Patent Abstract:
A replaceable lighting head assembly comprised of a high output LED (Light Emitting Diode) socket torch package, vertically aligned thermal heat sink, and electrical connector coupled with a secondary housing unit that conducts heat received from the heat sink to the external environment and acts as a conduit for the external electrical source. This second component also serves as a building block for further fixture design. In this manner, state-of-the-art LED&#39;s can be used to provide light within a small, durable package which in turn, provides lighting designers with the opportunity to explore new fixture designs and to improve the quality, energy-efficiency, safety and longevity of existing products.

Full Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to a new assembly for packaging a high power dimmable LED light source that can be further incorporated into a larger lighting assembly. More specifically, this invention relates to a replaceable lighting head assembly comprised of a high output LED socket torch, a vertically aligned thermal heat sink and an electrical connector.  
       BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates to a new assembly for packaging a high power dimmable LED light source that can be further incorporated into a larger lighting assembly. More specifically, this invention relates to a replaceable lighting head assembly comprised of a high output LED socket torch, a vertically aligned thermal heat sink and an electrical connector. In itself, this section acts as an electrical inter-connect as well as a thermal heat sink interface suitable for small package integration. The secondary housing unit of this assembly provides a thermal pathway for the heat received from the heat sink to the external environment and acts as a conduit for easy access to the external electrical source. If desired, it can also act as a base for further fixture design functions. This assembly, when integrated into the design of a light housing, provides a means by which to manipulate the light beam of the lighting fixture.  
         [0003]     The evolution of electric lighting began in the late 1800&#39;s with the first incandescent bulb—essentially a “glowing wire in a bottle”. In spite of all the improvements, the light bulb that we use today is really not much different than the one invented by Thomas Edison. Inherent problems such as premature failures due to delicate glass structure or filaments, environmental concerns with the mercury, lead or toxic and flammable gases used, and intrinsic inefficiencies are still a concern. Less than 10% of the energy required to burn an incandescent light bulb is converted to light. Even flourescent lighting—today&#39;s most efficient light source, converts only 30-40% into light. Although not yet at the levels of flourescent lighting, LED&#39;s have the potential to convert up to 90% of the energy they receive into light. Further, light from conventional sources is emitted in all directions, requiring the use of optics to re-direct the beam in the desired direction for effective illumination. Each time the light is redirected, fixture efficiency decreases. The light generated by an LED, however, is directional so its efficiency doesn&#39;t have to necessarily match other light sources to be more effective.  
         [0004]     Much of the energy a standard filament light source consumes is converted into hot infrared rays that radiate out within the light beam, thus requiring extra caution when handling the bulb. Because of the heat generated, restrictions to the type and size of the casing around these bulbs must be maintained—all of which reduce the flexibility of the lighting system.  
         [0005]     Since the human eye is naturally drawn to the brightest source of illumination, flexibility is often required in the distribution of the light. General and accent lighting applications utilize this premise to direct the attention of the viewer to particular areas or items. If the first thing a viewer sees is the harsh light source, then their first impression may be negative. The increased size of the bulb casing results in a larger area from which the light emanates, thus requiring greater attention to positioning of the fixture to avoid direct eye contact with the light source itself.  
         [0006]     This flexibility is sometimes related to the light being used in a space that has changing requirements. An example is a retail space where different products are displayed in different ways each week. In this example, spot lights may be desirable for small items and wider beam lights may be appropriate for larger items. The option available today is to use fixtures with integral reflectors that have different beam spreads. One example of this is low-voltage halogen lamps, of which MR-16 is a common type. The MR-16&#39;s are available in several light beam spreads from very narrow spot to very wide flood. This strategy causes complications when lamps are changed after burning out. All MR-16&#39;s are very similar in appearance, and beam patterns within a space are only maintained after re-lamping if the exact same lamp is used to replace the burned out lamp. This strategy also requires many different lamp types to be kept on hand.  
         [0007]     In outdoor lighting, a fixture should be flexible enough to allow landscape or architectural features to be highlighted as elements change, such as when trees or bushes grow—as well as being discrete enough as to not draw the attention of the eye. If not, the resulting brightness one sees actually makes it harder to observe the surrounding environment as it causes everything else to appear darker. Further, traditional light sources have a relatively short life span, necessitating bulb replacement. This can be both time consuming and dangerous if such fixtures are mounted in an elevated position such as on the soffit of a building or high in a tree.  
