Patent Publication Number: US-9845927-B2

Title: Modular LED lighting system

Description:
FIELD OF THE DISCLOSURE 
     This invention generally relates to lighting systems, and more particularly, to a modular LED lighting system. 
     BACKGROUND 
     The background information is believed, at the time of the filing of this patent application, to adequately provide background information for this patent application. However, the background information may not be completely applicable to the claims as originally filed in this patent application, as amended during prosecution of this patent application, and as ultimately allowed in any patent issuing from this patent application. Therefore, any statements made relating to the background information are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner. 
     Fluorescent light fixtures, such as strip and troffer light fixtures, have typically been installed to provide general lighting of large indoor spaces. For example, fluorescent light fixtures may include troffers that may be stem or pendant mounted or suspended from a ceiling. 
     Typically, such fluorescent fixtures may include a channel in the form of an inverted troffer, with the channel being attached to, or suspended from, a structure. Lamp holders or sockets are typically attached to the channel or troffer. A ballast is attached within the troffer and wiring attaches the ballast to the lamp holders. Power is supplied to the ballast by wiring brought into the troffer through the top or end of the channel. A ballast cover is used to cover the ballast and wiring. Linear fluorescent lamps are then placed in the lamp holders for operation of the fixture. The lamps may be left bare or covered, with a lens for example, for providing light to the space below. Because of their low cost and utilitarian use, fluorescent strip light fixtures are currently installed in abundance. For example, typical uses include warehouses, retail stores, such as grocery, drug, and department stores, where the fixtures are commonly mounted in continuous rows. 
     Since the introduction of the fluorescent lamp at the 1939 World Fair, fluorescent lighting technology has greatly advanced. For example, over the years, lamp and ballast manufacturers have developed fluorescent lamp-ballast systems with improved efficiencies. More recently, light emitting diode (LED) lamps have been developed. An LED lamp is a solid-state lamp that uses LEDs as the source of light. An LED may comprise a conventional semiconductor light emitting diode or an organic or polymeric light emitting diode. LED lamps may have one or more advantages over fluorescent lamps, for example, LED lamps do not contain mercury, they may turn on more instantaneously, they may have a longer service life, and they may have a greater efficiency. 
     It may be desired to provide advantages of LEDs to lighting systems. However, it may be difficult to provide an LED lighting system that may be tailored to a desired application. Thus, there is a need for modular LED lighting systems, kits, and methods that may provide a desired arrangement of LED lights in an LED lighting system. 
     SUMMARY 
     In at least one aspect of the present disclosure, a modular LED lighting system is disclosed. The modular LED lighting system comprises at least one LED lamp housing configured to house and hold at least one longitudinally extending LED lamp or an array of LEDs mounted inside the lamp housing and electrically connect the at least one longitudinally extending LED lamp or the array of LEDs to a power source. The LED lamp housing comprises two substantially parallel longitudinally extending sidewalls, each sidewall being at least as long as the at least one longitudinally extending LED lamp or the array of LEDs. Two substantially parallel end walls extend from edges of the sidewalls to form an LED lamp housing with a rectangular bottom light opening. Each of the sidewalls and each of the end walls comprise a flange extending outwardly from a perimeter of the light opening, the flange being configured for mounting the modular LED lamp on a ceiling suspension grid. An abutting surface extends upwardly from the flange and is configured for abutting each of the at least one LED lamp housings with an adjacent LED lamp housing, in the modular LED lighting system. 
     In at least one other aspect of the present disclosure, a modular LED lighting system is disclosed. The modular LED lighting system comprises at least one LED lamp housing, wherein the at least one LED lamp housing is configured to house and hold at least one longitudinally extending LED lamp or an array of LEDs mounted inside the lamp housing and electrically connect the at least one longitudinally extending LED lamp or the array of LEDs to a power source. The LED lamp housing comprises two substantially parallel longitudinally extending sidewalls, each sidewall being at least as long as the at least one longitudinally extending LED lamp or the array of LEDs. Two substantially parallel end walls extend from edges of the sidewalls and form an LED lamp housing with a rectangular lower light opening. Each of the sidewalls are configured to abut with a sidewall of an adjacent LED lamp housing in the modular LED lighting system. Each of the end walls are configured to abut with an end wall of an adjacent LED lamp housing in the modular LED lighting system. Each of the at least one LED lamp housings in the modular LED lighting system is configured to adjoin with an adjacent LED lamp housing. 
