LED light module

A light module includes a light engine having a printed circuit board and an array of light emitting diodes (LEDs) coupled to the printed circuit board. The printed circuit board has a power connector interface defining a separable interface for coupling with a power connector of the light module. A base ring holds the light engine and has side walls defining a cavity. The side walls have a securing feature. An optical component is received in the cavity and is positioned to receive light from the LEDs. The optical component has a predetermined lighting characteristic and emits the light generated by the LEDs in accordance with the predetermined lighting characteristic. A top cover is coupled to the base ring and has a securing feature engaging the securing feature of the base ring to couple the top cover to the base ring. A compression ring is positioned between the base ring and the optical component. The compression ring is compressed between the base ring and the optical component when the top cover is coupled to the base ring.

BACKGROUND OF THE INVENTION

The subject matter herein relates generally to solid state lighting systems and, more particularly, to a light emitting diode (LED) light module.

Solid-state light lighting systems use solid state light sources, such as light emitting diodes (LEDs), and are being used to replace other lighting systems that use other types of light sources, such as incandescent or fluorescent lamps. The solid-state light sources offer advantages over the lamps, such as rapid turn-on, rapid cycling (on-off-on) times, long useful life span, low power consumption, narrow emitted light bandwidths that eliminate the need for color filters to provide desired colors, and so on.

Solid-state lighting systems typically include different components that are assembled together to complete the final system. For example, the system typically consists of a light engine, an optical component and a power supply. It is not uncommon for a customer assembling a lighting system to have to go to many different suppliers for, each of the individual components, and then assemble the different components, from different manufacturers together. Purchasing the various components from different sources proves to make integration into a functioning system difficult. This non-integrated approach does not allow the ability to effectively package the final lighting system in a lighting fixture efficiently.

The light engine of the solid state light system generally includes an LED soldered to a circuit board. The circuit board is configured to be mounted in a lighting fixture. The lighting fixture includes the power supply to provide power to the LED. Typically, the circuit board is wired to the lighting fixture using wires that are soldered to the circuit board and the fixture. Generally, wiring the circuit board to the light fixture power source requires several wires and connections. Each wire must be individually joined between the circuit board and the lighting fixture.

Wiring the circuit board with multiple wires generally requires a significant amount of time and space. In fixtures where space is limited, the wires may require additional time to connect. Additionally, having multiple wires to connect requires multiple terminations, increasing the time required to connect the LEDs. Moreover, using multiple wires increases the possibility of mis-wiring the lighting system. In particular, LED light fixtures are frequently installed by unskilled labor, thereby increasing the possibility of mis-wiring. Mis-wiring the lighting system may result in substantial damage to the LED. Also, in a system where wires are soldered between the circuit board and the fixture, the wires and circuit boards become difficult to replace.

Furthermore, the light engines typically generate a lot of heat and it is desirable to use a heat sink to dissipate heat from the system. Heretofore, LED manufacturers have had problems designing a thermal interface that efficiently dissipates heat from the light engine.

A need remains for lighting systems that can be powered efficiently. A need remains for lighting systems with LEDs that have adequate thermal dissipation. A need remains for lighting systems with LEDs that are assembled in an efficient and cost-effective manner. A need remains for a lighting system that may be efficiently configured for an end use application.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a light module is provided that includes a light engine having a printed circuit board and an array of light emitting diodes (LEDs) coupled to the printed circuit board. A base ring holds the light engine. The base ring has side walls defining a cavity that have a securing feature. An optical component is received in the cavity and is positioned to receive light from the LEDs. The optical component has a predetermined lighting characteristic and is configured to emit the light generated by the LEDs in accordance with the predetermined lighting characteristic. A top cover is coupled to the base ring. The top cover has a securing feature engaging the securing feature of the base ring to couple the top cover to the base ring. A, compression ring is positioned between the top cover and the optical component. The compression ring is compressed between the top cover and the optical component when the top cover is coupled to the base ring.