         [0008]     Contrast to that, LED light sources offer small, directional pinpoints of light. Their size and directionality support highly controllable lighting systems capable of delivering high flux output at relatively low current levels for long periods of time. But in order to achieve this, thermal issues associated with high output LED lighting systems must be addressed. The challenge is to conduct the heat generated within the LED onto the fixture and then to dissipate that heat, via convection, to the surrounding ambient air. Proper design, therefore, must be given to the sizing of the heat sink to create both a pleasing aesthetic look and functional heat dissipation.  
         [0009]     It would thus be desirable to provide a lighting assembly contained within a small footprint that can be incorporated into various fixture designs. It would be further advantageous if that lighting assembly allows for easy adjustment of the light beam spread in addition to allowing for changes in light intensity through the use of collimating lenses—without having to change the bulb. It would be of further benefit if such assembly were to include a state-of-the-art high output LED for its long life, reduced maintenance cost and reduced cost of ownership—that is replaceable so that when advances in the industry become available the light source can be updated by the consumer.  
         [0010]     High output LED light sources are increasingly becoming the choice of illumination. These dimmable solid-state devices have no filament to break or glass to shatter, no mercury, toxic gases or lead to contaminate the environment and no infrared or UV in the light beam. They are fast approaching the efficiency of fluorescent light sources with new performance standards being achieved regularly.  
         [0011]     High output LED&#39;s differ from conventional LED light sources in that they are able to separate their thermal and electrical pathways. This enables them to draw more heat away from the emitter core and thus significantly reduce thermal resistance. As a result, high output LED&#39;s can handle significantly more power than conventional LED&#39;s. However, the higher electrical input also means they tend to operate at higher operating temperatures which can degrade their performance. Heat that is not effectively dissipated can shift colors, reduce brightness and significantly shorten their life span.  
         [0012]     Moreover, most heat sink configurations currently available are directed to a planar circuit board mount with a heat spreader or a horizontal finned heat sink design. Neither of these arrangements is suitable for small vertical package integration or compact lighting head construction.  
       ADVANTAGES AND SUMMARY OF THE INVENTION  
       [0013]     The present invention is a lighting assembly that provides for heat dissipation to achieve manufacturing efficiencies and product consistencies. The heat dissipating system removes heat from the LED that would otherwise shorten its life and/or reduce its brightness. Further, the present invention provides a lighting assembly wherein the light can be directed onto a single element or expanded to cover a wide area by its adjustable nature when called upon. The present invention further allows for easy replacement of the light source as called for when changes in light output, light pattern, or light color is desired—or as new performance standards are achieved.  
         [0014]     The present invention further provides a lighting head assembly that contains a high output dimmable LED socket torch attached to a vertically aligned thermal heat sink interface with a friction lock electrical interconnect. This assembly can be incorporated directly into the design of the fixture housing or inserted into the secondary housing unit to provide a thermal pathway for the heat generated by the LED and to provide for easy access to the external electrical source. This second component also serves as a foundation for additional design features—such as a sliding cylinder that adds further flexibility to the illumination system by allowing the expansion or contraction of the light beam or changing the intensity of the light beam through use of a collimating lens.  
         [0015]     The present invention further provides for simplified connection of the light assembly to the external power source and controller. Several controller options are readily available within the industry that allow for use of high power LED&#39;s in a variety of operating modes.  
         [0016]     Further details, objects and advantages of the present invention will be come apparent through the following descriptions, and will be included and incorporated herein.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]      FIG. 1  is a perspective view of one embodiment of the lighting head assembly  100  of the present invention.  
         [0018]      FIG. 2  is a perspective view of one embodiment of the high output LED socket torch  200 , vertically aligned thermal heat sink  13  and electrical connector assembly  15  and  19 .  
         [0019]      FIG. 3  and  4  are exploded side perspectives of an embodiment of the high output LED socket torch  200 , vertically aligned thermal heat sink  13  and electrical connector assembly  15  and  19  of the present invention  100 .  
         [0020]      FIG. 5  is an exploded perspective of one embodiment of the lighting head assembly  100  with sliding cylinder  30  removed.  
         [0021]      FIG. 6  is a cross-sectional view of the lighting head assembly  100  with sliding cylinder  30  in place.  
         [0022]      FIG. 7  is a sectional view of one embodiment of the LED emitter package  700 ;  
         [0023]      FIG. 8, 9  and  10  show alternative embodiments of LED emitter packages  700   a,    700   b  and  700   c.    
         [0024]      FIG. 11  is an exploded perspective of the high output LED socket torch  200   b  vertically aligned thermal heat sink  13   b  and electrical connector assembly  15  and  19  showing one type of coupler embodiment for alternative LED emitter packages.  