    
    
     
       BRIEF DESCRIPTIONS OF THE DRAWINGS 
       The following figures, which are idealized, are not to scale and are intended to be merely illustrative of aspects of the present disclosure and non-limiting. In the drawings, like elements may be depicted by like reference numerals. The drawings are briefly described as follows. 
         FIG. 1  is top view of an LED lamp housing of the modular LED lighting system of the present disclosure; 
         FIG. 2  is an upper perspective view of the LED lamp housing shown in  FIG. 1 ; 
         FIG. 3  is side perspective view of the LED lamp housing shown in  FIG. 1 ; 
         FIG. 4  is a bottom view of the LED lamp housing shown in  FIG. 1 ; 
         FIG. 5 a    is a bottom view of a portion of a lamp housing of the modular LED lighting system of the present disclosure showing a removed electrical cover; 
         FIG. 5 b    is a bottom view of the LED lamp housing shown in  FIG. 5 a    holding a longitudinally extending LED lamp; 
         FIG. 5 c    is a bottom view of the LED lamp housing shown in  FIG. 5 a    holding an array of LEDs; 
         FIG. 6 a    is a lower perspective view of a LED lamp housing having a mechanically mounted lens; 
         FIGS. 6 b  and 6 c    show a mechanically mountable lens; 
         FIG. 7  is lower perspective view of the modular LED lighting system of the present disclosure having adjacent LED lamp housings with abutted end walls; 
         FIG. 8  is an upper perspective view of the modular LED lighting system of  FIG. 7  showing an adjoining bar; 
         FIG. 9  is lower perspective view of the modular LED lighting system of the present disclosure having adjacent LED lamp housings with abutted sidewalls; 
         FIG. 10  is an upper perspective view of the modular LED lighting system of  FIG. 9  showing adjoining bars; 
         FIG. 11  is lower perspective view of the modular LED lighting system of the present disclosure having a plurality LED lamp housings, each having at least one sidewall abutted with a sidewall of an adjacent LED lamp housing; and 
         FIG. 12  is an upper perspective view of the modular LED lighting system of  FIG. 11  showing adjoining bars. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the present exemplary embodiments and aspects of the present invention, examples of which are illustrated in the accompanying figures. The same reference numbers may be used in the figures to refer to the same or like parts. The presently disclosed embodiments, aspects, and features of the present invention are not to limit the presently claimed invention as other and different embodiments, aspects, and features will become apparent to one skilled in the art upon reading the present disclosure. 
       FIGS. 1-4  show a top, upper perspective, side perspective, and bottom view, respectively, of an LED lamp housing  10 . Lamp housing  10  is configured to be a component part of the modular LED lighting system of the present disclosure. For example, a modular LED lighting system may comprise at least one LED lamp housing  10 . LED lamp housing  10  may be configured to house and hold at least one longitudinally extending LED lamp or an array of LEDs. LED lamp housing  10  may be configured to electrically connect the at least one longitudinally extending LED lamp or the array of LEDs to a power source such as a power source leading from a structure or another LED lamp housing in the modular LED lighting system. 
     LED lamp housing  10  may comprise two substantially parallel longitudinally extending sidewalls  12 , each longitudinally extending sidewall  12  is at least as long as the at least one longitudinally extending LED lamp or the array of LEDs to be mounted in LED lamp housing  10 . For example, sidewalls  12  may have a length l, greater than a length of the at least one longitudinally extending LED lamp or the array of LEDs to be mounted in LED lamp housing  10 . Sidewalls  12  may have tabs  22  extending inwardly. Tabs  22  may be configured and disposed for mechanically mounting a lens in, on, or about a light opening  17 , shown in  FIG. 4 . 
