Patent Publication Number: US-2020292156-A1

Title: Led module with mounting brackets

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application of and claims priority to U.S. Non-Provisional patent application Ser. No. 16/735,124, filed Jan. 6, 2020, and titled “LED Module With Mounting Brackets,” which is a continuation application of and claims priority to U.S. Non-Provisional patent application Ser. No. 16/538,709, filed Aug. 12, 2019, and titled “LED Module With Mounting Brackets,” and which issued as U.S. Pat. No. 10,527,264 on Jan. 7, 2020, which is a continuation application of and claims priority to U.S. Non-Provisional patent application Ser. No. 15/470,631, filed on Mar. 27, 2017, titled “LED Module With Mounting Brackets,” and which issued as U.S. Pat. No. 10,378,738 on Aug. 13, 2019, which is a continuation application of and claims priority to U.S. Non-Provisional patent application Ser. No. 14/690,188, filed on Apr. 17, 2015, titled “LED Module With Mounting Pads,” and which issued as U.S. Pat. No. 9,605,842 on Mar. 28, 2017, and which is a continuation application of and claims priority to U.S. Non-Provisional patent application Ser. No. 13/048,435, filed on Mar. 15, 2011, titled “LED Module With On-Board Reflector-Baffle-Trim Ring,” and which issued as U.S. Pat. No. 9,010,956 on Apr. 21, 2015. The entire contents of the foregoing applications are hereby incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to luminaires. More specifically, the invention relates to a light emitting diode (LED) module that is used in a recessed luminaire. 
     BACKGROUND 
     LEDs offer benefits over incandescent and fluorescent lights as sources of illumination. Such benefits include high energy efficiency and longevity. To produce a given output of light, LEDs consume less electricity than incandescent or fluorescent lights. Additionally, on average, LEDs last longer than incandescent or fluorescent lights before failing. 
     The level of light a typical LED outputs depends upon the amount of electrical current supplied to the LED and upon the operating temperature of the LED. That is, the intensity of light emitted by the LED changes according to electrical current and LED temperature. Operating temperature also impacts the usable lifetime of LEDs. 
     As a byproduct of converting electricity into light, LEDs generate heat and raise the operating temperature, resulting in efficiency degradation and premature failure. Typically, a heat management system, such as a heat sink, is used in conjunction with the LEDs to facilitate maintenance of proper LED operating temperatures. Conventional LED-based recessed luminaires include a housing and a conventional LED module that is coupled within the housing. The conventional LED module includes a heat sink, a fastening device for facilitating coupling between the conventional LED module and the housing, and one or more LEDs. The housing includes a cavity formed therein and an opening at one end. The housing is installed within and above an aperture formed in a support structure, such as a ceiling, and oriented such that the opening faces a desired illumination area, such as a room. Typically, a space is formed around and between the lower exterior portion of the housing and the perimeter of the aperture. The opening is positioned in substantially the same plane as a lower surface of the support structure; however, the opening can be positioned in a different plane, such as slightly above the lower surface of the support structure. 
     The heat sink is installed and fitted within the cavity of the housing, generally using one or more fastening devices, such as torsion springs, and substantially occupies the entirety of the diameter of the cavity to maximize its heat removal performance. The conventional LED module is designed to fit within a housing having an opening with a certain nominal diameter. For example, one conventional LED module is designed to fit within a housing having a six inch nominal diameter opening, while a different conventional LED module is designed to fit within a different housing having a five inch nominal diameter opening. Thus, the conventional LED module typically is not designed to flexibly fit within housings having differently sized nominal diameter openings. The LEDs are typically coupled to a substrate, which is in thermal communication with the heat sink. The LEDs emit light and are oriented in a manner such that the light is directed to the desired illumination area through the opening. 
     Conventional LED-based recessed luminaires can also include a trim ring. The trim ring is positioned adjacent to the opening and covers the opening. The trim ring typically is separably coupled to the heat sink or to a portion of the housing, generally by use of torsion springs, and is positioned so that at least a portion of the trim ring extends below the support structure and covers the space formed between the lower exterior portion of the housing and the support structure when viewed from an area below the support structure. The trim ring is thermally coupled to the heat sink; however, since the trim ring is separably coupled to either the heat sink or the housing, the amount of heat removal from the trim ring into the area below the support structure, or room area, is limited because the area of direct contact between the trim ring and the heat sink is reduced. Some conventional LED-based recessed luminaires also include a reflector. The reflector typically is separably disposed within the heat sink and surrounds the LEDs. The reflector directs light emitted from the LEDs toward the opening. Conventional LED-based recessed luminaires having several separably coupled components increase costs related to tooling costs and assembly costs. 
     SUMMARY 
     A light module can include a heat sink and one or more light sources. The heat sink can include an internal surface surrounding a heat sink cavity formed therein. The internal surface can include a mounting region, a reflector region, and a decorative region. The reflector region can extend from the perimeter of the mounting region to a distal end. The decorative region can extend from the distal end to a second distal end. The light sources can be coupled to the mounting region within the heat sink cavity. 