         [0025]      FIG. 12  is an exploded perspective of the lighting head assembly  100   b  using an alternative LED socket torch  200   b  and coupler  10   b  with sliding cylinder  30  removed.  
         [0026]      FIG. 13, 14  and  15  are side views of a complete lighting head assembly  100  with a tubular supplementary fixture design element  40  attached to the sliding cylinder  30  showing the contraction and expansion of the light beam  400 .  
         [0027]      FIG. 16  is a side view of the complete lighting head assembly  100  and one embodiment with a tubular supplementary fixture design element  40  attached to the sliding cylinder  30  and a collimating lens  42  inserted to manipulate the size and intensity of the light beam  400 .  
         [0028]      FIG. 17  and  18  shows an example of an alternative style element  40 d, that can be attached directly to the sliding cylinder  30  or supplementary fixture design element  40  and the subsequent manipulation of the light beam  400 .  
         [0029]      FIG. 19A, 19B ,  19 C and  19 D show alternative embodiments of lighting head assembly  100  each with a supplementary fixture design element  40 b with different shaped slit openings attached to the sliding cylinder  30 .  
         [0030]      FIG. 20A and 20B  show one embodiment of method of use of the present invention  100  on hanging object(s).  
         [0031]      FIG. 21A and 21B  show alternative embodiment of lighting head assembly  100  each with a supplementary fixture design element  40 c that attaches to the inside of the sliding cylinder  30  and also serves to lock the friction ring  31  in place.  
         [0032]      FIG. 22  shows one embodiment of another method of use of the present invention  100  on walkways.  
     
    
     DETAILED DESCRIPTION OF EMBODIMENTS  
       [0033]     The description that follows is presented to enable one skilled in the art to make and use the present invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be apparent to those skilled in the art, and the general principals discussed below may be applied to other embodiments and applications without departing from the scope and spirit of the invention. Therefore, the invention is not intended to be limited to the embodiments disclosed, but the invention is to be given the largest possible scope which is consistent with the principals and features described herein.  
         [0034]     It will be understood that in the event parts of different embodiments have similar functions or uses, they may have been given similar or identical reference numerals and descriptions. It will be understood that such duplication of reference numerals is intended solely for efficiency and ease of understanding the present invention, and are not to be construed as limiting in any way, or as implying that the various embodiments themselves are identical.  
         [0035]     The lighting head assembly  100  includes a high output LED socket torch  200 , a vertically aligned thermal heat sink  13 , an electrical connector assembly  15  and  19  and coupler  10  that fastens the lighting head assembly  100  to the secondary housing unit  20 . A sliding cylinder  30  attaches to the secondary housing unit  20  to provide a base to add various fixture design elements  40 ,  40   b,    40   c  and  40   d.    
         [0036]     As will hereinafter be more fully described, the present invention illustrates a lighting head assembly  100  that may be further incorporated into other lighting devices. In general, the present invention  100  is comprised of a replaceable high output LED socket torch  200  that provides essential heat transfer and electrical connectivity to a secondary housing unit  20  that further provides for manipulation of the light beam  400 . The present invention  100  therefore provides a convenient and economical assembly that has not been previously available in the prior art.  
         [0037]     The present invention  100  is specifically configured to incorporate high output LED lamps  700  into a socket torch package that can then be used in a lighting fixture. The high output LED lamp  700  as shown here is a Luxeon emitter. However, it should be understood that the mounting arrangement described is equally applicable to other high output LED lamps  700  as shown in  FIGS. 8, 9  and  10 .  
         [0038]     As shown in  FIG. 7 , the LED  700  has a mounting base  3  and a plastic lens  1  that encloses the LED emitter chip  2 . The LED  700  also includes two contact leads  5  that extend from opposite sides of the mounting base  3  to which power is connected to energize the emitter chip  2 . Since the emitter chip  2  in this type of high output LED lamp  700  has a greater surface area than conventional LED&#39;s, a great deal more heat is generated along with the increased light output. For this reason, a heat transfer slug  4  for the specific purpose of engagement with a supplementary heat sink  13  is provided. Within the LED  700 , the heat transfer slug  4  extends from the base  3  of the emitter chip  2 , to the bottom inside surface of the mounting base  3 , thus providing an thermal pathway to transfer the heat generated by the emitter chip  2 .  
         [0039]     In  FIG. 3 , the bottom portion of the LED base  3  mounts inside the upper portion of the emitter ring  11 , comprised of a thin non-conductive material capable of handling the anticipated temperature range within that area. The remaining portion of the emitter ring  11  then mounts over the heat transfer rod  12 , which is made of a thermally conductive solid cylindrical material. The end surface area of the rod  12  is sufficiently polished such that good thermal contact is made with the heat transfer slug  4 . In one embodiment, the heat transfer rod  12  is made of aluminum, however, other thermally conductive materials can also be used.  