     LED lamp housing  10  may comprise two substantially parallel end walls  20 , wherein each end wall  20  may extend from edges of longitudinally extending sidewalls  12  and form LED lamp housing  10  with a rectangular bottom light opening  17 . End walls  20  may have a width w and a configuration for holding one or more longitudinally extending LED lamps or the arrays of LEDs. For example, lamp housing  10  may be configured to hold or house a plurality of LED lamps or arrays of LEDs in a parallel configuration, and for providing a desired configuration of light opening  17 . For example, light opening  17  may be square. In the embodiment of end walls  20  shown in  FIGS. 1-4 , end walls  20  have a trapezoidal configuration. However, it is to be understood that end walls  20  may have a variety of configurations for enabling housing  10  to hold one or more longitudinally extending LED lamps or the arrays of LEDs and provide a desired configuration of light opening  17 . 
     A flange  16  may extend outwardly from each of the longitudinally extending sidewalls  12  and end walls  20  and around a perimeter of the light opening  17 . Flange  16  may be configured and disposed for mounting a modular LED lamp system comprising one or more LED lamp housing  10  on a ceiling suspension grid. In at least one embodiment of the present disclosure, flange  16  extends completely around light opening  17  and is void of interruptions. However, it is to be understood that flange  16  may not be required to extend outwardly from the four lower corners of LED lamp housing  10 . 
     An abutting surface  18  may extend upwardly from flange  16  and may be configured for abutting each of the at least one LED lamp housings  10 , in the modular LED lighting system of the present disclosure, with an adjacent LED lamp housing  10 . For example, an embodiment of the modular LED lighting system of the present disclosure may comprise at least two LED lamp housings  10  adjoined to one another, each LED lamp housing  10  may have a sidewall  12  abutted with a sidewall  12  of an adjacent LED lamp housing  10  or an end wall  20  abutted with an end wall  20  of an adjacent LED lamp housing  10 . The abutted surfaces  18 , of the sidewalls  12  or end walls  20  of the adjoined LED lamp housings  10 , may be entirely, or substantially entirely, in contact with one another upon adjoining. 
     The modular LED lighting system of the present disclosure may comprise one or more LED lamp housings with a top wall  14  extending from top edges of sidewalls  12  and top edges of the end walls  20 . Top wall  14  may enclose a top of LED lamp housing  10  and light opening  17  may be an open bottom of LED lamp housing  10 . Fastening sites  24  may be provided in top wall  14 . Fastening sites  24  may be configured and disposed for adjoining two or more lamp housings  10  together. For example, an adjoining bar may be fastened at one or more fastening sites  24 . 
       FIG. 5 a    shows a bottom view of a portion of a LED lamp housing  15  of the modular LED lighting system of the present disclosure having a removed electrical cover  26 . Electrical lead sites  32  may be configured and disposed for leading wires into LED lamp housing  15  and supplying power to at least one longitudinally extending LED lamp or an array of LEDs housed in LED lamp housing  15 . For example, one or more electrical wires may lead into LED lamp housing  15  from another LED lamp housing  15 , in the modular LED lighting system, or from electrical lines extending from a power source. 
     Electrical cover mounting tabs  28  may extend into LED lamp housing  15  and may be configured and disposed for mounting electrical cover  26  onto an inner side of a sidewall  20 , as shown in  FIG. 4 . Upon mounting electrical cover  26  onto an inner side of a sidewall  20 , an electrical junction between wires, wires leading into LED lamp housing  15  through electrical lead sites  32  and electrical wires leading to the at least one longitudinally extending LED lamp or an array of LEDs, may be covered. 
