. The device of the invention is thus termed 
a retrofit device. 
The invention comprises a thin sealed light source, including an array of 
lightable tubing, an electronic power converter and sealed light enclosure 
within a door frame optimally, refletive means may be included within the 
housing behind the tubing. 
In other embodiments of the invention, the cassette may omit either the 
door frame or the diffuser as either may be utilized in the existing 
installation, rather than recycled. This invention may also be utilized by 
original equipment manufactures of lighting fixtures as a ballast and 
light source in their product line. 
Probably the most important advantage of the invention as a retrofit device 
is its ease of installation into an existing housing shell in order to 
produce approximately twice the lumen efficiency of the obsolete ballast 
and flourescent arrangement it replaces. 
Another important advantage of the invention is the unique electronic high 
frequency power converter which energizes the retrofit device enabling it 
to double the lumen effeciency over the existing flourescent light 
fixtures that it replaces. 
Another important advantage of the invention is the unique MULTI-DYNAMIC 
SMART MAGNETIC STRUCTURE which automatically fills in the voltage input 
wave sign as the AC dimmer eliminates portions of the voltage while 
maintaining a high power factor and not creating undesirable 
electromagnetic interference and noise. 
The most important advantage of the invention including the power converter 
coupled with the new magnetic structure, is its ability to replace up to 5 
billion existing inefficient lights with such costs being recoverable 
through energy-saving in less than 2 years. 
The electronic power converter(ballast) of the present invention is 
operable from 110, 220, 277 volt A.C. mains and is able to obtain 
extraordinary efficiency while applying less than 1000 volts to the lamp 
load. Our ballast is capable of delivering more than 1000 volts for 
different parameters(re) larger diameter cold cathode tubing, etc. 
The MULTI-DYNAMIC SMART MAGNETIC STRUCTURE includes an isolation circuit 
between the final output winding and the switching windings to permit the 
load to be shorted without damage, and to prevent variances in the load 
from disturbing the switching functions. The isolation circuit also 
permits the elimination of otherwise required major components, such as 
capacitors, chokes, resistors and other semi-conductors because it 
controls the voltage and the current within the magnetics. 
A separate A.C. input winding extends A.C. main voltage directly to the 
load to allow even current and voltage in the final output to the load in 
spite of the conventional dimmer removes portions of A.C. main voltage. 
Synergistically, the use of the retrofit device with the electronic power 
converter, including the MULTI-DYNAMIC SMART MAGNETIC STRUCTURE, enables 
the same lumen output of the lamp load at one half the wattage required 
relative to the standard fluorescent ceiling fixture of the same size. 
Of course, these described components may comprise an original lamp for 
ceiling or other installation.

DESCRIPTION OF THE PREFFERED EMBODIMENT 
FIG. 1 Shows the retrofit cassette 1 of the present invention in 
perspective, attached to a suitable complementary door frame 2 for closing 
fixed commercial light housing 3. The commercial housing 3 may measure 
2'.times.2', 2'.times.4' or many other dimensions, and as found in most 
commercial buildings, functioning as ceiling lighting. In the United 
States alone over 1 billion such lighting fixtures are in existence. 
However, they employ standard flourescent tubes 4(FIG. 1) in 120 volt 
fixtures 5, in turn supported in a metal trough 3' determining the 
2'.times.2', 2'.times.4' etc. dimension of the commercial light 3. 
The conventional ballasts 6 and 7 are simply disconnected from the 120 volt 
main, as by cutting wires 8, 9, etc. and there are usually left in place 
because it costs money to dispose of these PCB containing devices. The 
trough 3' is perhaps 43/4" deep and the ballasts take up 13/4" of the 
trough space, but the thickness of cassette 1 is 2", over its principal 
length, and 31/2" at the end 1. Thus, ample space is provided for 
receiving cassette 1 when the tubes 4 are removed because end 1 is 
disposed beyond ballast 6. 
