Abstract:
A lighting device includes a support structure formed from a thermally conductive material such as aluminum. The support structure or extrusion has a channel for receiving and retaining a circuit board with a plurality of light emitting diodes (LEDs) disposed thereon. One or more fins adapted for dissipating heat produced by the LEDs may be disposed on the support structure. The support structure may also include one or more retaining members for retaining one or more optical elements in relation to the LEDs and a support tray for holding a power supply.

Description:
CLAIM OF PRIORITY 
       [0001]    This application claims priority to U.S. Provisional Patent Application, Ser. No. 61/252,931, filed Oct. 19, 2009. 
     
    
     TECHNICAL FIELD 
       [0002]    The disclosure relates to, among other things, an LED lighting device and system, including LED lighting systems that can be cost effective, modular, and very flexible from a design standpoint. 
       BACKGROUND 
       [0003]    LED lighting systems have been developed for general illumination applications, and LED conversions have been introduced to replace existing types of illumination. However, such systems have principally been focused on the replacement of incandescent or high intensity discharge (HID) sources with white LEDs. 
         [0004]    Current industry practices commonly employ fluorescent tubes as a light source for illumination. Fluorescent bulbs are generally available in various standard lengths, sizes, power output, and color temperature. The familiar bulbs typically include standard pin connectors provided at each end that provide for the attachment and replacement of a tube without the need for tooling. Such bulbs typically have a finite life based on hours of use. They also house consumable products, which can lead to a loss of light output over time. Moreover, many conventional bulbs contain mercury as a means for creating a broadband color spectra. Such tubes are also commonly made of glass—a material that is not tolerant to impact. 
         [0005]    Solid state replacements for various types of diffuse fluorescent sources typically requires the use of many LEDs in a line and specialized optics to generate the desired beam pattern. Most lighting system will include a light source, a lens, a power source, and some type of housing to protect the assemblage of components. The uniqueness of a lighting system can be driven by the uniqueness in the specifically intended lighting task. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    Embodiments of the invention are disclosed in the included drawing figures and illustrations. It is understood that the illustrated embodiments are not intended to limit the scope of the invention to the specific embodiments disclosed. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention. 
           [0007]      FIG. 1  illustrates a cross sectional view of an embodiment of a lighting device in accordance with teachings of the present disclosure; 
           [0008]      FIG. 2  illustrates a cross sectional view of another embodiment of a lighting device in accordance with teachings of the present disclosure, the device including multiple optical elements to provide separately directed lighting; 
           [0009]      FIG. 3  illustrates a cross sectional view of yet another embodiment of a lighting device in accordance with teachings of the present disclosure, the device including an integral housing; 
           [0010]      FIG. 4  illustrates a cross sectional view of a further embodiment of a lighting device in accordance with teachings of the present disclosure, the device including an attached housing; 
           [0011]      FIG. 5  illustrates a cross sectional view of still a further embodiment of a lighting device in accordance with teachings of the present disclosure, the device having a double-ended design; 
           [0012]      FIG. 6  illustrates yet a further embodiment of a lighting device in accordance with teachings of the present disclosure, the device including multiple reflective surfaces to provide indirect lighting; 
           [0013]      FIG. 7  illustrates an isometric view of an embodiment of a device in accordance with teachings of the present disclosure; 
           [0014]      FIG. 8  illustrates an isometric view of an embodiment of a device in accordance with teachings of the present disclosure, the device including a housing; 
           [0015]      FIG. 9  illustrates an isometric view of an embodiment of a device in accordance with teachings of the present disclosure, the device including multiple optical elements and multiple reflective surfaces; 
           [0016]      FIG. 10  illustrates a cross sectional view of an embodiment of a device in accordance with teachings of the present disclosure, the device including sealed optical lenses; 
           [0017]      FIG. 11  illustrates a cross sectional view of another embodiment of a device in accordance with teachings of the present disclosure, the device including multiple lenses; 
           [0018]      FIG. 12  illustrates a cross sectional view of an embodiment of a device, the device including a power supply and mounting features; 
           [0019]      FIG. 13  illustrates a side view of an embodiment of a cover of the type that may be associated with the device shown in  FIG. 11 ; 
           [0020]      FIG. 14  illustrates a cross sectional view of an embodiment of a device, the device depicting an LED circuit board, an LED, a power supply, connective wiring, and an attachment feature; and 
           [0021]      FIG. 15  illustrates a cross sectional view of an alternative embodiment of an attachment feature. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    As generally illustrated in  FIG. 1 , an embodiment of a device  10  includes, inter alia, an LED  20 , an optical element  30 , and a support structure  40 . Embodiments of the device can also include a plurality of LEDs that may, if desired, be provided as part of, or in the form of, a printed circuit board (PCB) array or LED strip  50 . In a simple embodiment, a linear string of white LEDs  20  may be mounted to a PCB. The optical element  30  may, without limitation, comprise a round rod. Moreover, the optical element  30  may be clear, translucent, or colored. In embodiments, the optical element may be comprised of, without limitation, acrylic or glass. 