     Another exemplary embodiment includes a light module that can include a heat sink, one or more light sources, and at least one mounting pad. The heat sink can include an internal surface surrounding a heat sink cavity formed therein. The light sources can be coupled to a portion of the internal surface of the heat sink cavity. The mounting pad can be coupled circumferentially around a portion of the heat sink. Each mounting pad can include a coupling hole, a first locator, and a second locator. The second locator can be positioned closest to an interior portion of the heat sink. The first locator can be positioned between the second locator and the coupling hole. 
     Another exemplary embodiment includes a light module. The light module can include a heat sink, one or more LED packages, and at least one mounting pad. The heat sink can include an internal surface surrounding a heat sink cavity formed therein. The internal surface can include a mounting region, a reflector region, and a decorative region. The reflector region can extend from the perimeter of the mounting region to a distal end. The decorative region can extend from the distal end to a second distal end. The LED package can be coupled to a portion of the internal surface of the heat sink cavity. The mounting pad can be disposed circumferentially around a portion of the heat sink. Each mounting pad can include a coupling hole, a first locator, and a second locator. The coupling hole, the first locator, and the second locator are radially and linearly aligned with one another. The second locator can be positioned closest to an interior portion of the heat sink. The first locator can be positioned between the second locator and the coupling hole. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description, in conjunction with the accompanying figures briefly described as follows: 
         FIG. 1A  is a perspective view of an LED module according to an exemplary embodiment of the present invention; 
         FIG. 1B  is another perspective view of the LED module of  FIG. 1A  according to an exemplary embodiment of the present invention; 
         FIG. 1C  is another perspective view of the LED module of  FIG. 1A  having the lens and LED packages removed according to an exemplary embodiment of the present invention; 
         FIG. 2  is an exploded view of the LED module of  FIG. 1A  according to an exemplary embodiment of the present invention; 
         FIG. 3  is a perspective view of the mounting bracket capable of being used in the LED module of  FIG. 2  according to an exemplary embodiment of the present invention; 
         FIG. 4  is a partial perspective view of the heat sink capable of being used in the LED module of  FIG. 2  illustrating the mounting pad according to an exemplary embodiment of the present invention; 
         FIG. 5  is a partial perspective view of the LED module of  FIG. 1A  illustrating the mounting bracket of  FIG. 3  coupled to the mounting pad of  FIG. 4  according to an exemplary embodiment of the present invention; and 
         FIG. 6  is an exploded view of an LED module according to another exemplary embodiment of the present invention. 
     
    
    
     The drawings illustrate only exemplary embodiments of the invention and are therefore not to be considered limiting of its scope, as the invention may admit to other equally effective embodiments. 
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     Exemplary embodiments of the present invention are directed to luminaires. The term “luminaire,” as used herein, generally refers to a system for producing, controlling, and/or distributing light for illumination. For example, a luminaire includes a system that outputs or distributes light into an environment, thereby allowing certain items in that environment to be more visible. Such a system could be a complete lighting unit that includes one or more LEDs, or LED packages, for converting electrical energy into light, sockets, connectors, or receptacles for mechanically mounting and/or electrically connecting components to the system, optical elements for distributing light, and mechanical components for supporting or attaching the luminaire. Luminaires are sometimes referred to as “lighting fixtures” or as “light fixtures.” A lighting fixture that has a socket for a light source, but no light source installed in the socket, is still considered a luminaire. That is, a lighting system lacking some provision for full operability still fits the definition of a luminaire. Luminaires are used in indoor or outdoor applications. 
     The invention may be better understood by reading the following description of non-limiting, exemplary embodiments with reference to the attached drawings, wherein like parts of each of the figures are identified by like reference characters, and which are briefly described as follows.  FIGS. 1A, 1B, and 1C  are various perspective views of an LED module  100  according to an exemplary embodiment of the present invention. Referring to  FIGS. 1A, 1B, and 1C , the LED module  100  includes a heat sink  110 , one or more chip on board LEDs  250  ( FIG. 2 ) thermally coupled to the heat sink  110 , and one or more torsion spring fastening devices  160  coupled to the heat sink  110  for coupling the LED module  100  to a housing (not shown). According to some exemplary embodiments, one or more discrete LEDs or separate LED dies are used in lieu of, or in combination with, the chip on board LEDs  250  ( FIG. 2 ). In one exemplary embodiment, the housing is a recessed downlight can housing installed within a support structure (not shown), such as a ceiling. The LED module  100  is positionable into a cavity (not shown) formed within the housing. According to some exemplary embodiments, the LED module  100  also includes a driver  170 , a gasket  180 , and a lens  190  described in further detail below. 
     The heat sink  110  is formed as a single component and includes a first portion  111 , a second portion  121  positioned below the first portion  111 , one or more mounting pads  130 , a trim ring  140 , and a cavity  135  formed therein. The exemplary mounting pads  130  are positioned at different circumferential positions around the second portion  121 . The exemplary trim ring  140  extends radially outward from a second end  124  of the second portion  121 . The exemplary cavity  135  is surrounded by an internal surface  139  of the heat sink  110 . 
