Abstract:
A lighting device having a support module supporting LEDs and having an outer perimeter defining a curved portion, and a housing with an inner surface having a curved portion configured to receive the curved portion of the support module to enable the disk to be aimed, while the curved portions of the disk and housing remain in contact. Optional adjustment means facilitate aiming of the support module without the need to open the sealed LED module.

Description:
RELATED APPLICATION 
     This application is a divisional application of U.S. patent application Ser. No. 13/396,852 filed Feb. 15, 2012, now pending, which is a continuation application of U.S. patent application Ser. No. 12/245,116 filed Oct. 3, 2008, now U.S. Pat. No. 8,152,334, which claims priority to U.S. Provisional Patent Application Ser. No. 61/095,159, filed 8 Sep. 2008, the entire content of which is incorporated herein by reference. A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 
    
    
     BACKGROUND 
     Light emitting diodes (“LEDs”) are increasingly being used in applications where incandescent or fluorescent lights had previously being used. There are inground lights that are currently used for various lighting applications such as landscape and outdoor lighting. Typical previously existing inground lights, even those employing LEDs, are not optimized for use of LEDs and concomitant thermal management issue. For, example, these devices can suffer from thermal issues such as poor heat management and heat retention due to, e.g., poor conduction and/or convection. Among other things, such thermal management issues can lead to shortened light service life. 
     The issues of aiming inground light assemblies are typically addressed by opening the sealed light structure and then adjusting the base/lighting assembly manually with the unit open, e.g., to the elements and while being susceptible to dirt, water intrusion, etc. 
     What is desirable, therefore, are devices and techniques that address such limitations described for the prior art. 
     SUMMARY 
     Embodiments of the present disclosure address the shortcomings previously described for the prior art. Exemplary embodiments of the present disclosure include inground LED lighting units/assemblies that can be aimed by external adjustment devices/features/means without the need to open the sealed LED module. Heat from the LEDs and/or LED mounting assembly can be transferred to the outside air or internal heat conducting structures while the module is tilted, e.g., up to 15 degrees or more, from vertical. Use of materials (e.g., thermally conductive grease and/or bronze alloys) with high thermal conductivity can facilitate thermal management. The thermal dissipation/management afforded by the designs of embodiments according to the present disclosure can allow for an increase of the LED useful service life. 
     The sealing of the inground light unit can preclude/minimize the chance of an end user (e.g., service technician) from causing the unit to leak and thereby cause premature failure. Additionally, the modular structure of the inground LED light can allow for upgrade/renewal of associated electronics with only minor disassembly. 
     Moreover, embodiments of the present disclosure can provide increased service life for inground modules and/or LEDs in use by superior/improved thermal management, e.g., by the selection and use of thermally conducting materials such as bronze bushings or thermally conductive greaser, and/or the presence of an annular gap (doughnut) between the outer housing and the surrounding concrete/cement, thus providing a desired space/volume for air floor (and convective cooling). 
     Other features and advantages of the present disclosure will be understood upon reading and understanding the detailed description of exemplary embodiments, described herein, in conjunction with reference to the drawings. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Aspects of the disclosure may be more fully understood from the following description when read together with the accompanying drawings, which are to be regarded as illustrative in nature, and not as limiting. The drawings are not necessarily to scale, emphasis instead being placed on the principles of the disclosure. In the drawings: 
         FIG. 1  depicts various views of an inground LED light, in accordance with exemplary embodiments of the present disclosure; 
         FIG. 2  includes  FIGS. 2A-2F , which depict a top view and various cross section views, respectively, of an exemplary embodiment of the present disclosure; and 
     
    
    
     While certain embodiments depicted in the drawings, one skilled in the art will appreciate that the embodiments depicted are illustrative and that variations of those shown, as well as other embodiments described herein, may be envisioned and practiced within the scope of the present disclosure. 