In another embodiment, a light module is provided including a light engine having a printed circuit board and an array of light emitting diodes (LEDs) coupled to the printed circuit board. The printed circuit board has a power connector interface defining a separable interface for coupling with a power connector of the light module. A base ring holds the light engine and has side walls defining a cavity. The side walls have a securing feature. An optical component is received in the cavity and is positioned to receive light from the LEDs. The optical component has a predetermined lighting characteristic and emits the light generated by the LEDs in accordance with the predetermined lighting characteristic. A top cover is coupled to the base ring and has a securing feature engaging the securing feature of the base ring to couple the top cover to the base ring. A compression ring is positioned between the top cover and the optical component. The compression ring is compressed between the top cover and the optical component when the top cover is coupled to the base ring.

In a further embodiment, a light module is provided including a base ring having side walls defining a cavity and a securing feature. A set of light engines are provided including at least two different types of printed circuit boards (PCBs) that have different arrays of light emitting diodes (LEDs) coupled thereto. A select one of the PCBs is positioned within the cavity. A set of optical components is provided including at least two different types of optical components. The different types of optical components differ from one another by having different lighting patterns. A select one of the optical components are received in the cavity adjacent to the selected PCB and receive light from the LEDs. The selected optical component is configured to emit the light generated by the LEDs in accordance with a predetermined lighting characteristic. A top cover is coupled to the base ring and has a securing feature engaging the securing feature of the base ring to couple the top cover to the base ring. A compression ring is positioned between the top cover and the optical component. The compression ring is compressed between the top cover and the optical component when the top cover is coupled to the base ring.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1illustrates a light module10for use in a device12(shown in phantom). The light module10generates light for the device12. The device12may be any type of lighting device, such as a light fixture. In exemplary embodiment, the device12may be a can light fixture, however, the light module10may be used with other types of lighting devices in alternative embodiments.

FIG. 2is an exploded view of the light module10. The light module10includes a light engine20, a base ring22holding the light engine20, an optical component24received in the base ring22, and a top cover26coupled to the base ring22to hold the optical component24within the base ring22. A compression ring28is configured to be held between the top cover26and the base ring22and/or the optical component24. A thermal pad34is optionally coupled to the light engine20to dissipate heat from the light engine20.

A power connector30is configured to be coupled to the light engine20to provide power to the light engine20. The power connector30is terminated to an end of a power cable32. In an exemplary embodiment, the power connector30is configured to be couple to the light engine20at a separable interface. For example, the power connector30may be plugged into the light module10and unplugged from the light module10.

The base ring22includes a side wall40defining a cavity42. In the illustrated embodiment, the side wall40has a cylindrical shape defined by an inner surface44and an outer surface46. The side wall40extends between a bottom edge48and a top edge50opposite the bottom edge48. In exemplary embodiment, the side wall40has a rim52proximate to the bottom edge48. The rim52extends outward from the outer surface46. The side wall40includes an opening54therethrough that is configured to receive the power connector30. The opening54provides access to the light engine20such that the power connector30may be coupled to the light engine20.

The light engine20includes a printed circuit board (PCB)60having a first surface62and a second surface64. The PCB60includes a plurality of openings74extending therethrough between the first and second surfaces62,64. The thermal pad34is coupled to the second surface64to dissipate heat from the PCB60. Optionally, the thermal pad34may be coupled to the second surface64using a thermally conductive epoxy, a thermal grease or a thermally conductive adhesive. Other securing means may be used to secure the thermal pad34to the second surface64in alternative embodiments.

An array of light emitting diodes (LEDs)66is coupled to the first surface62of the PCB60. The LEDs66emit light therefrom. Any number of LEDs66, including a single LED66, may be provided within the light engine20. Each of the LEDs66may be identical to one another. Alternatively, different types of LEDs66having different lighting characteristics, such as color, intensity and the like, may be provided. The LEDs66may be powered in accordance with a certain lighting scheme. Optionally, only a subset of the LEDs66may be powered at a given time in some situations. The LEDs66are arranged in a predetermined pattern on the PCB60. The LEDs66are spaced apart from one another in accordance with such pattern. The LEDs66are electrically connected to circuitry within the PCB60and power is fed to the LEDs66by the PCB60. The heat generated by the LEDs66is dissipated through the PCB60, such as into the heat sink.