         [0023]    The device may further include a plurality of protrusions or fins  60  that may be configured to provide a measure of thermal control, such as heat dissipation. By taking into account the power or heat associated with the LED  20  or LED strip  50 , the protrusions or fins  60  can be configured to adequately handle the associated heat transfer. That is, the protrusion or fins  60  may be configured to assist in pulling heat from individual LEDs and to spread the heat laterally. 
         [0024]    In embodiments, the device includes a plurality of LEDs  20 . The LEDs may be white or colored. Further, some embodiments may employ a multi-color chip (e.g., on comprising RGB LEDs) that permits the device to effectively emit almost any desired color of light. In a particular embodiment, the centers of the LEDs  20  may be arranged in a line. The spacing and cumulative flux of the LEDs may be used to establish the total illumination supplied to an area or surface to be illuminated. It is noted that a channel or opening may be created in a portion of the support structure to permit the LEDs (which may be on a PCB) to be positioned sufficiently precisely relative to the optical element. 
         [0025]    As generally illustrated in  FIG. 1 , the support structure  40  can be configured to hold or retain optical element  30 . In the illustrated embodiment, light emitted by the LED may be transmitted through an opening  41  associated with the support structure  40  such as that generally illustrated by arrow  70  in  FIG. 1 . The dispersion (e.g., angle) of the light  21  emitted by the LED  20  and passing through the optical element  30  may be controlled by (a) the distance between the LED  20  and the optical element  30 , and/or (b) modification of the opening  70  associated with the support structure. That is, the width of the pattern of light to be delivered to a surface or area may be determined by the shape of the optical element (e.g., transparent light rod), the area of optical element exposed at the light exit, and the position of the optical element in relation to the line of LEDs. A narrow opening in connection with an associated support structure or outer housing will create a narrow beam of light, a wider opening will allow a wider beam of light. The closer the optical element  30  is positioned to the LEDs  20 , the wider the beam pattern; the further away, the narrower the beam pattern. Beyond a certain point, the beam becomes unfocused. Notably, for a number of embodiments, the LED  20  will be spaced very closely to the optical element  30 , for example and without limitation, within about 0.010 to 0.020 inches. 
         [0026]    Additionally, without limitation, in an embodiment the support structure  40  may include opposing support segments or portions, e.g.,  42  and  44 , that at least in part form a receiving area there between into which the optical element may be received. In an embodiment in which the optical element  30  comprises a rod, the opposing support segments may provide a receiving area into which the rod may, for instance, be slid into and retained. 
         [0027]    Further, in embodiments, the support structure  40 , which may include one or more protrusions or fins  60 , may be formed integrally, e.g., via an extrusion process. This can permit the process of forming support structures to be fairly continuous and efficient from a production standpoint. In an embodiment, the support structure  40  may be, for example, comprised of aluminum. However, various other materials that are suitable for the intended environment and/or associated production techniques may be employed. It is noted that the disclosed structure, and the associated forms of processing—e.g., extrusion, supports both the array/strip  50  with the LEDs  20  and consequently provides and maintains a consistent relative positioning (which can be very important) between the LED and the optical element. The structure can further provide an integrated thermal control and/or protective structure for the device. 
         [0028]      FIG. 2  generally illustrates a cross sectional view of another embodiment of a lighting device that includes multiple optical elements. As generally depicted, the multiple optical elements  30  may be provided in a single, integral support structure  40  that is configured to provide separately directed lighting. In an embodiment, as shown, the support structure  40  may include an extension  80 , which can be commonly formed with the support structure  40 , and may be configured to support the device  10 . 