Cassette 1 is energized from the existing 120 volt wires 10, extending 
through U.L. approved plate 11. Wires 12 from the cassette 1 are connected 
to wires 10 in a conventional manner, as by wire nuts 13. 
However, some slack is intentionally left in wires 10, 12 to permit 
installation and servicing when door frame 2 is opened (in hinge fashion) 
relative to commercial light 3. 
(FIG. 1) Cassette 1 weighs about six pounds in the 2'.times.4' size with 
its aluminum enclosure 1A, accounting for approximately two pounds 
thereof. Thus, thinness and lightness of the cassette 1 allows its 
retrofit usage, and permits its support by the already present commercial 
fixture 3 via frame 2. 
The fixture 3 includes a frame, such as frame 2 and a diffuser, such as 
diffuser 14(FIG. 7). 
These two parts may be cleaned and used in cassette 1 on site, but it is 
preferred that cassette 1 be factory sealed by diffuser 14 and assembled 
in door frame 2(FIG. 1), suitable for use in the type fixture 3 being 
retrofitted. 
The cassette enclosure 1A (FIG. 2 and 7) includes peripheral flange 15 to 
which the peripheral edge of diffuser 14 is affixed to seal the cassette 1 
against light depreciating airborn contaminates. Silicone glue, ultra 
sonic welding or other conventional means may be used to effect sealing. 
A frame 2 (FIG. 1) is conventionally carried by fixture 3 with the 
periphery of frame 2 conforming to and closely fitting within the 
periphery 2' of fixture 3 (FIG. 2A). The T hooks 17 (FIGS. 2A and 8A) fit 
into slots 18 (FIGS. 2A and 9) to form a "hinge". 
Cassette 1 is then swung upwardly and latches 19 (FIG. 1) receive and 
engage slots 20 for locking. 
The lighting source for cassette 1 is the cold cathode tubing array 21. 
(FIGS. 1 & 3) 
Everbrite, Inc. of Harbor City, California is one supplier of such cold 
cathode tubing in various shapes. 
Commercially available pop rivetted flexible fasteners 23 (FIGS. 2 & 4) 
grip the tubing 24 and hold it spaced from the rear wall of retrofit 
enclosure 1A. 
The electronic converter circuitry is contained in box 2000 (FIGS. 3 & 4) 
and is explained, infra. 
FIGS. 3, 4, and 5 show the cassette 1, per se, without the diffuser 14, to 
a somewhat larger scale. The ends 30 and 31 of tubing 24 (FIG. 3) are 
shown respectively connected by wires 32, 33 to the high frequency 
powering electronic box 2000. 
The optional reflector is not shown but it may comprise the polished 
aluminum interior of enclosure 1A or it may be a coating or actually a 
shaped sheet held to the interior wall by the pop up rivet fasteners 23. 
FIG. 6 shows cassette 1 energized to emit light via diffuser 14. Diffuser 
14 is glued to cassette flange 15 by RTV glue 35. 
FIG. 7 shows the cassette housing 1A within the fixture 3, and the old 
unnecessary ballast is visible at 7. Ceiling tile 40 is shown with T bar 
41 support between it and the lower edge of fixture 3. Pressure relief is 
obtained by particle or dust filter 42 (FIG. 7) which may comprise 
ceramic, or the like, of the diameter of a pencil or smaller. Thus, the 
sealed lamp unit simply means sealed from dust and the like, not air 
tight. 
FIGS. 8A and 9 show asssembly steps for using the retrofit cassette 1. 
First, the door frame and the diffuser are removed from the commercial 
installation. Then, the wires from the AC mains to the ballasts are cut. 
Next, the cassette 1 is hooked to the fixture 3 frame 2' in hinge fashion 
17 to 18, as previously explained. The AC main wires are conventionally 
connected to the wires from the cassette power supply 1, and the door 
frame is hinged up and locked. 
It may now be appreciated that the cassette door frame 2 is compatible to 
the previously existing lighting fixture housing 3' (FIG. 2), such that it 
may be received by the housing 3'. 