The PCB60has a power connector interface68. In an exemplary embodiment, the power connector interface68includes one or more pads70provided on the first surface62. A clip72is coupled to the first surface62at the power connector interface68. The power connector30is coupled to the power connector interface68to supply power to the PCB60. The power connector30includes one or more power contacts (not shown) that are electrically connected to the power cable32to supply power to the PCB60. For example, the power contacts may be terminated to corresponding pads70at the power connector interface68. The clip72is used to secure the power connector30to the light module10. For example, the clip72may include latches or other securing features that engage the power connector30to couple the power connector30to the light module10. In an exemplary embodiment, the power connector interface68constitutes a separable interface. The power connector30may be mated and unmated to the power connecter interface68. A nonpermanent connection is made between the power connector30and the PCB60at the separable power connector interface68. For example, a solderless connection is provided between the power connector30and the power connector interface68. Other types of securing features other than the clip72may be used to couple the power connector30to the light module10. For example, the base ring22may include features to secure the power connector30within the light module10.

In an exemplary embodiment, the light module10may include a set of light engines20including at least two different types of light engines20. The different types of light engines20differ from one another by having different lighting characteristics. For example, the different types of light engines20may have a different number of LEDs66or a different arrangement of LEDs66on the surface of the PCB60. The different types of light engines20may have different types of LEDs66, such as LEDs66that generate different colors or intensities of light.FIG. 2illustrates a second light engine20′ that may be used with the light module in place of the light engine20. For example, during assembly, the manufacturer may select either the light engine20or the light engine20′ (or another light engine) to be received in the cavity42. Depending on which light engine20or20′ is selected, the light module10may have different lighting characteristics. The light module10is customizable by providing different types of light engines20,20′ for use therewith. The light module10is configurable by selecting from the set of light engines20to achieve a desired light distribution. As will be described in further detail below, the light module10is easily configurable either pre or post installation by replacing the light engine20with a different light engine20′ selected from the set of light engines usable with the light module10. As such, should the desired lighting characteristics of the light module10change or become different, the light engine20may be easily replaced.

The optical component24includes a lens80having an outer surface82. The optical component24is configured to be received in the cavity42such that the optical component24receives light emitted for the LEDs66. The optical component24has a predetermined light characteristic and is configured to emit the light generated by the LEDs66through the lens80in accordance with the predetermined characteristic. The lighting characteristic may have an effect on the light output of the light module10. For example, the lighting characteristic may correspond to a particular light beam output angle. The optical component24may be configured to provide a wide angle of illumination. Alternatively, the optical component24may be configured to provide a narrow or focused illumination angle. The particular lighting characteristic may be dependant on the number of LEDs66within the array and/or the type of LEDs66within the array.

In an exemplary embodiment, the light module10may include a set of optical components24including at least two different types of optical components24. The different types of optical components24differ from one another by having different lighting characteristics. For example, the different types of optical components24may have different lighting patterns and/or, different lighting characteristics.FIG. 2illustrates a second optical component24′ that may be used with the light module in place of the optical component24. The optical component24′ represents a reflector, however other types of optical components may be utilized in alternative embodiments. For example, during assembly, the manufacturer may select either the optical component24or the optical component24′ (or another optical component) to be received in the cavity42. Depending on which optical component24or24′ is selected, the light module10may have different lighting characteristics. The light module10is customizable by providing different types of optical components24,24′ for use therewith. The light module10is configurable by selecting from the set of optical components24to achieve a desired light distribution. As will be described in further detail below, the light module10is easily configurable either pre or post installation by replacing the optical component24with a different optical component selected from the set of optical components usable with the light module10. As such, should the desired lighting characteristics of the light module10change or become different, the optical component24may be easily replaced with a different optical component24′ without disrupting the light engine20.

