Patent Publication Number: US-10323839-B1

Title: LED light assembly having axially coupled LED light modules

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application No. 61/980,826, filed Apr. 17, 2014, the entire contents of which are incorporated by reference herein. 
    
    
     BACKGROUND OF THE INVENTION 
     Light emitting diode (LED) street lamps are well known in the art. Such street lamps are configured with various constructions to provide different light distribution patterns in accordance with various codes and requirements. As shown in  FIGS. 1 and 2 , a standard prior art design includes a frame-shaped housing in which a plurality of LED light modules are supported. The light modules each include an LED lighting element mounted to a heat dissipation block. The LED driver is controlled within the housing and electronically coupled to the LED elements using any known technique. The housings are configured so as to provide edge support to the modules with the modules being aligned side-by-side. With a single-column array, as shown in  FIGS. 1 and 2 , each module spans an open lighting window defined by the frame. One or more intermediate dividers may be provided, as shown in  FIG. 3 , which provide support for a multi-column array within the lighting window. Optical lenses may be provided with one or more of the light modules (covering the LED elements) to widen or otherwise distort a light distribution pattern. Such widening and/or distortion may be in single or multiple direction(s). 
     SUMMARY OF THE INVENTION 
     In a first aspect of the subject invention, an LED light assembly is provided comprising: a housing; and, a plurality of LED light modules coupled together in axial end-to-end fashion so as to define an elongated lighting strip, each said light module including at least one heat dissipation block and at least one LED element, wherein, said lighting strip is secured to said housing. 
     In a further aspect of the subject invention, an LED light assembly is provided comprising: a housing; at least one LED light module having an heat dissipation block and at least one LED element, at least one channel being defined through said heat dissipation block; and, at least one support formed to pass through said at least one channel, wherein, said light module is secured to said housing with said at least one support passing through said at least one channel. 
     In yet a further aspect of the subject invention, an LED light assembly is provided comprising: a housing having a mounting wall; at least one LED light module including at least one heat dissipation block and at least one LED element, wherein, said lighting strip is secured to said housing, and, wherein said heat dissipation block of at least one said light module is canted so that with placement of said canted heat dissipation block against said mounting wall, the corresponding said at least one LED element is disposed in a plane not perpendicular to the plane of said mounting wall. 
     In yet a further aspect of the subject invention, a LED module is provided comprising: a base; at least one LED element secured to said base; and, a plurality of fins extending from said base opposite said at least one LED element, wherein, portions of at least one said fin adjacent to said base defines protrusions. 
     These and other features of the invention will be better understood through a study of the following detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1-3  show prior art LED module lighting arrangements; and, 
         FIGS. 4-21  show various aspects of the subject invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A LED lighting assembly  10  is provided herein which is useable for various applications and is particularly well-suited for street and other outdoor lighting applications. As will be recognized by those skilled in the art, the subject invention allows for arrays of different light modules to be provided mounted in different orientations with different throw resulting in different light distribution patterns. The different aspects of the invention described herein may be used singularly or in various combinations. 
     In a first embodiment, with reference to the Figures, the LED light assembly  10  generally includes a housing  12  and at least one lighting strip  14 . The lighting strip  14  includes a plurality of LED light modules  16  arranged in axial end-to-end fashion. As a result, the lighting strip  14  has an elongated shape which extends between first and second ends  18 ,  20 . 
     Each of the light modules  16  includes at least one heat dissipation block  22  and at least one LED element  24 . The heat dissipation block  22  is formed of a heat conductive material such as aluminum or other metallic material. The LED element  24  may be of any known configuration, and may include one or more lighting elements. The LED element  24  may be provided as a board. The LED element  24  is secured to the heat dissipation body  22  so that heat from operation of the LED element  24  is drawn therefrom and dissipated by the heat dissipation block  22 . The heat dissipation block  22  may be of various configurations including being defined by a plurality of fins  26 . Optical lenses may be optionally provided with one or more of the light modules  16  to widen or otherwise distort the light generated by the LED elements  24 . 
     The light modules  16  each include first and second ends  28 ,  30  which are axially aligned in defining the lighting strip  14 . The ends  28 ,  30  of adjacent light modules  16  are joined using any known technique. For example, mechanical interlocking may be utilized wherein portions of the heat dissipation blocks  22  of adjacent light modules  16  are forcibly joined, such as through mechanical deformation. In addition, or alternatively, one or more joining elements  32  may be utilized, such as keys  34 . The ends  28 ,  30  of the light modules  16  may be formed with slots  36  into which the keys  34  may be inserted to provide retentive force to couple together adjacent light module  16 . The keys  34  and the slots  36  may have corresponding matching cross-sectional shapes, such as one or more dovetails. In addition, it is preferred that the keys  34  be shaped slightly larger than the corresponding slots  36  so that interference fits are provided. 
     One or more LED drivers may be accommodated inside the housing  12  as is known in the art. The drivers may be coupled with the LED element  24  in any known manner. Dimmers, light sensors, and other controls may be also provided. 