     The first portion  111  extends a first longitudinal length  112  and includes one or more fins  118 . The fins  118  extend from an interior portion  113  of the first portion  111  to an outer vertical periphery of the first portion  111 . These fins  118  are viewable from the exterior of the heat sink  110  according to certain exemplary embodiments. According to one exemplary embodiment, the fins  118  are integrally formed with the interior portion  113  during casting of the heat sink  110 . Alternatively, the fins  118  are coupled to the interior portion  113  of the first portion  111  subsequent to fabrication of the interior portion  113  using welding, fasteners or other methods known to people having ordinary skill in the art. According to one exemplary embodiment, the fins  118  extend substantially the entire first longitudinal length  112 . Alternatively, the fins  118  extend a portion of the first longitudinal length  112 . In yet another exemplary embodiment, one or more of the fins  118  extend at least a portion of the first longitudinal length  112  and also extend along at least a portion of the outer perimeter of the second portion  121 . The fins  118  extend substantially radially around the first portion  111  forming gaps  119  between adjacently positioned fins  118 . In other exemplary embodiments, the fins  118  extend substantially parallel to one another, also forming gaps  119  between adjacent fins  118 . These fins  118  provide for an increase in exterior surface area of the first portion  111 , thereby allowing the first portion  111  to release more of the heat generated by the LED packages  250  ( FIG. 2 ) and/or the driver  170 . The first portion  111  is fabricated using a thermally conductive, rigid material, such as a polymer, metal, or metal alloy. One example of the material used to fabricate the first portion  111  is aluminum. 
     The second portion  121  is positioned generally below the first portion  111  and extends a second longitudinal length  122 . The second portion  121  includes a first end  123 , a second end  124 , and a sidewall  125 . In certain exemplary embodiments, the first end  123  has a smaller perimeter than the second end  124 . In alternative embodiments, the first end  123  has a perimeter that is equal to or greater than the second end  124 . The side wall  125  extends from the first end  123  to the second end  124 . The second portion  121  also includes a top surface  126  that is located at the first end  123  and between lower portions of adjacent fins  118 . The second end  124  defines an opening  127  that extends within the heat sink  110  to form the cavity  135  therein. According to some exemplary embodiments, the second portion  121  is integrally fabricated with the first portion  111  as a single component. The second portion  121  is fabricated using a thermally conductive, rigid material, such as a polymer, metal, or metal alloy. One example of the material used to fabricate the second portion  121  is aluminum. 
     In certain exemplary embodiments, the mounting pads  130  are substantially “L” shaped and extend along a portion of the top surface  126  in a raised manner. However, in alternative embodiments the mounting pads  130  are not raised. According to some exemplary embodiments, a portion of each mounting pad  130  also extends along at least a portion of the sidewall  125 . In one exemplary embodiment, four mounting pads  130  disposed circumferentially along the second portion  121 . However, in other exemplary embodiments, there are fewer or greater numbers of mounting pads  130  disposed circumferentially along the second portion  121 . These exemplary mounting pads  130  allow coupling the LED module  100  to the housing using the fastening devices  160 , which is described in further detail below with reference to  FIGS. 3-5 . The mounting pads  130  allow the LED module  100  to be inserted within and coupled to housings having differently sized cavities since the mounting pads  130  include a first locating hole and a second locating hole  452 ,  453  ( FIG. 4 ) and the fastening devices  160  coupled to the LED module  100  are selectively positionable in either of these locating holes  452 ,  453  ( FIG. 4 ) depending upon the size of the housing, which is discussed in further detail with respect to  FIGS. 3-5 . For example, the LED module  100  is capable of being inserted within and coupled to a housing having a five-inch nominal diameter cavity and also to a housing having a six-inch nominal diameter cavity depending upon which of the first or second locating hole  452 ,  453  ( FIG. 4 ) of the mounting pads  130  is used in conjunction with the fastening devices  160 . According to some exemplary embodiments, the mounting pads  130  are integrally fabricated with the first portion  111  and the second portion  121  as a single component and therefore are fabricated using the same material. Alternatively, the mounting pads  130  are fabricated separately from the first portion  111  or the second portion  121  and thereafter coupled to at least one of the first portion  111  and/or the second portion  121  according to other exemplary embodiments. The mounting pads  130  are fabricated using a thermally conductive, rigid material, such as a polymer, metal, or metal alloy. One example of the material used to fabricate the mounting pads  130  is aluminum. Alternatively, the mounting pads  130  are fabricated using any other suitable material, such as any thermally non-conductive material. 