         [0040]     As shown in  FIG. 4 , the contact leads  5  of the LED  700  are then pressed down over the non-conductive emitter ring  11  surface. The heat transfer rod  12 , with LED assembly  700  attached, is then inserted into the tubular vertically aligned thermal heat sink  13  up to the bottom rim of the emitter ring  11 .  
         [0041]     In one embodiment, the vertically aligned thermal heat sink  13  is cylindrically shaped and extending in a direction to surround the heat transfer rod  12 . The outside diameter of the heat transfer rod  12  is slightly less than the inside diameter of the vertically aligned thermal heat sink  13  resulting in an intimate fit between the two thermally conductive materials such that sufficient contact is made to facilitate the transfer of heat from the heat transfer rod  12  to the vertically aligned heat sink  13 . In one embodiment, the vertically aligned thermal heat sink  13  is made of aluminum. However, other thermally conductive materials or compounds for improving thermal transfer can also be used.  
         [0042]     To further facilitate the transfer of heat and to aid in the strength of the connections, a thermally conductive adhesive or thermal compound may be applied at all heat transfer connections.  
         [0043]     A groove  14  is present on opposite sides of one end of the vertically aligned heat sink  13 . These grooves extend slightly past the bottom rim of the inserted heat transfer rod  12  and align with the two contact leads  5  that extend from the sides of the LED  700 .  
         [0044]     The electrical wires  16  of the electrical connector assembly  15  and  19  run inside the vertically aligned heat sink  13 , then feed through the cavity created by each of these grooves  14 . The wire ends are then soldered to the contact leads  5  of the LED  700  over the area of the non-conductive material of the emitter ring  11  such that no electrical contact is made with the rest of the assembly.  
         [0045]     The other end of the electrical wires  16  are connected via soldering to the back end of the pin headers  15  of the vertical friction lock  19 . This electrical connector assembly  15  and  19  is then encased within the 14-22 AWG nylon closed end connector  17  that has the tip of its stem opened to allow the electrical wires  16  to pass. In one embodiment, the 14-22 AWG nylon closed end connector  17  serves to center and contains the vertical friction lock for mating with the crimp terminal housing  21 . It should be understood that this function can be achieved using various alternatives materials. An anti-oxidant grease can be applied to each of the soldered connections and then covered with a non-conductive heat shrink material or similar electrically isolating material.  
         [0046]     As shown in  FIGS. 4, 5  &amp;  6 , electrical connector assembly  15  and  19  and 14-22 AWG nylon closed end connector  17  are then placed inside the coupler  10  so that the upper rim of the coupler  10  extends up to the bottom portion of the LED base  3 , covering the emitter ring  11 , the soldered connections of the two contact leads  5 , the heat shrink material and the grooves  14  of the vertically aligned thermal heat sink  13 . The upper half of the coupler  10  is then filled with a non-conductive potting epoxy  18  to encapsulate the area. The bottom half of the coupler  10  is left un-potted to allow coupling to the secondary housing unit  20 .  
         [0047]     As shown in  FIG. 5  and  6 , a sliding cylinder ring stop  27  is attached to the secondary housing unit  20  just beyond the reach of the bottom rim of the coupler  10  to prevent its dislodging by the sliding cylinder  30  when the lighting head assembly  100  is inserted. In one embodiment, the coupler  10  is of an electrically conductive metal material requiring separation from the soldered connections. Alternatively, if the coupler  10  is not intended to aid in the dissipation of heat in the overall fixture design, the coupler  10  can be made of a non-electrically conductive material. In which case the use of the electrically isolating material would not be necessary.  
         [0048]     It will be understood by those skilled in the art that any type of flared or shaped glare shield can be utilized in the present invention by coupling directly to the slidable cylinder  30  in order to focus, shape or direct the light emitted therefrom. Thus, an auxiliary flared or shaped glare shield can be moved backward and forward, along the secondary housing unit  20 , and over and around the LED socket torch portion  200  of the lighting head assembly of the present invention. The present invention provides a sliding cylinder  30  disposed around or on top of the secondary housing unit portion  20  in which any LED socket torch package or bulb  200  of the present invention can be utilized. Thus, depending upon the shape of an adapter glare shield fitting attached to the sliding cylinder  30 , the combination of sliding cylinder  30  and flared or shaped glare shield or beam shaper or other lens fitting can slide down over the LED light torch socket  200  in order to focus, shape, broaden or narrow the beam of light emitted therefrom.  