Fastening means carried by the door frame 2 of the cassette 1 cooperate 
with the fastening means of the housing for receiving the new door frame. 
In other words, the cassette 1 of the present invention is manufactured to 
take advantage of whichever fastening scheme the manufacturer originally 
employed, or at least, the holes, slots or other fastening means already 
present in the housing. Mostly these are slots, openings, springs, pins, 
rods, bayonets, hooks or the like, (e.g.) simple fasteners. 
The cassette of the present invention may also be utilized by prime 
manufacturers of the commercial fixtures to provide the primary light 
source as opposed to using standard flourescent tubes and ballasts. 
The cassette enclosure 1A may be formed of light weight aluminum because 
the fixture housing 3' is of heavy gage metal to meet UL specifications in 
preserving the requisite fire wall. Also, it should be mentioned that the 
retrofit unit 1 may be removed at any time and the fixture restored to its 
original condition easily. 
The powering unit including the MULTI-DYNAMIC SMART MAGNETIC STRUCTURE 
In todays ballast market, high power factors are associated with a noisy 
ballast and you cannot utilize a light dimmer without major difficulties. 
The powering unit 2000(FIG. 1) comprises the MULTI-DYNAMIC SMART MAGNETIC 
STRUCTURE 50 (FIGS. 10 and 13), coupled to oscillating circuit 52 (FIG. 
12) to make the ballast 2000' (FIG. 10) or 2000 (FIG. 1). The present 
invention is able to utilize a light dimmer 54 (FIG. 19) with the ballast 
2000 easily from the A.C. mains terminals A,B (FIG. 11) without extra 
wiring and still maintain a 0.94 of unity power factor or better, without 
noise. 
One major problem with todays ballasts is the toxic waste disposal needs of 
the ballast because of P.C.B. escaping from the tar, which the 
manufacturer uses as potting material in the structure contained in its 
ballast to act as a thermo-conductor plus a noise supressor within the 
ballast. We do not need to encapsulate the MULTI-DYNAMIC SMART MAGNETIC 
STRUCTURE, per se, or the ballast, nor does the combination ballast 
require encapsulation. We do not have the noise creation, nor the heat 
creation so potting is not needed to supress these factors. Thus, our 
ballast is environmentally safe with no inherent P.C.B. 
The main dimming problems in todays ballast are: 
1. Endeavoring to dim gas charged lamps with a standard dimmer without 
flickering, and 
2. Effecting lowering of the A.C. voltage and current evenly, without 
chopping up the sine wave. 
The way we achieve this in our MULTI-DYNAMIC SMART MAGNETIC STRUCTURE is: 
(1) Preferably use 8 (FIG. 14) windings, 60, 61, 62, 63, 64, 65, 67, and 
68, on a three section E core 55, being two sense windings 60, 61, two 
first primary circuit windings 62, 63, a first secondary winding 64, and a 
second primary winding 65 (load supply) connected as a continous loop 
isolation circuit 66 (FIG. 13). The lamp load supplying output winding 
(second secondary 67) and a unique A.C. 60 cycle main line input winding 
68 conclude the 8 windings. 
A pair of switching FETs F1 and F2 (FIG. 12), a full wave rectifier 70, and 
isolated components comprise the oscillator circuit 52 (FIG. 12). 
The oscillator section 52 (FIG. 12) drives the two first primaries 62, 63 
(FIG. 13) on the MULTI-DYNAMIC SMART MAGNETIC STRUCTURE 50, allowing for 
the dimmer 54 (FIG. 19) to eliminate portions of current to permit to 
permit dimming of lamp array 24 the oscillator to run at 80 khz. The 
current 60 hz surges on the second primary winding 65 (FIG. 13) to fill in 
the lower missing portions of the voltage to smooth out the local voltage 
across terminal 67. Therefore, the circuit runs much smoother and quieter 
due to the non-fluctuation of the voltage and current in winding 67. 