         [0029]    Yet another embodiment of a lighting device  10  is illustrated in  FIG. 3 . The illustrated device  10  includes a number of features in common with prior  FIGS. 1 and 2 , and additionally includes, inter alia, a power supply  90  (shown in broken lines) and a housing  100 . While elements of a power supply or power source may be included remotely from the device, if desired and included, at least a portion of a power supply  90  can be provided in a given segment within the device—for example upon or within a power supply support tray  110 . As generally illustrated, the housing  100  and/or a power supply support tray  110  may, if desired, be formed integrally with the support structure  40 . If included the support tray  110  may also be configured to, in addition to any protrusions or fins  60 , serve as an instrument for thermal management. 
         [0030]    Also as generally illustrated, the device may optionally provide a connection opening  120 , which may be in the form of an aperture or an “open” portion or segment of the housing  100  which may be used in connection with a means for connection or support. In the embodiment illustrated, the means for connection or support comprises a hanger  130  (e.g., a “T”-hanger) that can be inserted within the housing  100  and may be used to, at least in part, provide external support for the device  10 . If desired, the hanger  130  may include threading or other connection features (not show) at or about portion  140 . The device  10  may further additionally include an aperture or receiving opening  150 . The aperture or receiving opening  150  may, if desired, also be formed integrally in connection with the support structure  40 , and may be employed to, for example, secure an end cap (not shown). Moreover, as generally illustrated in  FIG. 3 , the device  10  may further include a smaller additional light  150 . The additional light  150  may be colored and may, for example, remain on for safety when the other LEDs are inactive. 
         [0031]      FIG. 4  illustrates a cross sectional view of a further embodiment of a lighting device  10 . The illustrated device  10  includes, inter alia, a separately provided attached housing  100 . The support structure  40  may include a means for receiving or connecting to a separate housing  100 . For example, as generally illustrated, the support structure  40  may comprise a receiving portion  160  that is configured to attach or connect with portions of a housing  100 . For some embodiments, the support structure  40  may comprise a separately extruded component and the outer housing  100  may essentially be or conform to a standard stock configuration. 
         [0032]    In addition to the depiction of a form of optional attachment or connection opening  120 ,  FIG. 4  also depicts an alternate configuration of protrusions or fins  60 . However, it is noted that various alternative configurations of the illustrated elements are also contemplated by the present disclosure, and the disclosure should not be construed as being limited to the specific configurations that are illustrated. 
         [0033]      FIG. 5  generally illustrates a cross sectional view of still a further embodiment of a lighting device  10  in accordance with teachings of the present disclosure. In the illustrated embodiment, the device  10  includes two optical elements  30  that are provided in a double-ended or back-to-back configuration. Such a configuration can permit light to be directed in multiple directions. The device can be configured to emit light, in this instance, up and down simultaneously, or separately in either direction, as controllably desired. The disclosure is of course not limited to the depicted configuration and the device may instead be structured to provide the illustrated optical elements at different relative angular positions and/or to include additional optical elements to provide for further directional lighting options. 
         [0034]      FIG. 6  illustrates yet a further embodiment of a lighting device in accordance with teachings of the present disclosure. As generally illustrated the device  10 , shown without a housing (which is optional), may include a plurality of optical elements  30  and a plurality of reflective surfaces  170  that can be configured to provide indirect lighting. As with other embodiments, the power source (not shown), may be provided remotely and can simply be connected (via wiring) to associated LEDs. In an embodiment, such as that shown in  FIG. 6 , one or more reflective surfaces  170  may be formed integrally with the support structure  40 . To facilitate reflection—such as illustrated by beam  180 —the reflective surfaces  170  may be painted (e.g., white or silver); the reflective surfaces may be comprised of a material that provides a sufficient/high degree of reflection (e.g., an aluminized surface, such as a diffused anodized silver surface); or may simply be plated with a material providing sufficient degree of reflection. 
         [0035]    Turning to subsequent figures, additional isometric embodiments are shown.  FIG. 7  generally illustrates an isometric view of an embodiment of a device  10  including an optical element  30  and support structure  40 .  FIG. 8  generally illustrates an isometric view of a device that is similar to the embodiment shown in  FIG. 4  and includes a housing  100 .  FIG. 9  illustrates an isometric view of an embodiment of a device  10  that includes multiple optical elements  30  and multiple reflective surfaces  170 . 
