Patent Abstract:
LED assemblies, lens-less luminaires, and methods of use are provided herein. According to some embodiments, the present technology may contemplate a lighting assembly that includes a reflector in association with a light emitting diode (LED) light source, the LED light source contacting a cooling device, wherein the LED light source is electrically coupled to a power source; and a mounting plate for coupling the lighting assembly to a luminaire.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
       [0001]    This Non-Provisional U.S. patent application claims the priority benefit of U.S. Provisional Application Ser. No. 61/661,330, filed on Jun. 18, 2012, which is hereby incorporated by reference herein in its entirety including all references cited therein. 
     
    
       [0002]    The present technology relates generally to light emitting diode (LED) lighting assemblies, and more specifically, but not by way of limitation, to LED lighting assemblies and lighting fixtures, such as luminaires, which incorporate the LED lighting assemblies of the present technology. Additionally, LED lighting assemblies of the present technology may be utilized to retrofit existing lighting fixtures that currently utilize inefficient lighting technology. 
       FIELD OF THE PRESENT TECHNOLOGY 
       [0003]    The present technology relates generally to light emitting diode (LED) lighting assemblies, and more specifically, but not by way of limitation, to LED lighting assemblies and lighting fixtures, such as luminaires, which incorporate the LED lighting assemblies of the present technology. Additionally, LED lighting assemblies of the present technology may be utilized to retrofit existing lighting fixtures that currently utilize inefficient lighting technology. 
       BACKGROUND 
       [0004]    Existing luminaires (e.g., light fixtures such as stage lights) utilize energy inefficient lighting sources. Commonly utilized lighting sources include high performance lamps (HPL), high-intensity discharge lamps (HID), as well as metal-halide lamps, fluorescents, incandescents, and so forth. While HID lamps provide some increase in energy efficiency relative to HPL lamps, both HID and HPL lamps require hundreds of watts of power to function at their designed output levels. 
         [0005]    Moreover, these conventional lamp-type luminaires produce a significant amount of heat. It has been estimated that venues which utilize these conventional lamp luminaires, a significant portion of the operating expenses of the venue can be attributed to climate control processes (e.g., HVAC) to offset the heat produced by these conventional lamp luminaires. Thus, what is needed are LED lighting assemblies that can replace and/or be retrofit into conventional luminaires, such as stage lighting, (or other lighting assemblies) that reduce not only the amount of energy consumed, but also the heat produced by the luminaires. The present technology provides these benefits without deleteriously affecting the performance (e.g., lumen intensity) of the luminaires. Additionally, the present technology utilizes LED light sources which have a much longer operating life than standard filament light sources (e.g., HID and HPL lamps). 
       SUMMARY 
       [0006]    According to some embodiments, the present technology may be directed to a lighting assembly having: (a) a reflector in association with (b) a light emitting diode (LED) light source, the LED light source contacting (c) a cooling device, wherein the LED light source is electrically coupled to (d) a power source; and (e) a mounting plate for coupling the lighting assembly to a luminaire. 
         [0007]    According to some embodiments, the present technology may be directed to a lens-less luminaire having: (a) a housing assembly; and (b) a lighting assembly at least partially disposed within the housing assembly, the lighting assembly comprising: (i) a reflector in association with (ii) an LED light source, the LED light source contacting (iii) a cooling device, wherein the LED light source is electrically coupled to (iv) a power source, wherein the reflector replaces a lens of the standard luminaire; and (v) a mounting plate for coupling the lighting assembly to the housing assembly of the luminaire. 
         [0008]    According to some embodiments, the present technology may be directed to a method that includes the steps of: (a) removing an existing lighting assembly from the luminaire; (b) replacing the existing lighting assembly with a light emitting diode (LED) lighting assembly that comprises: (i) a reflector in association with an LED light source, the LED light source contacting a cooling device, wherein the LED light source is electrically coupled to a power source; and (ii) a mounting plate for coupling the lighting assembly to the housing assembly of the luminaire. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Certain embodiments of the present technology are illustrated by the accompanying figures. It will be understood that the figures are not necessarily to scale and that details not necessary for an understanding of the technology or that render other details difficult to perceive may be omitted. It will be understood that the technology is not necessarily limited to the particular embodiments illustrated herein. 
           [0010]      FIG. 1  is a front perspective view of an exemplary lighting assembly of the present technology. 
           [0011]      FIG. 2  is a rear perspective view of the exemplary lighting assembly of  FIG. 1 . 
           [0012]      FIG. 3  is a partial exploded rear perspective view of the exemplary lighting assembly of  FIGS. 1 and 2 . 
           [0013]      FIG. 4  is a partial exploded front perspective view of the exemplary lighting assembly of  FIGS. 1-3 . 
           [0014]      FIG. 5  is another exploded front perspective view of the exemplary lighting assembly of  FIGS. 1-3 , showing additional fasteners. 
           [0015]      FIG. 6A  is a perspective view of a Reflector. 
           [0016]      FIG. 6B  is a bottom-up view of the Reflector. 
           [0017]      FIG. 6C  is a cross-sectional view of the Reflector taken along line A-A of  FIG. 6B . 
           [0018]      FIG. 7  includes perspective views of a Mounting Sub-Assembly and a Reflector. 
           [0019]      FIG. 8A  is a top-down view of a portion of the exemplary lighting assembly, showing the Mounting Sub-Assembly and an LED Sub-Assembly. 
           [0020]      FIG. 8B  is an elevational view of the Mounting Sub-Assembly. 