The compression ring28is configured to be coupled to the base ring22and/or the optical component24after the optical component24is loaded into the cavity42. For example, the compression ring28may be placed over the outer surface82and/or the top edge50prior to coupling the top cover26the base ring22. The compression ring28is made from a compressible material, such as foam material, a silicone rubber material, or another type of compressible material. In an alternative embodiment, the compression ring28may be manufactured from a metal material formed as a spring, such as a wave spring washer, that may be placed between the top cover26and the base ring22and/or the optical component24. The compression ring28is ring shaped having an open interior. The open interior is aligned with the lens80such that the light may be emitted from the lens80through the compression ring28. The compression ring28takes up tolerances between the optical component24and the top cover26when the top cover26is coupled to the base ring22. The compression ring28provides compliancy for connecting the securing features of the base ring22with the securing features of the top cover26during assembly.

The top cover26includes a side wall90and a top wall92. The top wall92has an opening94therethrough. The opening94is aligned above the lens80and allows light emitted by the lens80to be emitted from the light module10. The top cover26is configured to be coupled to the base ring22during assembly of the light module10. In an exemplary embodiment, the top cover26is rotatably coupled to the base ring22, however the top cover may be coupled to the base ring22in a different manner using different securing means in alternative embodiments. During assembly, the top cover26is loaded onto the base ring22and rotated to a locked position. The top cover26holds the optical component24in the cavity42. The compression ring28is received between the top cover26and optical component24to take up any tolerance between the top cover26and the optical component24. Alternatively, the compression ring28may be positioned between the top cover26and the base ring22and a lip of the top cover26may engage the optical component24to hold the optical component24in the cavity42. In an exemplary embodiment, the top cover26includes finger grips96on the outer surface of the side wall90to provide gripping features for gripping the top cover26during assembly with the base ring22. In an exemplary embodiment, the top cover26includes one or more openings98at a bottom of the side wall90. The openings98accommodate a portion of the power connector30when the power connector30is coupled to the light module10.

FIG. 3a top perspective view of the base ring22with the light engine20coupled thereto.FIG. 4is bottom perspective view of the base ring22with light engine20coupled thereto. In an exemplary embodiment, the base ring22includes one or more keying features100extending into the cavity for orienting the light engine20with respect to the base ring22. The PCB60includes one or more keying features102that interact with the keying feature100to orient the light engine20with respect to the base ring22. In the illustrated embodiment, the keying feature100constitutes tabs extending from the inner surface44of the side wall40into the cavity42. The keying features102constitute cut outs in the PCB60that have a similar size and shape to the tabs.

In an exemplary embodiment, the light engine20is coupled to the base ring22by loading the PCB60through the bottom edge48of the base ring22. The thermal pad34is coupled to the PCB60. The first surface62faces upward such that the LEDs66are exposed within the cavity42. The PCB60is loaded into the cavity42until the PCB60bottoms out against fastener mounts104of the base ring22. The fastener mounts104hold fasteners106therein. The fasteners106are used to secure the light module10to another structure, such as the device12(shown inFIG. 1) or a heat sink of the device12. The fastener mounts104extend inward from the inner surface44of the side wall40into the cavity42. The fastener mounts104receive the fasteners106through the top of the fastener mounts104. The fasteners106extend through the lugs108and the openings74in the PCB such that the fasteners106extend below the light module10.

The fastener mounts104include lugs108extending from the bottom of the fastener mounts104. The lugs108are received in the openings74of the PCB60when the PCB60is loaded into the base ring22. The lugs108engage the PCB60in an interference fit to hold the PCB60within the base ring22. Optionally, the lugs108may include crush ribs or other features to engage and hold the PCB60. Other types of fastening means may be used to hold the PCB60within base ring22an alternative embodiment.