       FIG. 5 b    is a bottom view of LED lamp housing  15  holding a longitudinally extending LED lamp  11 .  FIG. 5 c    is a bottom view of the LED lamp housing  15  holding an array of LEDs  13 . It is to be understood that lamp housing  15  may be configured to hold a plurality of longitudinally extending LED lamps  11  or multiple array configurations of LEDs  13 . For example, an array of LEDs  13  may comprise one or more LED strips disposed in parallel. 
     A modular LED lighting system of the present disclosure may comprise at least one LED lamp housing  15  configured to house and hold at least one longitudinally extending LED lamp  11  or an array of LEDs  13  mounted inside lamp housing  15  and electrically connect the at least one longitudinally extending LED lamp  11  or the array of LEDs  13  to a power source, not shown. LED lamp housing  15  may comprise two substantially parallel longitudinally extending sidewalls  12 , each sidewall  12  being at least as long as the at least one longitudinally extending LED lamp  11  or the array of LEDs  13 . Two substantially parallel end walls  20  may extend from edges of sidewalls  12  and form LED lamp housing  15  with a lower rectangular light opening  17 . Each sidewall  12  may be configured to abut with a sidewall  12  of an adjacent LED lamp housing  15 , in the modular LED lighting system of the present disclosure. Each of the end walls  20  may be configured to abut with an end wall  20  of an adjacent LED lamp housing  15 , in the modular LED lighting system of the present disclosure. Each of the LED lamp housings  15 , in the modular LED lighting system of the present disclosure, may be configured to adjoin with an adjacent LED lamp housing  15 . 
     The modular LED lighting system of the present disclosure may be configured to be mounted on a ceiling suspension grid. For example, LED lamp housing  15  may comprise a top wall  14  extending from top edges of the sidewalls  12  and end walls  20 . Top wall  14  may enclose a top of LED lamp housing  15  and light opening  17  may be an open bottom. The modular LED lighting system of the present disclosure may comprise at least one adjoining bar attached to top walls  14 , of the adjacently adjoined LED lamp housings  15 . Upon adjoining adjacent LED light housings  15 , in modular LED lighting system of the present disclosure, each of the adjoined LED lamp housings have at least one sidewall  12  abutted with a sidewall  12  of an adjacent LED lamp housing  15  or at least one end wall  20  abutted with an end wall  20  of an adjacent LED lamp housing. 
     LED lamp housing  15  may further comprise a flange  16  extending outwardly from each of the sidewalls  12  and end walls  20  and about a portion of a perimeter of the light opening  17 . Flange  16  may be disposed and configured for mounting the modular LED lighting system of the present disclosure on a ceiling suspension grid. The modular LED lighting system of the present disclosure may comprise at least two LED lamp housings  15  adjoined to one another, wherein each of the LED lamp housings  15  have a sidewall  12  abutted with a sidewall  12  of an adjacent LED lamp housing  15  or an end wall  20  abutted with an end wall  20  of an adjacent LED lamp housing  15 . For example, LED lamp housing  15  may further comprise an abutting surface  18  extending upwardly from flange  16 , which may be configured for abutting each of LED lamp housing  15  with an adjacent LED lamp housing  15 , in the modular LED lighting system of the present disclosure. However, in at least one embodiment of the LED lamp housing of the present disclosure, the LED lamp housing is void of a flange and/or abutting surface. 
       FIG. 6 a    shows a lower perspective view of LED lamp housing  10  having a mechanically mounted lens  34 . The modular LED lighting system of the present disclosure may have lens  34  mechanically mounted to or with LED lamp housing  10 . For example, lens  34  may be comprised of a flexible light transmissible material, such as polymeric material, polycarbonate for example, and may be configured to bend into a concave configuration and snap into lamp housing  10  and be held with tabs  22 , shown in  FIGS. 1-5   a.    