     As previously mentioned, a portion of the cavity  135  is surrounded by the internal surface  139  which extends within the interior of the heat sink  110 . The cavity  135  is formed during the casting process of the heat sink  110  according to certain exemplary embodiments. Alternatively, the cavity  135  is formed by machining into at least a portion of the second end  124  of the heat sink&#39;s second portion  121 , or by other methods known to people having ordinary skill in the art. The internal surface  139  includes a mounting region  136 , a first region  137 , and a second region  138 . The mounting region  136  is located within the first portion  111  of the heat sink  110  and is substantially planar according to some exemplary embodiments. The mounting region  136  is oriented substantially parallel to the opening  127  and faces the desired illumination area. According to certain exemplary embodiments, the mounting region  136  is circular in shape. Alternatively, the mounting region  136  is shaped into other geometric or non-geometric shapes. 
     In certain exemplary embodiments, the first region  137  and the second region  138  collectively form a parabolic shape extending from the perimeter of the mounting region  136  to the perimeter of the opening  127 . The first region  137  includes a proximal end  145  and a distal end  146 , wherein the diameter of the distal end  146  is greater than the diameter of the proximal end  145 . However, according to other exemplary embodiments, the diameter of the distal end  146  is smaller than or equal to the diameter of the proximal end  145  in other exemplary embodiments. The proximal end  145  is disposed around the perimeter of the mounting region  136  and the distal end  146  extends outwardly towards the opening  127 . The first region  137  is fabricated to be reflective and facilitate directing light emitted from the LED packages  250  ( FIG. 2 ), which are coupled to the mounting region  136 , through the opening  127 . In some examples, the surface of the first region  137  is entirely smooth. In another example, the surface of the first region  137  includes at least one of a faceted surface, a prismatic surface, and a dimpled surface. The first region  137  is fabricated using the same material used for fabricating the first portion  111 , except that the first region  137  is made to be reflective if the first portion  111  is fabricated using non-reflective material. In some examples, the first region  137  is fabricated using a polished metal. In other exemplary embodiments, the first region  137  is fabricated using any suitable reflective material or any material capable of being made reflective, for example, a material capable of having white reflective paint adhered to its surface. 
     The second region  138  includes the distal end  146  of the first region and a second distal end  147 , wherein the diameter of the second distal end  147  is greater than the diameter of the distal end  146 . According to other exemplary embodiments, the diameter of the second distal end  147  is smaller than or equal to the diameter of the distal end  146 . The second distal end  147  extends to the opening  127  and defines the opening  127 . In some examples, the surface of the second region  138  is baffled. In another example, the surface of the second region  138  is smooth. In yet another example, the surface of the second region  138  includes at least one of a faceted surface, a prismatic surface, a dimpled surface, and a painted surface. The second region  138  is fabricated using the same material as that used to fabricate the first region  137 , but is finished similarly or differently than the finishing of the first region  137  depending upon design choices. 
     The trim ring  140  extends radially outward from the second end  124  of the heat sink&#39;s second portion  121  and includes a top surface  141  and a bottom surface  142 . The trim ring  140  is typically positioned just below the plane of the opening  127 . In certain exemplary embodiments, the trim ring  140  is integrally formed with the remaining portions of the heat sink  110 . Once the LED module  100  is installed into the housing, the bottom surface  142  of the trim ring  140  is oriented to face the desired illumination area and is observable to one present within the desired illumination area. Also, once the LED module  100  is installed within the housing, the trim ring  140  conceals the space formed around and between the lower exterior portion of the housing and the perimeter of the aperture formed within the support structure. In certain exemplary embodiments, the trim ring  140  is fabricated using a thermally conductive material, such as a polymer, metal, or metal alloy. One example of the material used to fabricate the outer trim ring  140  is aluminum. In the exemplary embodiments where the trim ring  140  is integrally formed with at least the second portion  121 , the heat transfer from the second portion  121  to the trim ring  140  is improved because the trim ring  140  is always in constant contact around the entire circumference of the second portion  121 . At least a portion of the heat from the heat sink  110  is released into the desired illumination area using the pathway from the second portion  121  of the heat sink  110  to the trim ring  140  and to the desired illumination area. 
     The heat sink  110  is described as including several components, such as the first portion  111 , the second portion  121 , one or more mounting pads  130 , and the trim ring  140 . Each of the components are integrally formed with one another according to several exemplary embodiments; however, some exemplary embodiments have at least one component separately fabricated and thereafter coupled to the remaining portions of the integrally formed heat sink  110 . For example, the fins  118  are separately formed and thereafter coupled to the interior portion  113  of the first portion  111  according to some exemplary embodiments. The heat sink  110  is fabricated using a thermally conductive, rigid material, such as a polymer, metal, or metal alloy. One example of the material used to fabricate the heat sink  110  is aluminum. The material used to form some portions of the heat sink  110  is finished differently than another portion of the heat sink  110  according to some exemplary embodiments. For example, at least a portion of the internal surface&#39;s first region  137  is polished to be made more reflective according to some exemplary embodiments. 