         [0049]     As shown in  FIG. 8, 9  and  10 ,  11  and  12 , larger LED lamps  700   a,    700   b  and  700   c  can be accommodated within the lighting head assembly  100  by scaling the components including LED base  3   b,  coupler  10   b,  heat transfer rod  12   b,  thermal heat sink  13   b,  secondary housing unit  20   b,  nylon closed end connector  25   b  and sliding cylinder stop  27   b  to fit the size of the LED lamps  700   a,    700   b  and  700   c.    
         [0050]     In one embodiment, a single LED may comprise a plurality of emitter chips. Often red diode(s) are placed with green diode(s) and blue diode(s). In other cases, other combinations of colors can be used. As shown in  FIG. 8 , the LED lamp  700   a  has a single emitter chip  2 ′ within each lens  1 ′. In the LED lamp  700   b  shown in  FIG. 9 , a single lens  1 ″ houses multiple emitter chips  2 ″.  
         [0051]     The replaceable high output LED socket torch  200  is inserted into the secondary housing unit  20  to provide thermal transfer of the heat sink  13  to the external environment or can be inserted into a thermal design embodied within a fixture that is equally effective.  
         [0052]     In one embodiment, the vertically aligned thermal heat sink  13  is cylindrically shaped. The outside diameter is slightly less than the inside diameter of the secondary housing unit  20  resulting in an intimate fit between the two thermally conductive materials when inserted. Therefore, when inserted, heat from the vertically aligned thermal heat sink  13  is conducted to the secondary housing unit  20  and then released to the environment through convection. A heat sink compound can be applied to further aid in the heat transfer. Further, if a permanent connection is desired, then a heat sink adhesive can be applied.  
         [0053]     It should be understood that the mounting arrangement described is equally applicable to various dimensions and shapes of the mating units as long as the fit allows for the thermal transfer of heat.  
         [0054]     The replaceable high output LED socket torch  200  is electrically connected to the secondary housing unit  20  through connection of the electrical connector assembly  15  and  19  and the crimp terminal housing  21 , as best shown in  FIG. 5 .  
         [0055]     Another embodiment shown in  FIGS. 5 &amp; 6  illustrates the lower portion of the crimp terminal housing  21  encased in a  14 - 22  AWG or similar nylon or other material closed end connector  23  that has the tip of its stem opened to allow the electrical wires  26  to pass. In one embodiment, 14-22 AWG nylon closed end connector  23  serves to align the crimp terminal housing  21  within the secondary housing unit  20  and provides a means to connect the spring  24  to the crimp terminal housing  21 .  
         [0056]     Also as shown in  FIG. 5 , the spring  24  provides insertion resistance necessary for mating of the pin headers  15  of the vertical friction lock  19  to the wire crimp terminals  22  found within the crimp terminal housing, and aids in the positioning of the crimp terminal housing  21  for accepting the vertical friction lock  19  of the electrical connector assembly  15  and  19  At the base of the spring  24  is a 12-10 AWG nylon closed end connector  25  that has the tip of its stem opened to allow the electrical wires  26  to pass. The 12-10 AWG nylon closed end connector  25  serves to center and contain the spring  24  at its proper depth although other means could achieve the same desired effect.  
         [0057]     Electrical wire leads  26  extending beyond the secondary housing unit  20  provide connection of the light assembly  100  to a variety of external power sources and controllers. Several options are readily available within the industry that allow for use of high output LED&#39;s in a variety of operating modes and wiring configurations. Alternate assemblies could use additional wiring to connect multiple LED emitter chips that are packaged within a single die  700   a  or within a single cavity  700   b.  Therefore, combinations of 2 or more wires might be used to individually control each emitter chip within the LED die.  
         [0058]     As shown in  FIG. 6, 13 ,  14 ,  15  and  16 , the cylindrical shape of the secondary housing unit  20  allows for a cylindrically shaped coupler to be manipulated up or down its length. In one embodiment a sliding cylinder  30  is added to the secondary housing unit  20  to provide a means by which to manipulate the light beam  400  and/or aid in the transfer of heat to the environment.  
         [0059]     One opening of the sliding cylinder  30  aligns the shaft of the secondary housing unit  20  to fit within a friction ring  31  used to avoid metal to metal contact when the secondary housing unit  20  is manipulated within the sliding cylinder  30 . In one embodiment, the friction ring  31  is comprised of High Density Polyethylene (HDPE) tubing for its excellent chemical, fatigue, wear resistance and heat tolerance. Other materials could serve the same purpose of providing sufficient frictional grip to prevent the secondary housing unit  20  from slipping once it is positioned, while still allowing for shaft movement when desired.  