     Other and different lens configurations may be used with the modular LED lighting system of the present disclosure. For example, a lens may be configured to be magnetically attached to LED lamp housing  10 . In at least one embodiment, a lens may have magnets or ferromagnetic materials and the LED lamp housing may have the other of magnets or ferromagnetic materials, wherein the magnets or ferromagnetic materials are configured and disposed to magnetically attach and hold lens to an LED lamp housing. For example, a lens may be substantially flat and may be configured to magnetically attach with or about a flange extending from the sidewalls or end walls. For example, as shown in  FIG. 6 a   , lower right, lens  54  may be magnetically mounted about the light opening. Lens  54  may be substantially flat and may be configured to be held with LED lamp housing  10  with magnets  52 . Magnets  52  may be disposed with LED lamp housing  10  or lens  54  and the other of LED lamp housing  10  or lens  54  may have a ferromagnetic material disposed to magnetically cooperate with magnets  54  and hold lens  54  to LED lamp housing  10 . 
       FIGS. 6 b  and 6 c    show another embodiment of a mechanically mounted lens  35 . The modular LED lighting system of the present disclosure may have lens  35  mechanically mounted to or with LED lamp housing  10 . For example, lens  35  may be comprised of a flexible light transmissible material, such as polymeric material, polycarbonate for example. Lens  35  may have a convex portion  39  and outwardly and/or concave extending portions  37 , extending about longitudinal edges of lens  35 . Lens  35  may be configured to bend into a configuration and snap into lamp housing  10  and be held with tabs  22 , cooperating with outwardly extending portions  37 . LED lamp holders  44  are shown extending from top wall  14 , in  FIG. 6 c   . Electrical connector  42  is shown disposed and configured to electrically connect with an LED lamp or array of LEDs. 
       FIGS. 7 and 8  show lower and upper perspective views of a modular LED lighting system  40  of the present disclosure having adjacent LED lamp housings  10  with abutted end walls  20 . Two or more LED lamp housings  10  may be adjacently adjoined to one another with their end walls  20  abutted. Sidewalls  12  may have a length l and end walls  20  may have a width w. Adjoining two LED lamp housings  10  together with their end walls  20  abutted provides modular LED lighting system  40  having a length of 2l and a width of w. In at least one embodiment of LED lighting system  40 , the abutted and adjoined LED lamp housings  10  have an overall length of about 4 feet and a width of about 1 foot. LED lighting system  40  may have two, three, or any plurality of lamp housings  10  arranged in a variety of configurations. 
     A flange  16  may extend outwardly from each of the longitudinally extending sidewalls  12  and end walls  20  and abutting surface  18  may extend upwardly from flange  16 . The abutted end walls  20 , of each adjoined LED lamp housing  10 , may have their adjacent abutting surfaces  18  completely, or substantially completely abutted or in contact with one another. 
     LED lamp housings  10  have top wall  14  extending from top edges of sidewalls  12  and top edges of the end walls  20 . Top wall  14  may enclose a top of LED lamp housing  10  and have fastening sites  24 , shown in  FIGS. 1-4 . Modular LED lighting system  40  may comprise one or more adjoining bars  36 . Adjoining bars  36  extend between adjacent LED lamp housings  10  and are attached to the top walls  14  of adjacent lamp housings  10 , at fastening sites  24 . The adjoining bars  36  adjoin adjacent LED lamp housings  10 , wherein each of the at least two adjoined LED lamp housings  10  have an end wall  20  abutted with an end wall  20  of an adjacently adjoined LED lamp housing  10 . Adjoining bars  36  may be configured for mounting modular LED lighting system  40  to a portion of a structure. Adjacently adjoined LED lamp housings  10  may be in electrical communication with one another by way of electrical connection  19 . Modular LED lighting system  40  may be configured to be mounted on a ceiling suspension grid. 
       FIGS. 9 and 10  show lower and upper perspective views of modular LED lighting system  50  having adjacent LED lamp housings  10  with abutted sidewalls  12 . Two or more LED lamp housings  10  may be adjacently adjoined to one another with their sidewalls  12  abutted. Sidewalls  12  may have a length l and end walls  20  may have a width w. Adjoining two LED lamp housings  10  together with their sidewalls  12  abutted provides modular LED lighting system  50  having a length of l and a width of 2w. In at least one embodiment of LED lighting system  50 , the abutted and adjoined LED lamp housings  10  have an overall length of about 2 feet and a width of about 2 feet. LED lighting system  50  may have two, three, or any plurality of lamp housings  10  arranged in a variety of configurations. 