     As previously mentioned, the exemplary LED module  100  includes the driver  170 . The driver  170  includes circuitry for controlling one or more LED packages  250  ( FIG. 2 ). The driver  170  modifies the power entering the driver  170  through a power supply cable  175  to appropriately control at least a portion of the LED packages  250  ( FIG. 2 ). For example, the driver  170  controls the operation, color, and/or intensity of the light being emitted from the LED packages  250  ( FIG. 2 ). The power supply cable  175  supplies power to the driver  170  from a power source (not shown). According to some embodiments, the power supply cable  175  is fabricated using an insulative cover  176  surrounding one or more thermally conductive wires (not shown). In certain exemplary embodiments, the driver  170  is thermally coupled to a portion of the heat sink  110 . According to some exemplary embodiments, the driver  170  is thermally and directly coupled to the top portion of the heat sink&#39;s first portion  111  using coupling devices  202  ( FIG. 2 ), such as screws, nails, or rivets. According to another exemplary embodiment, the driver  170  is thermally and indirectly coupled to the top portion of the heat sink&#39;s first portion  111  using thermal transference devices (not shown), such as heat pipes. The driver  170  emits heat which is transferred into the heat sink  110 . According to some exemplary embodiments, at least a portion of the heat generated from the driver  170  is released into the desired illumination area using the pathway from the driver  170 , to the first portion  111  of the heat sink  110 , to the second portion  121  of the heat sink  110 , to the trim ring  140 , and to the desired illumination area. 
     As previously mentioned, the LED module  100  also includes one or more chip on board LEDs  250  ( FIG. 2 ). The LED packages  250  ( FIG. 2 ) are coupled, either directly or indirectly, to the mounting region  136  of the heat sink  110 . According to some exemplary embodiments, the LED packages  250  ( FIG. 2 ) are coupled to a substrate (not shown) which is then coupled to the mounting region  136 . The exemplary substrate includes one or more sheets of ceramic, metal, laminate, circuit board, Mylar®, or another material and is coupled to the mounting region  136  of the heat sink  110 . Each LED package  250  ( FIG. 2 ) includes a chip of semi-conductive material that is treated to create a positive-negative (“p-n”) junction. When the LED or LED package  250  ( FIG. 2 ), such as a chip-on-board LED package, is electrically coupled to a power source, such as the LED driver  170 , current flows from the positive side to the negative side of each junction, causing charge carriers to release energy in the form of incoherent light. 
     The wavelength or color of the emitted light depends on the materials used to make the LED or LED package  250  ( FIG. 2 ). For example, a blue or ultraviolet LED typically includes gallium nitride (“GaN”) or indium gallium nitride (“InGaN”), a red LED typically includes aluminum gallium arsenide (“AlGaAs”), and a green LED typically includes aluminum gallium phosphide (“AlGaP”). Each of the LEDs in the LED package  250  ( FIG. 2 ) can produce the same or a distinct color of light. For example, in certain exemplary embodiments, the LED package  250  ( FIG. 2 ) includes one or more white LED&#39;s and one or more non-white LEDs, such as red, yellow, amber, or blue LEDs, for adjusting the color temperature output of the light emitted from the LED module  100 . A yellow or multi-chromatic phosphor may coat or otherwise be used in a blue or ultraviolet LED to create blue and red-shifted light that essentially matches blackbody radiation. The emitted light approximates or emulates “white,” incandescent light to a human observer. In certain exemplary embodiments, the emitted light includes substantially white light that seems slightly blue, green, red, yellow, orange, or some other color or tint. In certain exemplary embodiments, the light emitted from the LEDs has a color temperature between 2500 and 5000 degrees Kelvin. 
     In certain exemplary embodiments, an optically transmissive or clear material (not shown) encapsulates at least a portion of each LED or LED package  250  ( FIG. 2 ). This encapsulating material provides environmental protection while transmitting light from the LEDs. In certain exemplary embodiments, the encapsulating material includes a conformal coating, a silicone gel, a cured/curable polymer, an adhesive, or some other material known to a person of ordinary skill in the art having the benefit of the present disclosure. In certain exemplary embodiments, phosphors are coated onto or dispersed in the encapsulating material for creating white light. In certain exemplary embodiments, the white light has a color temperature between 2500 and 5000 degrees Kelvin. 
     In certain exemplary embodiments, the LED is an LED package  250  ( FIG. 2 ) that includes one or more arrays of LEDs that are collectively configured to produce a lumen output from 1 to 5000 lumens. The LEDs or the LED packages  250  ( FIG. 2 ) are attached to the substrate by one or more solder joints, plugs, epoxy or bonding lines, and/or other means for mounting an electrical/optical device on a surface. The substrate is electrically connected to support circuitry (not shown) and/or the LED driver  170  for supplying electrical power and control to the LEDs or LED packages  250  ( FIG. 2 ). For example, one or more wires (not shown) couple opposite ends of the substrate to the LED driver  170 , thereby completing a circuit between the LED driver  170 , substrate, and LED packages  250  ( FIG. 2 ). In certain exemplary embodiments, the LED driver  170  is configured to separately control one or more portions of the LED packages  250  ( FIG. 2 ) in the array to adjust light color or intensity of the light that is emitted through the opening  127 . 