         [0060]     The friction ring  31  is held in place on one end by the narrowing cavity of the sliding cylinder  30 , and on the other by the thermally conductive friction ring lock  32 . The inside diameter of the friction ring lock  32  is slightly greater than the outside diameter of the secondary housing unit  20  and the outside diameter of the friction ring lock  32  is slightly smaller than the inside diameter of the sliding cylinder  30  resulting in an intimate fit between the thermally conductive materials. Therefore, the friction ring lock  32  serves to transfer heat from the secondary housing unit  20  to the sliding cylinder  30 . The friction ring  31  can also be locked in place by use of a supplementary fixture design element  40   c  that attaches to the inside of the sliding cylinder  30 .  
         [0061]     It should be understood that the mounting arrangement described is equally applicable to sliding couplers of differing designs, shapes and sizes.  
         [0062]     In one embodiment, as shown in  FIGS. 13-16 , the sliding cylinder  30  serves as a base on to which additional design elements can be attached. By adding a removable tubular glare shield  40  over or within the flared opening of the sliding cylinder  30  and sliding it up and down the shaft of the secondary housing unit  20 , the LED  700  can be manipulated to the forefront or backmost region of the glare shield  40  to produce a light beam  400  that alters from spot as shown in  FIG. 13  to flood as shown in  FIG. 15 . Alternatively, the sliding cylinder  30  itself can be shaped to achieve the above-mentioned functions.  
         [0063]     As best shown in  FIG. 16 , by inserting one of the many collimating lenses  42  and their supplementary lens holders  41  readily available in the industry within the removable glare shield  40 , the shape and intensity of the light beam  400  can be further manipulated within set patterns.  
         [0064]     As shown in  FIGS. 17 &amp; 18 , additional design elements  40 d can be added to the secondary housing unit  20  by coupling either over or inside the sliding cylinder  30  or tubular glare shield  40 , or by use of different size tubing, couplers and/or cylinders to produce alternative fixture designs and functions.  
         [0065]     As best shown in  FIG. 19A, 19B ,  19 C and  19 D, the use of oval, rectangular or other shapes of design elements attached to the removable glare shield  40 b can be used to achieve the corresponding desired light beam  400  pattern. As shown in  FIG. 20A and 20B , in this manner, items on a horizontal or vertical plane can be “framed” with light beam  400  from the adjustable fixture.  
         [0066]      FIGS. 21A and 21B  show an alternative method of controlling shape of light beam  400  by attaching supplementary fixture design element  40   c  within the sliding cylinder  30 . The further away the LED unit  700  is from the opening of supplementary fixture design element  40   c,  the narrower the light beam  400 , and vice versa. In this manner, user(s) can easily change the effect of light beam  400  from spot light to flood light effects.  
         [0067]      FIG. 22  shows one embodiment of another method of use of the present invention  100  on a walkway. By altering the light beam  400  effects, user(s) can generate a desirable lighting ambiance for both practical and aesthetic purposes.  
         [0068]     Modifications and alterations to the above described embodiments will become manifest to those skilled in the art upon reading and understanding the preceding detailed description. It is intended that the various modifications are to be within the scope of the present invention insofar as they come within the scope of the appended claims or the equivalents thereof.  
         [0069]     In order to better utilize the advantageous features high output LED&#39;s offer, proper thermal design is imperative. The objective is to dissipate the electrical energy the LED receives that is not converted into light, to the surrounding ambient air. To achieve this, the amount of energy the final fixture design will need to dissipate should be calculated. The following shows a general outline for calculating thermal heat sink requirement of a luminaire or other LED socket touch package of the present invention  100  operating under various conditions.  
         [0070]     Step 1) Take the manufacturer specified maximum allowable junction temperature of the LED emitter. Subtract the maximum ambient air temperature the fixture is likely to encounter and Divide by the Power Dissipated (P d ) of the LED as measured in Watts [Forward current (I f )*Forward voltage (V f )] Or: 
 
 R⊖   junction-ambient =( T   junction-ambient )/ Pd  
 
         [0071]     Step 2) Subtract the manufacturer specified junction thermal resistance of the LED to emitter slug 4(R⊖ j-b ) Or: 
 
(R⊖ junction-ambient )−(R⊖ j-b ) 
 
         [0072]     Which will give you the amount of energy—as measured in ° Celsius (ΔT)/Watts (P d ), which needs to be dissipated within the exposed surface area of the heat sink of the fixture.  