The current surge on the second primary winding 65 is accomplished through 
the unique A.C. 60 cycle main input winding 68 (FIG. 11) and occurs as a 
consequence of a disruption in the current flow such as the operation of 
dimmer 54. For example, if dimmer 54 reduces the current to the oscillator 
circuit 52 (FIG. 12) the current is reduced in isolation winding 65. If 
the unique A.C. 60 cycle main input winding 68 did not exist in the 
circuit, the voltage at winding 67 would be unstable and fluctuate due to 
the fact that dimmer 54 would remove portions of the current in the 60 hz 
sign wave of the A.C. main. The unstable condition at winding 67 would 
interrupt the operation of gas discharge lamp array 24 and result in 
flickering of the lamp. With the presence of the unique A.C. 60 cycle main 
input winding 68 (FIG. 11), when the dimmer 54 removes a portion of the 
current from the oscillator circuit 52, winding 68 compensates for the 
current that is lost due to the operation of the dimmer 54 thereby 
stabilizing the voltage and current delivery to winding 67. This results 
in a flicker-free gas discharge lamp. 
The MULTI-DYNAMIC SMART MAGNETIC STRUCTURE 50, consists of two sensing 
windings 60, 61 of one turn each, two primary windings 62, 63 of 35 turns 
each. The first secondary winding 64 consists of 89 turns of Litz wire 
model 15/38 winding on a single core 55A (FIG. 14). 
The tighter the coupling of the primary 62, 63 to secondary 64, the greater 
the magnitude of induction of the oscillating into the load. The isolation 
circuit 66 (FIG. 11) substantially diminishes any load originated 
variences induced into core section 55A (FIG. 14), thus minimizing any 
effect at sense windings 60, 61. Thus, a steady output frequency is 
produced by F1 and F2 (FIG. 11). The isolation of core 55A (FIG. 14), 
within its own winding structure and isolated core permits the sense 
windings 60, 61 to track their respective primary windings 62, 63, hence 
intelligent or smart adaptation. 
The second section of the MULTI-DYNAMIC SMART MAGNETIC STRUCTURE 50 (FIG. 
13) is the second primary winding 65 with 98 turns. This winding is 
connected directly to the first secondary winding 64, and these two 
windings 65, 64 will control the voltage and current output to the lamp 
24. Windings 65 and 68 are on core section 55B (FIG. 14) of common core 
55,. On the same core section 55B, is the 18 turns, of 24A A.W.G. copper 
wire of windings that will supply any needed current voltage to keep the 
lamp evenly lit while dimming. 
The final winding 67, on the same core section 55C, is the second secondary 
winding 67 which is a 36 A.W.G. wire with 800 turns on a custom made three 
section bobbin 80 (FIGS. 17A, 17B, and 18), this winding supplying the 
final output voltage and current for driving the lamp load 24 (FIG. 13). 
The power unit 2000 (FIG. 3) will sense a dead short in the second 
secondary winding 67 (FIG. 13) and only draw 5 watts, or it will sense an 
open circuit, and only draw 5 watts due to inherent losses. 
In general, the high frequency power supply 2000 (FIG. 3) of the present 
invention is the current sensing MULTI-DYNAMIC SMART MAGNETIC STRUCTURE 50 
(FIG. 13) which energizes from 4 to 30 feet of cold cathode tubing 24 feet 
coupled to the low component count electronic oscillator circuit 52 (FIG. 
12). This circuit may be powered by 120, 220 or 277 volts A.C. at 50-60 
HZ. The MULTI-DYNAMIC SMART MAGNETICS STRUCTURE 50 (FIG. 13) also may be 
powered by D.C. mains for standby applications or D.C. mains only for 
space or military use, or the like. 
The MULTI-DYNAMIC SMART MAGNETICS STRUCTURE 50 may operate satisfactory 
with no load or a shorted load. The unit will also run at, for example, 80 
khz at 950 volts at a 0.94 of unity or better power factor. 