     A flange  16  may extend outwardly from each longitudinally extending sidewall  12  and/or end walls  20  and abutting surface  18  may extend upwardly from flange  16 . The abutted sidewalls  12 , of each adjoined LED lamp housing  10 , may have their adjacent abutting surfaces  18  completely, or substantially completely abutted or in contact with one another. 
     LED lamp housings  10  have top wall  14  extending from top edges of sidewalls  12  and top edges of the end walls  20 . Top wall  14  may enclose a top of LED lamp housing  10  and have fastening sites  24 , shown in  FIGS. 1-4 . Modular LED lighting system  50  may comprise one or more adjoining bars  38 . Adjoining bars  38  extend between each of adjacent LED lamp housings  10  and are attached to the top walls  14  of adjacent lamp housings  10 , at fastening sites  24 . The adjoining bars  38  adjoin adjacent LED lamp housings  10 , wherein each of the at least two adjoined LED lamp housings  10  have a sidewall  12  abutted with a sidewall  12  of an adjacently adjoined LED lamp housing  10 . Adjoining bars  38  may be configured for mounting modular LED lighting system  50  to a portion of a structure. Modular LED lighting system  50  may be configured to be mounted on a ceiling suspension grid. Adjacently adjoined LED lamp housings  10  may be in electrical communication with one another by way of electrical connection  19 . 
       FIGS. 11 and 12  show lower and upper perspective views of modular LED lighting system  60  having a plurality of adjacent LED lamp housings  10  with abutted sidewalls  12 . Three, four, or more LED lamp housings  10  may be adjacently adjoined to one another with their sidewalls  12  abutted. Sidewalls  12  may have a length l and end walls  20  may have a width w. Adjoining four LED lamp housings  10  together with their sidewalls  12  abutted provides modular LED lighting system  60  having a length of l and a width of 4w. In at least one embodiment of LED lighting system  60 , the abutted and adjoined LED lamp housings  10  have an overall length of about 2 feet and a width of about 4 foot. 
     A flange  16  may extend outwardly from at least a portion of each longitudinally extending sidewall  12  and end wall  20  and abutting surface  18  may extend upwardly from flange  16 . The abutted sidewalls  12 , of each adjacently adjoined LED lamp housing  10 , may have their adjacent abutting surfaces  18  completely, or substantially completely abutted or in contact with one another. 
     LED lamp housings  10  have top wall  14  extending from top edges of sidewalls  12  and top edges of the end walls  20 . Top wall  14  may enclose a top of LED lamp housing  10  and have fastening sites  24 , shown in  FIGS. 1-4 . Modular LED lighting system  60  may comprise one or more adjoining bars  39 . Adjoining bars  39  extend between LED lamp housings  10  and are attached to the top walls  14  of lamp housings  10 , at fastening sites  24 . The adjoining bars  39  adjoin LED lamp housings  10 , wherein each of the adjoined LED lamp housings  10  have a sidewall  12  abutted with a sidewall  12  of an adjacently adjoined LED lamp housing  10 . Adjoining bars  39  may be configured for mounting or hanging modular LED lighting system  60  with a portion of a structure. Modular LED lighting system  60  may be configured to be mounted on a ceiling suspension grid. 
     The presently disclosed modular LED lighting system may be configured to provide at least two linear LED sources and may be configured to connect to the branch circuit using a luminaire disconnect and may have a junction box covering the connection point which may be mounted to a wall of a LED lamp housing. The presently disclosed modular LED lighting system may be configured to be mounted with a ceiling grid or conventionally mounted with any number of mounting means including, but not limited to, S-Hook chain hung from an adjoining bar or surface mounted to a ceiling surface.