     DETAILED DESCRIPTION 
     Embodiments of the present disclosure include lighting modules that can include multiple LEDs in a sealed housing suitable for use in inground applications. The lighting assemblies can be aimed by external adjustment devices/features/means without the need to open the sealed lighting module. The lighting modules additionally are optimized for thermal management of heat produced from the LEDs and related structure(s). For example, by use of heat conducting materials, heat from the LEDs and/or LED mounting assembly can be transferred to the outside air while the module is tilted, e.g., up to 25 degrees, or more, from vertical. The modular structure of the inground LED light assemblies can allow for upgrade/renewal of associated electronics with only minor disassembly. Moreover, the thermal dissipation/management afforded by the designs of embodiments can allow for an increase of the LED useful service life. 
     Embodiments of the present disclosure, e.g., inground LED lights and lighting modules, can be used to illuminate a desired area, e.g., including but not limited to, structures such as buildings, signs, landscape materials, flag poles, interior architectural features, product displays, automobiles, etc., and the like. Embodiments of an inground LED light (product) can be pre-cast in concrete, or directly placed in soil, etc. An outer (e.g., rough-in) housing section/portion of the light assemblies can be installed and connected to a conduit system and appropriate power supply/cables, e.g., one with 120 V power of suitable current. 
       FIG. 1  includes  FIGS. 1A-1D , which depict top, first section, bottom and second section views, respectively, of an inground LED light assembly  100 , in accordance with exemplary embodiments of the present disclosure. 
     Referring to  FIG. 1A , the light assembly  100  includes a support  110  on which a plurality of LEDs  112  are positioned on a support surface  114  (e.g., a printed circuit board). The support  110  can be received by a first (inner) housing  120  in such a way that the support  110  can be moved to reorient the optical output from the LEDs  112 . As shown the interior surface of housing  120  can have a partially spherical (curved) portion that can mate with a corresponding spherical (curved) portion of the support  110 . The curved portion of the first housing has an upper end and a lower end. The lower end is located radially inward of the upper end such that the curved portion of the first housing opens upward. 
     As shown in  FIG. 1B , which shows a section view along cutting plane  1 - 1  in  FIG. 1A , the inner housing  120  can be positioned within a second (outer) housing  130 . A driver and/or power supply (driver/power supply)  116  can be positioned within the first housing  120 . A lens  132  can be held by a lens frame  136 , which itself can be held within the second housing  130 , e.g., by suitable fasteners including but not limited to screws  138  as shown. The lens  132  encloses the support module  110  within the first housing  120  such that the curved portion of the first housing  120  opens upward toward the lens  132 . Also, within the second housing a junction box  140  can be present and connected to the driver/power supply  116  of the first housing  120  by suitable wiring and connector  144 . 
       FIG. 1C  depicts a bottom view of the light assembly  100 , with the second housing  130 , area of the junction box  140  and apertures  150  for electrical connections shown. 
       FIG. 1D  depicts a cross section view similar to  FIG. 1B  in which support  110  is shown oriented (e.g., aimed) in a different direction than as shown for  FIG. 1B . In the view, the curved (e.g., spherical) outer surface of the support  110  is shown as remaining in contact with the curved (e.g., spherical) surface of the inner housing  120 , while the direction of the optical output (optical axis) of the LEDs  112  are directed at an angle  1  from the longitudinal axis  2  of the light assembly  100 . To facilitate optimal heat transfer characteristics, thermally conductive grease may be used between the spherical surface of the support  110  and the corresponding spherical surface of the first (inner) housing  120 . As shown, in  FIG. 1 , the driver/power supply  116  (which can be encapsulated in epoxy or other materials as desired) can be located as desired in the assembly, e.g., adjacent to a wall of the inner housing  120 . It should be noted that the driver/power supply  116  can be implemented on a two-sided circuit board with alternate circuits/features selectable on each of the two sides. Such two-sided functionality can allow the same driver/power supply  116  board to be used for multiple applications (potentially reducing manufacturing costs). The driver/power supply  116  can be placed in other locations, as for example the embodiment shown and described for  FIG. 2 . 