In an exemplary embodiment, the PCB60has a generally circular outer perimeter and includes a flat side110along a portion thereof. In an exemplary embodiment, the flat side110is provided at the power connector interface68. The flat side110provides a keying feature for orienting the PCB60within the base ring22. The flat side110provides an edge for receiving the power connector30(shown inFIG. 1) when the power connector30is coupled to the light engine20. In an exemplary embodiment, the base ring22includes shoulders112extending along the flat side110. The shoulders112provide a surface for the flat side110to rest against. The shoulders112define a keying feature of the base ring22to orient the PCB60within the base ring22. The shoulders112are provided at the opening54and are provide on either side of the opening54.

While the light module10is illustrated and described as being a circular light module, it is realized that other shapes are possible in alternative embodiments. For example, the base ring22and top cover26may have a non-circular shape, such as a rectangular shape. While the base is described as being a ring, the shape of the base may define a non-circular ring surrounding the PCB60. The use of the term base ring is not intended to be limited to circular geometries. The shape of the PCB60and optical component24may correspond with the shape of the base ring22and/or top cover26.

FIG. 5is a sectional view of a portion of the light module10around the fastener mount104and fastener106.FIG. 5illustrates the fastener106held within the fastener mount104. In an exemplary embodiment, the fastener mount104includes a latch120along one of the walls of the fastener mount104. The latch120is used to hold the fastener106within the fastener mount104. For example, the latch120is positioned over the top of the fastener106to prevent removal of the fastener106from the fastener mount104. The latch120is deflectable to allow the fastener106to be loaded into the fastener mount104. Once the fastener106is positioned within the fastener mount104, the latch120covers a portion of the fastener106to block removal of the fastener106from the fastener mount104. The latch120may be manually deflected outward to remove the fastener106from the fastener mount104.

When the PCB60is loaded into the base ring22, the lug108is received in the opening74. The outer surface of the lug108presses against the PCB60to hold the PCB60in position with respect to the base ring22. Alternative securing means may be provided to hold the PCB60in the base ring22. Optionally, rather than securing the PCB60in the base ring22, the PCB60may be held on the heat sink, such as using locating features, and then the base ring22is coupled to the heat sink over the PCB60. The base ring22may compress and hold the PCB60against the heat sink to ensure good thermal transfer therebetween. The thermal pad34(shown inFIG. 2) may be positioned between the PCB60and the heat sink to increase the thermal transfer therebetween. Other types of thermal materials may be used therebetween, such as a thermal interface material, a thermal epoxy, thermal grease, a thermal film or foil, and the like.

FIG. 6is a sectional view of a portion of the light module10illustrating the optical component24being loaded into the cavity42of the base ring22. The optical component24includes a plurality of cones130extending downward from the lens80. Optionally, the cones130and the lens80may be integrally formed with each another such as during a molding process. Each cone130converges to a base132at the bottom of the cone130. The base132is smaller than the portion of the cone130proximate to the lens80. A recess134is provided in the base132that extends into the cone130.

The optical component24is loaded into the base ring22such that the cones130are aligned with, and positioned adjacent to, corresponding LEDs66of the light engine20. In an exemplary embodiment, when the optical component24is coupled to the base ring22the LED66is partially received in the recess134. The cones130receive light emitted from the LEDs66and direct the light through the lens80. The number of cones130corresponds with the number of LEDs66. The positioning of the cones130corresponds with the positioning of the LEDs66on the PCB60. In an exemplary embodiment, the optical component24is loaded into the base ring22until the base132is positioned adjacent to a corresponding LED66.

The PCB60includes a plurality of holes136extending therethrough. The optical component24includes a plurality of posts138extending from the bottom of the lens80. The posts138are aligned with the holes136in the PCB60. When the optical component24is loaded into the base ring22, ends of the post138are received in the holes136. The holes136and post138operate to align the optical component24with respect to the PCB60such that the cones130may be aligned with the corresponding LEDs66. In an exemplary embodiment, at least a portion of the lens80is received in the cavity42prior to the posts138being received in the holes136. As such, the optical component24may be substantially aligned with the PCB60prior to the posts138being loaded into the holes136. Having the optical component24at least partially loaded into the cavity42prior to the post138being loaded into the holes136locates and orients the optical component24with respect to the PCB60such that the post138are substantially aligned with holes136. As the lens80is further loaded into the cavity42, the posts138are loaded into the holes136. In an exemplary embodiment, the cones130are elevated above the LEDs66when the posts138are outside of the holes136. As such, the optical component24may be moved slightly within the cavity42to align the optical component24with respect to the PCB60with out damaging the LEDs66.