OPERATION 
The circuit of FIG. 11 is capable of driving a cold cathode 12 mm. neon 
lamp equivalent to the Voltarc 4500 kelvin white. A.C., SUCH AS THE LAMP 
ARRAY 21 OF (FIG. 3) A.C. mains supply input voltage to terminals A and B 
(FIG. 11). 
The starting mode of operation proceeds from the time the A.C. input power 
is applied across terminals A and B of the lamp load tubing array 24 
between secondary terminals 82 and 83 which load presents a very high 
resistance to the high frequency output of winding 65. The resistance of 
lamp load 24 drops to set the current value in winding 67, depending on 
the lamp load applied to the circuit i.e. the lenth of tubing, the tubing 
diameter, the temperature within the tube, the type of gas etc. 
The rectified current I (FIG. 11), from rectifier 70, flows along conductor 
101 to ground 102. Resistor R1 of 9 k ohms and zener 103 comprises a 
voltage divider with 3.9 volts D.C. appearing at junction 104. Resistor R2 
(100 ohms) reduces current to the sense winding 61 (FIGS. 11 or 13). 
Resistor R3 (15 ohms) is connected in sense lead 108 to reduce the current 
to sense winding to 60 via terminals X (FIGS. 12, 13). Resistor R3 (15 
ohms) (FIGS. 11, 12) prevents the sensing circuits from turning on at the 
same magnitude of voltage or current. This prevents the FETs F1 and F2 
from turning on at the same time during startup and causing too much 
current through L1 and opening the fuse S1. Resistor R3 decreases the 
current enough in lead 108, relative to lead 105, to allow F1 to always 
turn on first during startup, i.e. the moment power is applied to 
terminals A and B. 
Now that sense voltage has been supplied to windings 60 and 61 (FIGS. 
11,13), the gates 115 and 119 of FETs F1 and F2 receive voltage of almost 
3.9 volts via windings 60 and 61 (FIG. 11). Since they turn on at +2.5 
volts, the one (61) receiving higher voltage will turn on. This is true 
because lead 111 is grounded at 112, and the DC circuit extends from 
rectifier 70, via junction 120 and lead 121, through inductor L1, along 
leads 122, 123, winding 63 and leads 124, 125, point 126 and drain lead 
127. Current flows between drain 128 and source 129. 
First primary winding 63 is wound opposite(see dots) to its sense winding 
61, such that the pulse from FET F1 going on charging C2 to oppose the 
sense winding 61 of first primary winding 63, causing the gate voltage of 
F1 to approach zero volts, opening F1. 
Sense winding 61 is now below DC ground so sense winding 60 can turn on FET 
2 by its gate 115. 
A current path exists from point 120, leads 121, L1, 122, 130, second 
primary winding 62, lead 131 to other side of C2 and via drain 133 FET 2, 
and source 134 to ground 112. 
Sense winding 60 is now below DC ground, so sense winding 61 turns on FET 
1. 
Windings 63 and 62 are the two primary windings which are wound oppositly 
(See dots FIG. 11). When F1 and F2 are switching, these two windings form 
a sinusoidal waveform is at winding 64. 
FIG. 17 shows the unique bobbin 80 used in this invention to hold the 
second secondary winding 67 and isolate it from transient voltage 
breakdown. The bobbin 80 is made of DUPONT Rynite which allows for 
dielectric strength of 600 volts per/mil. 
In FIG. 17A the bobbin 80 has three sections, 80A, 80B and 80C, start 
section 80A, a cross-over section 80B, and a finish section 80 C. The O.D. 
of the bobbin 80 is 1.250 and the core 140 of bobbin 80 is 0.594". The 
core bobbin winding area has a diameter of 0.688" the wall thickness is 
0.047" on all walls, the start hole 161 (FIG. 17A) is a 45 degree downward 
penetrating opening of 0.016" diameter and the center cross-over spacing 
or slot 80B has a width of 0.172", while the width of sections 80A and 80C 
are 0.0142" and the width of the spaces (e.g.) 150, 151 and 152 are each 
0.047". 