       EXAMPLE 1  
       [0073]     A Blue Luxeon III emitter with an average V f  of 3.7 Volts, driven at 700 mA would require a heat sink that can dissipate 2.59 Watts of energy (making no adjustments for the energy that is converted to light). Assuming a maximum ambient air temperature of 40° C. (104° F.) that the designer feels the fixture is likely to encounter, and the maximum junction temperature the emitter can handle of 135° C. (varies with model of LED), and the manufacturer&#39;s specified thermal resistance of the LED emitter chip to slug of 13° C./W (as defined by the manufacturer), then 
 
( R⊖   junction-ambient )−( Rβ   j-b )=23.68° C./W 
 
         [0074]     A luminaire or other LED socket torch package of the present invention operating under these conditions would need approximately 2 to 6 sq. inches of heat sink surface area depending on the material used and its orientation.  
       EXAMPLE 2  
       [0075]     If you wanted to increase the light output of this same LED socket torch, then you could increase the current at which the LED is driven. By increasing the current from 0.700 mA to 1.0 MA, the heat sink would have to now dissipate 3.7 Watts of energy. The necessary surface area would change to 12.68° C./W which equates to anywhere from 9 to 12 sq. inches of heat sink surface area—depending on the materials used in the construction of the luminaire and its orientation.  
       EXAMPLE 3  
       [0076]     If you changed the maximum temperature you want the LED&#39;s emitter junction to reach to 90° C. under the same expected conditions in order to increase the life of the LED, then driven at 1.0 mA you would have to increase the surface area of the heat sink to approximately 20 sq. inches or more.  
         [0077]     Various strategies are available to keep the LED emitter chip  2  below its rated operating junction temperature which include: 1] Control the maximum operating ambient air temperature to be encountered by the luminaire 2] Control the orientation of the heat sink portion of the luminaire (vertical versus horizontal, etc.), 3] Manage the Power Dissipated by the LED by limiting the current applied to the LED and/or using only LED&#39;s within an allowable forward voltage range, 4] Select an appropriate heat sink material with sufficient thermal conductivity, 5] Use an LED with a higher operating temperature rating, 6] Provide sufficient heat sink surface area within the luminaire.  
         [0078]     Of these, providing sufficient heat sink surface area and selecting appropriate heat sink materials fall within the fixture design process. For example, referring to  FIG. 13  if the secondary housing unit  20  has an outside diameter of ½ inch, then the Surface Area=2*Π* radius*height or 1.57 sq. inches of Surface Area per inch of length. A sliding cylinder  30  that tapers from 0.625 to 0.875 inches and is 1 ½ inches long would have a Surface Area of 3.73 sq. inches and a glare shield  40  that has an outside diameter of 1 inch would have 3.14 sq. inches of Surface Area per inch of length.  
         [0079]     Various combinations can be configured to meet surface area requirements. A luminaire requiring 10 sq. inches of heat sink surface area could be met with a secondary housing unit ( 20 ) 6 ½ inches in length or a combination of 4 ½ inches of secondary housing unit used in conjunction with the sliding cylinder  30 . Using materials with better thermal conductivity (e.g. copper vs. stainless steel) can greatly effect the amount of heat sink surface area required.  
         [0080]     Further, as temperature tolerances of next-generation high output LED&#39;s increase, heat sink requirements will be reduced—opening new design possibilities with higher current operation for increased light output. With implementation of the present invention, lighting designers will be able to incorporate a replaceable lighting assembly contained within a small footprint into various fixture designs that allow for easy adjustment of the light beam spread, pattern, color and intensity.  
         [0081]     The present invention is a lighting head assembly having: a directional, high output, replaceable LED socket torch; a vertically aligned thermal heat sink shaft for communicating thermal energy away from the LED socket torch in a direction opposite the orientation of directionality of the LED; a cylindrical housing having a proximal end and a distal end, the proximal end for receiving and maintaining the socket torch in intimate contact with the heat sink shaft; and an electrical connection disposed within the housing for coupling the LED socket torch to an external electrical source adjacent the distal end of the cylindrical housing.  
         [0082]     In an embodiment, the replaceable LED socket torch comprises: an LED emitter; a base portion formed of a heat-resistant material, the LED emitter coupled directly to the base portion; an essentially transparent protective covering over the LED emitter connected to the base portion; an intermediate heat sink, the heat sink in intimate contact with the base portion for providing efficient thermal conduction away from the LED emitter; a distal end having a socket connector mounting portion, thus providing a secure, releasable and reconnectable mechanical connection between the replaceable LED socket torch and the lighting head assembly; and at least two electrical leads connected to the LED emitter extending beyond the base portion, at least one of the at least two electrical leads electrically isolated from the heat sink, the at least 2 electrical leads terminating at the distal end, thus providing at least two contacts for communication of electrical energy to the lighting head assembly.  