       FIG. 2  includes  FIGS. 2A-2F , which depict a top view and various cross section views, respectively, of an exemplary embodiment of a lighting assembly (or device)  200  according to the present disclosure. 
       FIG. 2A  depicts a top view of an inground light assembly  200 . In the top view shown, a housing  230  receives a lens frame  234  that holds a lens  232 . The lens functions to pass light from a number of light sources (e.g., LEDs) located within the device  200 . As will be described in greater detail below, the light sources (not shown in  FIG. 2A ) can be supported on a support (module) that is held by another housing in such a way that the orientation of the support is adjustable (or aimable) by an adjustment assembly (or equivalently, a means for adjusting). A representative aiming (orientation) adjustment screw  250  is shown in  FIG. 2A . 
       FIG. 2B  depicts a cross section view of light assembly  200  along section line  1 - 1 . Support  210  is configured and arranged to support one or more LEDs  212  on a supporting surface (e.g., printed circuit board)  214 . Corresponding optics/optical elements  216  can be present. The support  210  (alternatively called “support module”  210 ) can be received by a first (inner) housing  220  in such a way that the support  210  can be moved to reorient the optical output from the LEDs  212 . As shown the interior surface of housing  220  can have a partially spherical (curved) portion that can mate with a corresponding outer spherical (curved) portion of the support  210 . An adjustment assembly/means (e.g., as shown in  FIG. 2E ) can be present to reorient the support and LEDs without the need of disassembly of the light assembly  200 . As with the embodiment of  FIG. 1 , to facilitate optimal heat transfer characteristics, thermally conductive grease may be used between the spherical surface of the support  210  and the corresponding spherical surface of the first (inner) housing  220 . 
       FIG. 2C  depicts a cross section view of light assembly  200  along section line  2 - 2 . The view in  FIG. 2C  is normal to the view in  FIG. 2B . 
       FIG. 2D  depicts a cross section view of light assembly  200  along section line  3 - 3 , in which the section details of an adjustment assembly/means are visible. Included are an aiming adjustment screw  250 , wormgear  252 , and wormgear retainer pin  258 . Pivots (e.g., pivot screws)  260  are shown, which allow the support module  210  to rotate about an axis (between the two screws). In alternate embodiments, the support module  210  can be aimed over a solid angle for increased illumination area coverage; for such, solid angle adjustment, the inner housing  220  can be rotatable (about the longitudinal axis of the outer housing). Alternately, the support module can be rotatable (about the longitudinal axis of the outer housing) in which can an alternate adjustment means/assembly would be required. In exemplary embodiments, a second pair of pivot screws configured with an intermediate housing or housing portion between the inner housing  220  and outer housing  230  could be utilized so as to provide a functional gimbal for aiming the support module (with the light optical axis) over a solid angle. The intermediate housing could have an inner and outer curved (e.g., spherical surface to mate with the corresponding surfaces of the inner  220  and outer  230  housings. 
       FIG. 2E  depicts a cross section view of light assembly  200  along section line  4 - 4 . As shown, the aiming adjustment screw  250  can be exposed to an outer surface of the second housing  230  so that the orientation of the support module and LEDs can be adjusted without requiring disassembly of the assembly  200 . The adjustment screw  250  (e.g., made from 304 stainless steel) can be knurled to retain a wormgear  252 . O-rings  254  and a retaining ring  256  can be present, as shown. 
       FIG. 2F  depicts a cross section view of light assembly  200  along section line  5 - 5 .  FIG. 2F  shows the wormgear  252  from another perspective. 
     In exemplary embodiments, as indicated in  FIG. 2 , a housing (a/k/a a finishing section) of the lighting housing, containing a LED support (e.g., which may be referred to as a “SSL19” in reference to solid state lighting employing 19 LEDs), can be connected via a suitable connection, e.g., IP67 submersible connector and placed into an outer housing (rough-in housing, or “RIH”) as pre-cast in concrete. Suitable connectors of desired number and type, e.g., three screws, can connect the outer housing to the RIH. The LEDs of the unit/assembly can then be aimed in a desired orientation/direction, e.g., by rotating an adjustment screw/knob with a suitable tool such as a screw driver or Allen wrench, or manually. 