FIG. 7is a top perspective, partially exploded view of the light module10showing the optical component24loaded into the base ring22.FIG. 7illustrates the top cover26and compression ring28poised for mounting onto the base ring22. In an exemplary embodiment, the optical component24includes a keying feature140that interacts with the keying feature100of the base ring22. In the illustrated embodiment, the keying feature140constitutes a notch formed in the lens80. The keying features140,100orient the optical component24with respect to the base ring22. Orienting the optical component24with respect to the base ring22also properly orients the optical component24with respect to the light engine20(shown inFIG. 2). In an exemplary embodiment, when the optical component24is loaded into the base ring22the lens80is substantially flush with the top edge50of the base ring22.

The compression ring28is aligned above the top edge50of the base ring22and the outer surface82of the optical component24. During assembly the compression ring28is seated on the top edge50and the outer surface82of the optical component24. The compression ring28takes up any tolerance between the top cover26and the base ring22and/or optical component24when the top cover26is coupled to the base ring22.

In an exemplary embodiment, the base ring22and the top cover26include securing features142,144, respectively. The securing features142,144engage one another when the top cover26is coupled to the base ring22. The engagement between the securing features142,144secures the top cover26to the base ring22. In an exemplary embodiment, the securing features142,144allow mating and unmating of the top cover26to the base ring22. As such, the top cover26may be removed from the base ring to access the other components, such as the optical component24. As such, the optical component24maybe removed and replaced with a different type of optical component24. In the illustrated embodiment, the securing feature142constitutes a recessed track formed in the side wall40. The securing feature144constitutes a protrusion extending inward from the side wall90that is configured to be received in the recessed track to secure the top cover26to the base ring22. Alternatively, the securing feature142may constitute a protrusion extending out from the side wall40and the securing feature144may constitute a recessed track in the inner surface of the side wall90. Other types of securing features142,144may be used in alternative embodiments. For example, the securing features142,144may constitute threads on the side walls40,90that allow threaded coupling between the top cover26and the base ring22. Other examples of securing features142,144include latches, pins, fasteners, and the like that are used to secure the top cover26with respect to the base ring22.

In the illustrated embodiment, the securing features142,144define a bayonet-type connection. The securing feature142constitutes a recessed track and may be referred to hereafter as a recessed track142. The recessed track142includes a loading zone146and a mating zone148. In the loading zone146, the recessed track142extends generally vertically. In the mating zone148, the recessed track142extends generally horizontally. During assembly, the securing feature144(represented by the protrusion in the illustrated embodiment) is initially loaded into the loading zone146in a first direction, represented by arrow A, and then the securing feature144is moved in a mating direction, represented by arrow B. The top cover26may be rotated or twisted in the mating direction.

In an exemplary embodiment, the securing feature142includes a cam surface150and a locking notch152at an end of the cam surface150. The cam surface150is angled such that as the top cover26is rotated in the mating direction, the securing feature144rides along the cam surface150. As the securing feature144rides along the cam surface150, the top cover26is drawn downward onto the base ring22. For example, the top wall92is drawn towards the top edge50of the side wall40when the securing feature144is rotated along the cam surface150. As the top cover26is drawn downward, the compression ring28is compressed against the optical component24. The top cover26and the compression ring28hold the optical component24against the light engine20. The pressure on the optical component24is also transferred into the PCB60, which forces the PCB60downward against the heat sink. The pressure from the compression ring28is therefore used to increase the thermal transfer between the PCB60and the heat sink.