         [0036]      FIG. 10  illustrates a cross sectional view of an embodiment of a device  10  that includes one or more optical lenses  190 —shown in the figure in a dual-end configuration. The illustrated device  10  additionally includes a plurality of LED strips  50 , a power supply  90 , and a housing  100 . In embodiments, one or more optical lenses may be sealed and/or may be configured to modify the emitted light. Such lenses  190  may, without limitation, be comprised of an extruded acrylic and may, if desired, be secured, at least in part, by an adhesive. It is noted that the invention is not limited to the configurations of lenses disclosed herein and other lens configurations are anticipated. It is readily understood that others lens types, that if desired may be molded or extruded, may provide various beam patterns. For instance, a round optical element may provide relatively little lateral control of beam spread. In embodiments, the inclusion of a molded lens with refractive optics may limit the spread of light, which may be desirable for some task lighting situations. Further, if desired, a lens  190  may be configured to provide various optical characteristics, e.g., total internal reflection (TIR), and may if desired serve to straighten light beams out prior to externally dispersion. Housing  100  may be configured to include one or more recesses or channels  200  that may be configured to receive and/or secure a portion of an optical lens  190 . As generally illustrated, device  10  may also include one or more mounting features  210  (such as a threaded or unthreaded aperture or other receiving means) that may be used to secure an end cap or end plate (not shown). 
         [0037]      FIG. 11  illustrates a cross sectional view of another embodiment of a device  10  that includes multiple optical lenses  190 . As generally illustrated, one or more optical lens  190   a  may be received and retained within a receiving formation  220  that is connected to or formed integrally with the support structure and/or housing. For example, some extruded support structures and/or housings may include a channel into which a lens may be inserted and, depending upon the configuration, additional fasteners may not be needed to retain the lens. 
         [0038]      FIG. 12  generally illustrates a cross sectional view of a device  10 . The illustrated embodiment is shown including a power supply  90  and a plurality of mounting features  210 . It is noted that device  10  could, if desired, include an optical lens that extends over the optical element  30  to seal the optical element and/or modify the dispersion of light.  FIG. 13  illustrates an embodiment of an end plate or cover  210  that may be connected to a device of the type shown in  FIG. 12 . In the illustrated embodiment, end plate or cover  210  includes a formation that may, if desired, be used to support or mount the device. In embodiments, optical elements are retained in channels formed in an extruded support structure and end covers are secured at each end of the support structure. Moreover, if desired, features for screw retention can be provided in the extruded support structure. 
         [0039]      FIGS. 14 and 15  are cross sectional views of embodiments of a device that depict an LED circuit board  50 , an LED  20 , a power supply  90 , connective wiring  91 , and attachment features  92 . The figures generally illustrate, without limitation, a configuration for providing power to and within the various components of a device. 
         [0040]    It is understood that the invention is not limited to the specific disclosed embodiments. Some variations may, without limitation, provide the following: 
         [0041]    different diameter optical elements (e.g., rods) 
         [0042]    different shaped optical elements 
         [0043]    additional optical features on or in connection with the optical elements, such as lenses—which may provide further light control or effect 
         [0044]    differing LEDs for both light output, color, and angular beam spread 
         [0045]    different colored LEDs for decorative or accent lighting either in the main or supplemental emitter 
         [0046]    additional emitters in conjunction with a primary emitter 
         [0047]    additional light emitters projecting in different directions 
         [0048]    additional light optical elements projecting in either white, colored, or multi-colored light based on the LEDs used 
         [0049]    variations associated with the housing construction, such as: being extruded in conjunction with the other light emitting components of the device, utilizing a separate extruded or formed tube made from any material that can be suitably formed and utilized, and finishing the housing with a commercially available coating process 
         [0050]    when a preformed housing is used, a slot created axially along the length of the housing that will then slide into a pair of opposed slots in an extruded section 
         [0051]    the housing can provide various decorative and/or protective elements to the device or assembly. 
         [0052]    The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and various modifications and variations are possible in light of the above teachings. The embodiments were chosen and described in order to explain the principles of the invention and its practical application, to thereby enable others skilled in the art to utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.