     The housing  12  may be of any known configuration and may include a mounting flange  38  or other mounting structure for mounting the LED light assembly  10  to a desired location. The mounting flange  38  may be adapted for surface mounting, wire mounting (e.g., wire suspended mounting), or pole mounting. In addition, the housing  12  defines at least one mounting surface  40  to which the lighting strip  14  is secured. Mounting features, such as screw holes, hooks, detents, and so forth may be provided which are configured to securingly engage the lighting strip  14 . 
     It is preferred that the lighting strip  14  be secured to the housing  12  at the mounting surface  40  with one or more points of securement  42  located at mid-points along its length between the first and second ends  18 ,  20 . The points of securement  42  may be at channels  44  formed in one or more of the heat dissipation blocks  22  of the LED modules  16 . The channels  44  may be perpendicular to and/or parallel to the LED element  24  depending on the intended mounting orientation of the lighting strip  14  to the housing  12 . For example, the lighting strip  14  may be mounted to project light generally perpendicularly from, or, alternatively, generally parallel to, the axis of mounting of the housing  12 , e.g., through the mounting flange  38 , to a target surface (e.g., wall mounted (light projection generally perpendicular to axis of mounting ( FIG. 4A )), ceiling mounted (light projection generally parallel to axis of mounting ( FIG. 4B ))). Fasteners  46 , such as screws, may be passed through the channels  44  to engage the housing  12 . In addition, or alternatively, one or more channels  44  may pass through the keys  34 . 
     As will be appreciated by those skilled in the art, to provide for multi-column arrays of the light module  16 , a plurality of lighting strips  14  may be arranged in general parallel fashion and secured to an adjacent lighting strip  14  and/or to the housing  12  ( FIG. 14 ). For example, the channels  44  of a plurality of the lighting strips  14  may be aligned with fasteners  46  passing through each of the lighting strips  14  for providing securement. In addition, or alternatively, one or more of the keys  34  may be provided with sufficient length to pass through a plurality of pairs of the light modules  16  to retain a plurality of parallel sets of joined light modules  16  ( FIG. 14 ). The keys  34  and/or the fasteners  46  may be used to secure adjacent pairs of the lighting strips  14  in various combinations. 
     To provide additional stability, one or more straps  48  may be secured from the housing  12  to the first and/or second ends  18 ,  20  of one or more of the lighting strips  14 . The one or more straps  48  may be used to secure one or more of the lighting strips  14  to the housing  12 . The straps  48  may generate a force which presses one or more of the lighting strips  14  against the housing  12 , e.g., pressing against at least one mounting surface  40 , sufficiently to provide retention thereof. In this manner, additional mounting features may be optionally avoided. 
     One or more spacers may be provided between adjacent pairs of the lighting strips  14  to permit air flow therebetween. In addition, as shown in  FIGS. 4-6 , decorative strips  49  may be provided along one or more sides of the lighting strip  14  to provide a more aesthetically appealing look for the LED lighting assembly  10 . The decorative strips  49  preferably are spaced from the heat dissipation blocks  22  to not restrict air flow therepast. The decorative strips  49  may be perforated to allow air flow therethrough. The decorative strips  49  may be metallic and/or non-metallic. 
     As will be understood by those skilled in the art, the fasteners  46  need not be threaded to provide securement to the housing  12 . The fasteners  46  may be secured to the housing  12  with various interconnections, such as bayonet locking, friction fit, and so forth. 
     With reference to  FIGS. 15-17 , one or more of the LED light modules  16  may be canted so as to have angled faces  50  between its ends  18 ,  20 . As best shown in  FIG. 16 , with the canted light module  16  being placed against the mounting surface  40 , the LED element  24  is disposed to not be perpendicular to the plane A of the mounting surface  40 . Face-to-face engagement may be provided between the canted light module  16  and the mounting surface  40  to allow for stable securement of the canted light module  16  to the housing  12 . This allows for additional throw to be provided for the canted light module  16 . The additional throw may obviate the need for an optical lens (e.g., a larger light distribution pattern may be achieved without the need for optical lenses). 
     The housing  12  may be shaped as a prior art frame-shaped housing described above. One or more lighting strips  14  may be edge supported by the frame without need for intermediate dividers. In this manner, a plurality of the light modules  16  coupled together in axial end-to-end fashion may be provided to span the frame without requiring mid-span support from intermediate divider(s). 
     With reference to  FIGS. 18-21 , portions  52  of the heat dissipation block  22  may be formed with protrusions  54  to increase heat dissipation. It is preferred that the portions  52  be located in proximity to base  56  to which the LED element  24  is secured. The fins  26  may extend from the base  56  opposite from the LED element  24 . In this manner, heat is drawn for the LED element  24  by the base  56  to the fins  26 . 
     The portions  52  may be defined on the fins  26  adjacent to the base  56 . Preferably, the portions  52  extend only partially along the fins  26  near the base  56 . It is preferred that the protrusions  54  be disposed along a limited length of the fins  26  extending from the base  56 . With this arrangement, greater heat dissipation may be achieved adjacent to the base  56 . With the escaping of this dissipated heat between the fins  26 , greater heat dissipation may be achieved along the full length of the fins  26 . The heat escaping between the fins  26  will cause air flow along the fins  26  with such air flow causing additional heat dissipation along the length of the fins  26 . 
     The portions  52  may be of various configurations which increase surface area of the fins  26 . By way of non-limiting example, the portions  52  may be fin-shaped. The portions  52  may be continuous or discontinuous and extend in various directions (away from the base  56 , parallel to the base  56 , oblique to the base  56 , random or irregular directions, and so forth). 
     The different aspects herein (the lighting strip; channel mid-support; canting; protrusions) may be used singularly or in any combination.