     The LED packages  250  ( FIG. 2 ) emit heat which is transferred into the heat sink  110 . According to some exemplary embodiments, at least a portion of the heat generated from the LED packages  250  ( FIG. 2 ) is released into the desired illumination area using the pathway from the LED packages  250  ( FIG. 2 ), to the mounting region  136  of the heat sink&#39;s first portion  111 , to the second portion  121  of the heat sink  110 , to the trim ring  140 , and to the desired illumination area. 
     As previously mentioned, the exemplary LED module  100  includes the gasket  180 . The exemplary gasket  180  is ring-shaped and includes an inner perimeter  181 , and outer perimeter  182 , an upper surface  183 , and a lower surface (not shown). In alternative embodiments, the gasket  180  is shaped in other geometric or non-geometric shapes. The inner perimeter  181  is substantially equal to or larger than the outer perimeter of the second portion&#39;s second end  124 . The outer perimeter  182  is substantially equal to or smaller than the outer perimeter of the trim ring  140 . The gasket  180  is typically disposed on the top surface  141  of the trim ring  140  such that the gasket&#39;s lower surface (not shown) is in contact with the trim ring&#39;s top surface  141 . Once the LED module  100  is inserted into the housing&#39;s cavity, at least a portion of the gasket  180 , if included within the LED module  100 , is disposed between at least a portion of the trim ring&#39;s top surface  141  and the surface of the support structure. The exemplary gasket  180  is fabricated using a foam material. However, other suitable materials, such as a rubber and other polymer materials, are suitable for manufacturing the gasket  180  in other exemplary embodiments. 
     The exemplary LED module  100  also includes the lens  190 . The lens  190  is coupled to substantially the distal end  146  of the internal surface&#39;s first region  137 . According to some exemplary embodiments, the lens  190  is coupled to the distal end  146  using clips (not shown). Alternatively, other devices, such as screws or using the baffles as support, are used to couple the lens  190  in place. Furthermore, in certain alternative embodiments, the lens  190  is positioned either above or below the distal end  146 . In certain exemplary embodiments, the lens  190  is fabricated using a transparent or translucent material, such as glass or plastic, which allows light generated from the LED packages  250  ( FIG. 2 ) to pass therethrough. In some exemplary embodiments, the lens  190  is tinted or milky colored to diffuse the light being emitted from the LED packages  250 , thereby avoiding an overly bright light source to be seen. The exemplary lens  190  is smooth; however, alternative embodiments utilize a lens  190  that includes micro-patterns, dimples, and/or prismatic elements. The lens  190  provides protection to the LED packages  250  ( FIG. 2 ) from dust and other contaminants. The exemplary lens  190  is substantially concave-shaped having the concaved portion facing the LED packages  250  ( FIG. 2 ). In alternative embodiments, the lens  190  is shaped substantially planar, convexed, or some other shape. 
     The exemplary LED module  100  also includes fastening devices  160  adjustably coupled to the mounting pads  130 . The fastening devices  160 , in conjunction with the mounting pads  130 , facilitate the adjustable coupling of the LED module  100  into housings having different cavity diameter sizes. Each fastening device  160  includes a mounting bracket  162  and a torsion spring  163  coupled to the mounting bracket  162 . Torsion springs  163  are known to people having ordinary skill in the art and are used for coupling the LED module  100  to an interior wall surrounding the cavity formed within the housing (not shown). The torsion spring  163  includes a ring portion  164 , a first rod  165  extending from the ring portion  164  in a first direction, and a second rod  166  extending from the ring portion  164  in a second direction. As the first rod  165  is moved closer to the second rod  166 , the first and second rods  165 ,  166  produce a biasing effect which, once coupled within a torsion spring receiver (not shown) in the housing, facilitates coupling of the LED module  100  into the housing&#39;s cavity, which is known to people having ordinary skill in the art. The fastening device  160  is coupled to the mounting pad  130  using a coupling device  206  ( FIG. 2 ), such as a screw, being inserted through a portion of the mounting bracket  162  and into the mounting pad  130 . The fastening device  160  and the adjustable coupling of the fastening device  160  to the mounting pads  130  are described in further detail below in conjunction with  FIGS. 3-5 . 
       FIG. 2  is an exploded view of the LED module  100  according to an exemplary embodiment of the present invention. Referring to  FIGS. 1A, 1B, 1C, and 2 , the heat sink  110  is formed as a single integral component and includes the first portion  111 , the second portion  121 , the mounting pads  130 , and the trim ring  140 . The LED package  250  is inserted into the cavity  135  formed within the heat sink  110  and is coupled to the mounting region  136 . The lens  190  also is inserted into the cavity  135  and is coupled to the internal surface  139  at about the distal end  146 , located between the first region  137  and the second region  138 . The gasket  180  is disposed on the trim ring  140  according to the description provided above. The fastening devices  160  are coupled to the mounting pads  130  using coupling devices  206 , such as screws, according to the description provided above and further descriptions to be provided below. The driver  170  is coupled to the top end of the heat sink&#39;s first portion  111  using coupling devices  202  according to the description provided above. Although  FIG. 2  illustrates several components being coupled together to form the LED module  100 , the LED module  100  is formed using fewer components and/or additional components, such as a modular reflector  610  ( FIG. 6 ), according to other exemplary embodiments. 