         [0083]     In an embodiment, of the lighting head assembly, a slidable focusing element is coupled to the housing and light torch assembly for focusing the light created by the LED emitter as desired.  
         [0084]     In an embodiment, of the lighting head assembly, a mounting bracket is coupled to the cylindrical housing for mounting the lighting head assembly as desired  
         [0085]     The present invention is a directional, high output, replaceable LED socket torch for use in lighting applications, the LED socket torch comprising: an LED emitter having an electrically isolated base and plurality of electrical inputs; a heat sink shaft in intimate contact with the base of the LED emitter; an emitter ring for coupling the heat sink shaft to the LED emitter; a housing having a proximal end and a distal end, the LED emitter seated within the housing at the proximal end such that the heat sink shaft extends distally there within; an end socket connector seated within the distal end of the housing; and electrical contacts extending through the housing from the plurality of electrical inputs of the LED emitter to the end connector, whereby upon coupling the LED socket torch to a source of electrical energy, light is produced by the LED emitter and heat formed by the LED emitter is transferred through the base to the heat sink shaft for dissipation through the end socket connector.  
         [0086]     In an embodiment of the LED socket torch, the electrical contacts further comprise wire prongs extending distally from the distal end of the housing.  
         [0087]     The present invention is a lighting head assembly for providing directional, high-output illumination, the lighting head assembly having: a high output, replaceable LED socket torch comprising:  
         [0088]     an LED emitter having an electrically isolated base and plurality of electrical inputs which provides high-output beam of illumination; a vertically aligned thermal heat sink shaft in intimate contact with the base of the LED emitter for dissipating heat generated by the LED emitter; an emitter ring for maintaining the heat sink shaft in intimate contact with the LED emitter; a socket torch housing having a proximal end and a distal end, the LED emitter located adjacent the proximal end such that the heat sink shaft extends axially through at least a portion of the socket torch housing at the proximal end; an end socket quick connect-type connector located at the distal end of the socket torch housing; and electrical contacts extending through the socket torch housing from the plurality of electrical inputs of the LED emitter to the end socket connector, whereby upon coupling the LED socket torch to a source of electrical energy, light is produced by the LED emitter and heat formed by the LED emitter is transferred through the electrically isolated base to the heat sink shaft for dissipation of heat therethrough; a tubular base portion housing having a proximal end and a distal end, the proximal end for receiving and maintaining the replaceable LED socket torch; a slidable tubular coupling having a proximal end and a distal end, the distal end having a predetermined internal diameter such that the distal end is disposed in intimate contact around the tubular base portion, the slidable coupling further having a proximal end, the slidable coupling having a predetermined length such that when the slidable coupling is positioned adjacent the proximal end of the tubular base portion housing the proximal end of the slidable tubular coupling shields the glare of the beam of LED illumination and permits shaping of the beam of illumination as desired; and an electrical connection disposed within the housing for coupling the LED socket torch to an external electrical source adjacent the distal end of the cylindrical housing.  
         [0089]     In an embodiment of the present invention, the slidable tubular coupling is adapted for coupling a glare shield portion thereto.  
         [0090]     In an embodiment of the present invention, a glare shield portion is removably coupled to the slidable tubular coupling for shaping and directing the beam of illumination as desired.  
         [0091]     In an embodiment of the present invention, a mechanical stop is adjacent the proximal end of the tubular base portion for preventing the slidable coupling from moving past the proximal end of the tubular base portion.  
         [0092]     In an embodiment of the present invention, the mechanical stop comprises a cylindrical ring bonded to the proximal end of the tubular base portion.  
         [0093]     In an embodiment of the present invention, the internal diameter of the proximal end of the slidable coupling is greater than the outside diameter of the cylindrical ring, such that the proximal end of the slidable coupling is unimpeded by the cylindrical ring mechanical stop.  
         [0094]     In an embodiment of the present invention, the proximal end of the slidable coupling has a predetermined internal diameter greater than the predetermined internal diameter of the distal end thereof.  
         [0095]     Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs. Although any methods and materials similar or equivalent to those described can be used in the practice or testing of the present invention, methods and materials are now described. All publications and patent documents referenced in the present invention are incorporated herein by reference.  
         [0096]     While the principles of the invention have been made clear in illustrative embodiments, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted to specific environments and operative requirements without departing from those principles. The appended claims are intended to cover and embrace any and all such modifications, with the limits only of the true purview, spirit and scope of the invention.

Technology Classification (CPC): 5