Looking at FIG. 17A, 17B and 18, the winding wire 83 enters the start hole 
161 and proceeds in a counter clockwise direction about the spool 80A for 
one half of the winding 67A (FIG. 16). In the structure of FIG. 17A and 
18, the cross-over slot 165 is shown guiding the wire 83 of the second 
secondary winding 67. The cross-over turn is shown at 183 (FIG. 18) of 
section 80B, this one turn 183 enters the cross-over section 80B via 
peripheral notch 165 in spacer 149 and is turned to encircle the core 140 
(FIG. 17B) in section 80B for one turn 183, splitting the secondary 
winding 67 (FIG. 16) into two equal halves. 
Once the crossover turn 183 penetrates opening 201, wire 83 is wound in the 
same direction on bobbin section 80C as the first half was wound on bobbin 
section 80A. 
Winding 67 is shown on bobbin 80 in FIGS. 15A and 15B for mounting on 
righthand E core section 55C. Windings 68 and 65 are carried by 
conventional bobbin 75, in turn mounted on E section 55B. Conventional 
spacer 250 gap separates middle legs 251-252 of sections 55B and 55C when 
assembled. The outside legs are separated by glue in conventional fashion. 
(FIG. 11) E core section 55A carries 8 pin bobbin connector 260 and a 
conventional bobbin 261 including 5 windings, 60, 61, 63, 62, 64. 
(FIG. 15A) Spacer 263 separates E core middle leg 264 of section 55A from 
the back of section 55B. 
Note that this assembly requires no potting, nor special insulation, is 
light weight and does not heat up unduly. 
The MUTI-DYNAMIC MAGNETIC STRUCTURE 50 may be installed in any asymetrical 
switching oscillating electronic circuit. The preferred circuit we 
designed herein described for MULTI-DYNAMIC SMART MAGNETICS appears 
optimally efficient for its intended purpose. 
Typical values of the components of switching circuit are as follows: 
L1 600 M.H. 
L2 250 M.H. 
RESISTOR R1 5 WATT 9 K OHM 
RESISTOR R2 1/4 WATT 100 OHM 
RESISTOR R3 1/4 WATT 15 OHM 
ZENER 1/4 WATT 3.9 V 
DIODE 1.5 AMP 200 V 
DIODE 1.5 AMP 200 V 
DIODE 1.5 AMP 200 V 
DIODE 1.5 AMP 200 V 
FILM CAP 5.0 MFD. 200 VOLT 
FILM CAP 4700 P.F. 2000 VOLT 
ETD 39 FERRITE CORE--3 SECTIONS 
8 PIN BOBBIN CONNECTOR TAILORED TO FIT ETD 39 CORE 
WINDINGS 62, 63, 64, 65 LITZ WIRE 
M.O.V. 2 AMP 170 VOLT 
FUSE 3 AMP. 200 VOLT 
F.E.T SSP4N70 
F.E.T SSP4N70 
HEAT SINKS H2 H1 5700 AAVID 
These parts are valued for the 120 volt oscillator. 
It may now be appreciated that the MULTI-DYNAMIC SMART MAGNETICS 50 with a 
two F.E.T asymetrical 80 KHZ oscillator complete with dimming capabilities 
and a high power factor may be used as the most efficent means for 
powering the CASSETTE light. The oscillator we designed around the 
MULTI-DYNAMIC SMART MAGNETICS 50 (FIG. 13) has only a minimal number of 
componets which means there are fewer chances of part to part breakdown in 
the circuit. We found that coupling this circuit and the MULTI-DYNAMIC 
SMART MAGNETICS 50 with the CASSETTE light permitted us to acheive at 
least 50% greater overall efficencies and with the simple dimming of the 
lightable tubing, efficiencies can be even greater. 
A master dimming control may be employed to control a plurality of lights, 
manually or by photo sensing.