       FIG. 3  is a perspective view of the mounting bracket  162  according to an exemplary embodiment of the present invention.  FIG. 4  is a partial perspective view of the heat sink  110  illustrating the mounting pad  130  according to an exemplary embodiment of the present invention.  FIG. 5  is a partial perspective view of the LED module  100  illustrating the mounting bracket  162  coupled to the mounting pad  130  according to an exemplary embodiment of the present invention. Referring to  FIGS. 3-5 , the mounting bracket  162  is adjustably coupled to the mounting pad  130  and the torsion spring  163  is coupled to a portion of the mounting bracket  162 . 
     Referring to  FIG. 3 , the mounting bracket  162  includes a first portion  310 , a second portion  320 , and a tab  330 . In one exemplary embodiment, the second portion  320  and the tab  330  each extend substantially perpendicular to the first portion  310 . The first portion  310  and second portion  320  are substantially planar. Alternatively, one or both of the first  310  and second  320  portions is non-planar. The exemplary first portion  310  extends longitudinally from a first end  312  to a second end  314 . The first portion  310  includes a slot  316  that extends longitudinally along the first portion  310  and is positioned between the first end  312  and the second end  314 . The exemplary slot  316  extends through the first portion  310  and is formed during the casting process of the mounting bracket  162 . The first portion  310  also includes a lateral edge  311  extending downwardly from each of the longitudinal edges  309  of first portion&#39;s planar portion. The inner distance between each of the lateral edges  311  is slightly bigger than the width of the mounting pad  130  ( FIG. 4 ) to prevent the mounting bracket  162  from rotating or moving from side-to-side once couple to the respective mounting pad  130  ( FIG. 4 ). 
     The second portion  320  extends longitudinally from the first end  312  to an opposing end  322 . The second portion  320  includes a torsion spring bracket  324 , which facilitates coupling the torsion spring  163  to the second portion  320 . The torsion spring bracket  324  is formed by cutting through an interior portion of the second portion  320  and pushing a portion of the second portion  320 , which forms the torsion spring bracket  324 , into a different plane that is at an angle with the plane that the rest of the second portion  320  resides. The plane in which the torsion spring bracket  324  resides intersects with the first portion  310  according to some exemplary embodiments. 
     The exemplary tab  330  is substantially planar and extends longitudinally from a portion of the second end  314  to a distal end  332 . In certain exemplary embodiments, the tab  330  extends substantially from the middle of the second end  314 . The tab  330  extends in a plane that is substantially parallel to the plane of the second portion  320 . The exemplary mounting bracket  162  is fabricated as a single component, but can alternatively be fabricated in several components and thereafter assembled together. The mounting bracket  162  is fabricated using a polymer material, metal, metal alloy, or other suitable materials known to people having ordinary skill in the art. 
     Referring to  FIG. 4 , the mounting pad  130  includes a first portion  450  and a second portion  460  and, in certain exemplary embodiments, is positioned between two adjacent fins  118 . The first portion  450  extends substantially along a portion of the top surface  126  in a raised and radial manner, while the second portion  460  is substantially perpendicular to the first portion  450  and extends from one end of the first portion  450  along at least a portion of the sidewall  125 . The first portion  450  includes a first locating hole  452  and a second locating hole  453 , each dimensioned for receiving the tab  330  ( FIG. 3 ), and a coupling hole  454  that is dimensioned for receiving the coupling device  206  ( FIG. 2 ). In one exemplary embodiment, each locating hole  452 ,  453  and the coupling hole  454  are linearly aligned, but can be non-linearly aligned in other exemplary embodiments. According to some exemplary embodiments, the first locating hole  452  is positioned closest to the interior portion  113 , the coupling hole  454  is positioned furthest from the interior portion  113 , and the second locating hole  453  is positioned between the first locating hole  452  and the coupling hole  454 . The locating holes  452 ,  453  and the coupling hole  454  are formed by machining through at least a portion of the mounting pad&#39;s first portion  450 . The exemplary locating holes  452 ,  453  and coupling hole  454  are circular. Alternatively, the locating holes  452 ,  453  and/or the coupling hole  454  are shaped in other geometric or non-geometric shapes. According to one exemplary embodiment, the centerpoint of each adjacent locating hole  452 ,  453  are distanced one inch apart. However, the distance is variable in other exemplary embodiments. 