During assembly, the top cover26is rotated in the mating direction until the securing feature144is received in the locking notch152. The locking notch152is notched upward from the cam surface150to provide a space that receives the securing feature144. When the securing feature144is received in the locking notch152rotation of the top cover26in an unmating direction, generally opposite to the mating direction, is restricted.

FIG. 8illustrates a light module210for use in a device212(shown in phantom). The light module210generates light for the device212. The device212may be any type of lighting device, such as a light fixture. In exemplary embodiment, the device212may be a can light fixture, however, the light module210may be used with other types of lighting devices in alternative embodiments.

FIG. 9is an exploded view of the light module210. The light module210includes a light engine220, a base ring assembly222, an optical component224, and a top cover assembly226. A compression ring228is configured to be held between the top cover assembly226and the optical component224. A thermal pad may optionally coupled to the light engine220to dissipate heat from the light engine220.

The base ring assembly222includes a base ring230and a contact holder232. The contact holder232holds power contacts234that are configured to be electrically connected to the light engine220. A power connector236is configured to be coupled to the contact holder232to provide power to the light engine220. The power connector236is terminated to an end of a power cable238. In an exemplary embodiment, the power connector236is configured to be couple to the contact holder232at a separable interface. For example, the power connector236may be plugged into the base ring230and unplugged from the base ring230to mate and unmate from the contact holder232. A nonpermanent connection is made between the power connector236and the contact holder232at a power connector interface of the contact holder232. For example, a solderless connection is provided between the power connector236and the power connector interface. In the illustrated embodiment, the contact holder232constitutes a circuit board having the power contacts234terminated thereto and pads (not shown) at the power connector interface.

The base ring230includes a side wall240defining a cavity242. In the illustrated embodiment, the side wall240has a cylindrical shape defined by an inner surface244and an outer surface246. The side wall240extends between a bottom edge248and a top edge250opposite the bottom edge248. In exemplary embodiment, the side wall240has a rim252proximate to the bottom edge248. The rim252extends outward from the outer surface246. The side wall240includes an opening254therethrough that is configured to receive the power connector236. The opening254provides access to the contact holder232such that the power connector236may be coupled to the contact holder232.

The light engine220includes a printed circuit board (PCB)260having a first surface262and a second surface264. The PCB260includes a plurality of openings274extending therethrough between the first and second surfaces262,264. A thermal pad may be coupled to the second surface264to dissipate heat from the PCB260. Optionally, the thermal pad may be coupled to the second surface264using a thermally conductive epoxy or thermally conductive adhesive. Other securing means may be used to secure the thermal pad to the second surface264in alternative embodiments.

An LED266is coupled to the first surface262of the PCB260. The LED266emits light therefrom. Any number of LEDs may be provided in alternative embodiments. The LED266is electrically connected to circuitry within the PCB260and power is fed to the LED266by the PCB260. The PCB260has a plurality of power terminals268. In an exemplary embodiment, the power terminals268constitute pads provided on the first surface62. The power terminals268are configured to be engaged by corresponding power contacts234. Power is transferred from the power contacts234to the power terminals268.

In an exemplary embodiment, the light module210may include a set of light engines220including at least two different types of light engines220. The different types of light engines220differ from one another by having different lighting characteristics. For example, the different types of light engines220may have a different number of LEDs266or a different arrangement of LEDs266on the surface of the PCB260. The different types of light engines220may have different types of LEDs266, such as LEDs266that generate different colors or intensities of light. The light module210is configurable by selecting from the set of light engines220to achieve a desired light distribution.

The optical component224constitutes a reflector. The optical component224may be a different type of component in an alternative embodiment, such as a lens. In the illustrated embodiment, the reflector is manufactured from a metalized plastic body. Alternatively, the reflector may be manufactured from a metal material. The optical component224emits the light generated by the LED266. The optical component224is configured to be received in the cavity242. The optical component224includes mounting features280that interact with corresponding mounting features282of the base ring230to secure the optical component224with respect to the base ring230. Alternatively, another component, such as an optical holder may be coupled to the base ring230or the top cover assembly226to hold the optical component224with respect to the LED266. Optionally, the optical holder may be movably coupled to the base ring230or the top cover assembly226to change a relative position of the optical component224with respect to the LED266, such as to change a lighting effect of the light module210. In an exemplary embodiment, the light module210may include a set of optical components224including at least two different types of optical components224. The different types of optical components224differ from one another by having different lighting characteristics. For example, the different types of optical components224may have different lighting patterns and/or different lighting characteristics.