     In exemplary embodiments of device  200 , the LEDs can be Nichia NS6 white LEDs (see, e.g.,  FIG. 3 ) configured to nominally operate on 350 mA, the lens frame can be made of bronze alloy, the optics can be made of molded acrylic, the lens can be made of low-iron tempered glass, the lens gasket can be made of molded silicon, the second (outer) housing can be made of SMC polyester composite, the support  210  can be made of bronze alloy (e.g., with 5-15% copper), the seal  246  can be a gland type cord seal, the driver/power supply can be encapsulate din an epoxy encapsulant, the gasket  248  can be made from die cut silicon, the cover for the junction box can be made of RIH SMC polyester composite, the inner housing  220  can be made of bronze alloy, and gasket  238  can be made of die cut silicon. It should be noted that all materials indicated for the drawings are examples that may be used for exemplary embodiments; other materials may be used within the scope of the present disclosure. 
     With continued reference to  FIG. 2 , cross section views of the shape of a number of optics/optical element  216  of a suitable material, e.g., clear acrylic or PMMA, are shown in  FIGS. 2B-2D . One skilled in the art will appreciate, however, that other shapes and configurations of the optics  216  may also (or in the alternative) be used, e.g., any type of suitable cross section, such as spherical, hyperbolic, parabolic, combinations of such, etc.; moreover, reflective elements could also (or in the alternative) be used for guiding light away from the one or more LEDs  212 . 
     An exemplary embodiment of an optic (optical element) used for dispersion/light shaping of LEDs (e.g., as shown by  216  in  FIG. 2 ) in accordance with the present disclosure may be referred to herein by the part number “SAC-002,” though this is merely for convenience. This exemplary embodiment comprised an SAC-002 molded with acrylite d120 from DMB Relfex Lighting Solutions. Where used with a Nichia NS6 white LED with half angle divergence of 14°, PEAK curve type, PMMA lens material and an operating temperature of −40° C. to +90° C., the SAC-002 produced a half angle divergence efficiency of 39% and a collection efficiency of 91%; an output distribution provided 8.9× multiplicator rate and had a maximum intensity of 188 Cd; and provided the following illuminance values: 179 Lux at 1.0 meters; 45 Lux at 2.0 meters; 20 Lux at 3.0 meters. 
     Accordingly, embodiments of the present disclosure can provide one or more advantages relative to prior inground lighting apparatus and techniques. For example, embodiments can provide equivalent performance to prior 39 Watt metal halide lamps in 15 fixed spot or 60 fixed flood distribution options. Embodiments may provide for 180 rotation of beam and/or 0-15 tilt angle from vertical. 
     Further, exemplary embodiments can provide equivalent performance to 100 W Metal Halide lamps with 10-25 variable spot, 30-60 variable flood, asymmetric wall wash (“AWW”), and/or superior wall wash (“SPW”) distribution options. Exemplary embodiments may provide up to 360 rotation of beam (or multiple rotations), and/or 0-25 (or more) tilt angle from vertical. Furthermore, tilt and rotation can be adjustable without the need to open any housing. And, embodiments can offer the ability to aim the LEDs (and resulting beam) without a main power supply being on. Any suitable LEDs can be used for embodiments according to the present disclosure. Such can include, but are not limited to, LEDs have a color temperature over a range from about 3000 to 6000 degrees K, e.g., 5000 degrees K. Each electrical component/part of devices/assemblies described herein can be water-proofed or sealed to prevent damage by water/moisture or other liquids. 
     While certain embodiments have been described herein, it will be understood by one skilled in the art that the methods, systems, and apparatus of the present disclosure may be embodied in other specific forms without departing from the spirit thereof. 
     Accordingly, the embodiments described herein, and as claimed in the attached claims, are to be considered in all respects as illustrative of the present disclosure and not restrictive.