     Referring to  FIGS. 3-5 , the fastening device  160  is assembled and coupled to the mounting pad  130 . The fastening device  160  is assembled by snapping the torsion spring  163  onto the torsion spring bracket  324 . Specifically, the ring portion  164  is slid from the opposing end  322  of the mounting bracket&#39;s second portion  320  until the ring portion  164  snaps onto the torsion spring bracket  324 . However, other methods known to people having ordinary skill in the art can be used to coupled the torsion spring  163  to the mounting bracket  162 . 
     The fastening device  160  is coupled to the mounting pad  130  by positioning the mounting bracket&#39;s first portion  310  above and substantially parallel to the mounting pad&#39;s first portion  450  and the mounting bracket&#39;s second portion  320  adjacent and substantially parallel to the mounting pad&#39;s second portion  460 . According to one exemplary embodiment, the tab  330  is inserted into the second locating hole  453  and the coupling device  206  is inserted through the slot  316  and into the coupling hole  454 . Thus a portion of the coupling device  206  rests above the mounting bracket&#39;s first portion  310 , while a portion of the coupling device  206  is inserted and coupled within the coupling hole  454 . When the tab  330  is inserted into the second locating hole  453 , the LED module  100  fits within a housing having a certain nominal diameter cavity. However, if the LED module  100  is to be fitted within a housing having a smaller nominal diameter cavity, the coupling device  206  is loosened so that the tab  330  is removed from the second locating hole  453  and moved into the first locating hole  452 . When moving the tab  330  from the second locating hole  453  to the first locating hole  452 , the mounting bracket  162  is moved closer to the interior portion  113  by sliding the coupling device  206  along the length of the slot  316 . Once the tab  330  is inserted into the first locating hole  452 , the coupling device  206  is securely re-coupled into the coupling hole  454 . Alternatively, instead of loosening the coupling device  206 , the coupling device  206  is removed when adjusting the position of the mounting bracket  162 . Thus, the LED module  100  is capable of being installed within different housings having different nominal diameter cavities. 
     Although one example has been provided for achieving this flexibility, this flexibility is achievable in different manners, all of which are encompassed within the several exemplary embodiments. For instance, instead of a slot  316  formed into the first portion  310  of the mounting bracket  162 , two or more openings (not shown) are formed into the first portion  310  of the mounting bracket  162  in other exemplary embodiments. Each of these openings are capable of receiving the coupling device  206  therethrough. In another example, instead of locating holes  452 ,  453  formed into the mounting pad&#39;s first portion  450 , bosses (not shown) are formed in the same locations as the locating holes  452 ,  453  and openings (not shown) are formed into the first portion  310  of the mounting bracket  162  such that at least one opening fits onto and surrounds one of the bosses. The bosses are formed to extend above the top surface of the mounting pad&#39;s first portion  450 . In yet another example, instead of a slot  316  formed into the first portion  310  of the mounting bracket  162 , at least one opening (not shown) is formed into the first portion  310  of the mounting bracket  162  and a portion of the heat sink  110  includes one or more receiving holes (not shown) such that the coupling device  206  couples the mounting bracket  162  to the heat sink  110  by being inserted into the receiving hole through the opening on the mounting bracket  162 . 
       FIG. 4  is an exploded view of an LED module  600  according to another exemplary embodiment of the present invention. LED module  600  is similar to LED module  100  ( FIG. 2 ) except that LED module  600  includes the modular reflector  610 . The modular reflector  610  is parabolic-shaped and has a proximal end  620 , a distal end  630 , and a sidewall  640  extending from the perimeter of the proximal end  620  to the perimeter of the distal end  630 . The proximal end  620  has a smaller perimeter than the distal end  630  according to some exemplary embodiments; however, the proximal end  620  has a perimeter that is not smaller than the distal end  630  in other exemplary embodiments. The proximal end  620  includes a proximal opening  622  that is dimensioned so that the proximal end  620  is installed within the cavity  135  ( FIG. 1C ) and is disposed around the LED package  250  once installed therein. In one exemplary embodiment, the distal end  630  forms a flange  632  that bends outwardly from the reflector  610 . In certain exemplary embodiments, the creation of the flange  632  facilitates the coupling of the lens  190  to the distal end  630  of the reflector  610 . The exemplary parabolic-shaped reflector  610  focuses the light emitted by the LED packages  250  to create a beam of light that is emitted to the desired illumination area. The sidewall  640  of the reflector  610  includes an internal surface (not shown), which is reflective and smooth. Alternatively, the internal surface includes at least one of facets, prismatic elements, and/or dimples around the internal surface. The reflector  610  is fabricated using a reflective material or fabricated using a non-reflective material and subsequently made to be reflective by painting the internal surface with white reflective paint or other known methods. 
     Although the invention has been described with reference to specific embodiments, these descriptions are not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention will become apparent to persons of ordinary skill in the art upon reference to the description of the exemplary embodiments. It should be appreciated by those of ordinary skill in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures or methods for carrying out the same purposes of the invention. It should also be realized by those of ordinary skill in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. It is therefore, contemplated that the claims will cover any such modifications or embodiments that fall within the scope of the invention.