The compression ring228is configured to be positioned between the top cover assembly226and the optical component224. The compression ring228may be placed over the top of the optical component224prior to coupling the top cover assembly226to the base ring assembly222. The compression ring228is made from a compressible material, such as foam material, a silicone rubber material, or another type of compressible material. In an alternative embodiment, the compression ring228may be manufactured from a metal material formed as a spring, such as a wave spring washer, that may be placed between the top cover assembly226and the optical component224. The compression ring228takes up tolerances between the optical component224and the top cover assembly226when the top cover assembly226is coupled to the base ring230.

The top cover assembly226includes a collar288having side wall290and a top wall292. The top wall292has an opening294therethrough. The opening294is aligned above the optical component224and allows light emitted by the optical component224to be emitted from the light module210. The collar288is configured to be coupled to the base ring230during assembly of the light module210. In an exemplary embodiment, the collar288is rotatably coupled to the base ring230, however the top cover may be coupled to the base ring230in a different manner using different securing means in alternative embodiments. During assembly, the collar288is loaded onto the base ring230and rotated to a locked position. The collar288holds the optical component224in the cavity242. The compression ring228is received between the collar288and optical component224to take up any tolerance between the collar288and the optical component224.

In an exemplary embodiment, the base ring230and the collar288include securing features300,302, respectively. The securing features300,302engage one another when the collar288is coupled to the base ring230. The engagement between the securing features300,302secures the collar288to the base ring230. In an exemplary embodiment, the securing features300,302allow mating and unmating of the collar288with respect to the base ring230. As such, the collar288may be removed from the base ring230to access the other components, such as the optical component224. As such, the optical component224maybe removed and replaced with a different type of optical component224.

In the illustrated embodiment, the securing features300,302define a bayonet-type connection. The securing feature300constitutes a recessed track formed in the side wall240. The securing feature302constitutes a protrusion extending inward from the side wall290that is configured to be received in the recessed track to secure the collar288to the base ring230. Alternatively, the securing feature300may constitute a protrusion extending out from the side wall240and the securing feature302may constitute a recessed track in the inner surface of the side wall290. Other types of securing features300,302may be used in alternative embodiments. For example, the securing features300,302may constitute threads on the side walls240,290that allow threaded coupling between the collar288and the base ring230. Other examples of securing features300,302include latches, pins, fasteners, and the like that are used to secure the collar288with respect to the base ring230. In an exemplary embodiment, the securing feature300includes a cam surface304and a locking notch306at an end of the cam surface304. During assembly, the collar288is rotated in a mating direction along the cam surface304until the securing feature302is received in the locking notch306.

FIG. 10is a bottom perspective view of the contact holder232. The power contacts234are provided on the bottom surface of the circuit board of the contact holder232. An electrical component, such as a temperature sensor, is mounted to the circuit board. Other types of electrical components may be mounted to the circuit board, such as a microprocessor, to control the power scheme for the light module210. A temperature sensor may be coupled to the circuit board of the contact holder232.

FIG. 11is a partial sectional view of the light module210. During assembly, the light engine220is coupled to the base ring230by loading the PCB260through the bottom edge248of the base ring230. The first surface262faces upward such that the LED266is exposed within the cavity242. Fasteners296secure the contact holder232to the base ring230. The fasteners296are used to secure the base ring assembly222to another structure, such as a heat sink or another structure within the fixture212(shown inFIG. 8). The optical component224is then mounted to the base ring230above the LED266. The compression ring228is loaded onto the optical component224and then the collar288is mounted to the base ring230.