           [0021]      FIG. 8C  is a front elevational view of the Reflector. 
           [0022]      FIG. 9A  is a top-down view of a Mounting Plate of the Mounting Sub-Assembly. 
           [0023]      FIG. 9B  is an elevational view of the Mounting Plate of the Mounting Sub-Assembly. 
           [0024]      FIGS. 10A-B , collectively, illustrate an exemplary process for retrofitting a conventional luminaire with an exemplary lighting assembly of the present technology. 
           [0025]      FIGS. 11A-D  are various views of an exemplary Cooling Assembly (Heat Sink) for use in accordance with the present technology. 
           [0026]      FIG. 12A  is an exemplary mounting bracket that accommodates various reflectors which are utilized in accordance with the present technology. 
           [0027]      FIG. 12B  is an exemplary reflector that is configured to mate with the mounting bracket of  FIG. 12A . 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0028]    While this technology is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail several specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the technology and is not intended to limit the technology to the embodiments illustrated. 
         [0029]    It will be understood that like or analogous elements and/or components, referred to herein, may be identified throughout the drawings with like reference characters. It will be further understood that several of the figures are merely schematic representations of the present technology. As such, some of the components may have been distorted from their actual scale for pictorial clarity. 
         [0030]      FIGS. 1 and 2  are perspective views of an exemplary lighting assembly, hereinafter “assembly  100 ” constructed in accordance with the present technology. Generally speaking, the assembly  100  may be utilized in luminaires (such as the luminaire of  FIGS. 10A and 10B ) to increase the energy efficiency of the luminaires and also to reduce the heat generated by the luminaires. In some instances, the assembly  100  may provide an increase in energy efficiency of approximately 600% relative to a conventional luminaire, such as a 575 Watt ETC Source Four® manufactured by Electronic Theater Controls, Inc. of Middleton, Wis. 
         [0031]      FIGS. 3 and 4  are exploded perspective views of the assembly  100  of  FIGS. 1 and 2 . According to some embodiments, the assembly  100  may comprise a Reflector  105 , an LED Sub-Assembly  110 , a Mounting Sub-Assembly  115 , and/or a Thermal Transfer Sub-Assembly  120 . It is noteworthy that the assembly  100  may comprise fewer or more components than those illustrated.  FIG. 5  is an alternate exploded perspective view of the exemplary lighting assembly of  FIGS. 1-4 . 
         [0032]    According to some embodiments, the assembly  100  comprises an LED Sub-Assembly  110 , which in some embodiments comprises an LED Array  150  that is disposed on a Substrate  155 . The Substrate  155  may comprise any commonly known substrate material that may be selected for its supportive, conductive, and/or insulating properties. Exemplary substrates may comprise fiberglass-filled epoxies, ceramics, and/or insulated metals. 
         [0033]    In other embodiments, the LED Array  150  may comprise only a single LED light. In other embodiments, the LED Array  150  may comprise a plurality of LED lights arranged onto the Substrate  155  according to a predetermined pattern. Advantageously, each of the LED lights may have a substantially flat shape, although other LED light shapes such as round, pear, funnel, tubular, rope, domed, and so forth are also contemplated for use in accordance with the present technology. Advantageously, the LED lights of the LED Array  150  may all produce the same amount of light (e.g. lumens), or may produce differing amounts of light relative to one another. 
         [0034]      FIGS. 6A-C  collectively illustrate an exemplary embodiment of a Reflector  105  for use in accordance with the present technology. In some instances, the Reflector  105  may be constructed of a plastic, polymeric, or resin-based material, although other materials that would be known to one of ordinary skill in the art are likewise contemplated for use in accordance with the present technology. In accordance with the present disclosure, the Reflector  105  is shown as having a substantially frustoconical shape. Additionally, a Sidewall  130  of the Reflector  105  is shown as being slightly arcuate such that the Reflector  105  flares outwardly from an Upper Opening  135  to a Lower Opening  140 . It will be understood that the exact shape and dimensions of the Reflector  105  may vary according to design requirements such as the configuration of the LED array (or LED light). Advantageously, variations in the size and/or shape of the Reflector  105  may affect the shape of the beam of light that is directed outwardly from the Reflector  105 . For example, as the diameter of the Lower Opening  140  increases, the width of the beam of light emanating from the Reflector  105  increases. 
         [0035]    According to some embodiments, the Reflector  105  comprises a Sidewall  130  that flares outwardly and frusto-conically from an Upper Opening  135  to a Lower Opening  140  thereof. 
         [0036]    Additionally, the Reflector  105  is shown as comprising a plurality of Reflector Cells  145  that are disposed on the inner surface of the Sidewall  130 . It is noteworthy to mention that the shape and size of the individual Reflector Cells  145  may vary along the length of the Reflector  105 . For example, Reflector Cells  145  disposed near the Upper Opening  135  may be smaller relative to the Reflector Cells  145  disposed proximate the Lower Opening  140  of the Reflector  105 . In operation, the layout of the Reflector Cells  145 , along with the geometrical configuration of the inner surface of the Reflector  105 , determine how light that is generated by the LED Array  150  ( FIG. 4 ) will be focused into a beam. Thus, the width of the beam of light produced by an exemplary assembly may directly relate to the shape and size of not only the Reflector  105  in general, but specifically to the sizing and arrangement of Reflector Cells  145  within the body of the Reflector  105 . 
         [0037]    Referring back to  FIGS. 2 and 3 , the Reflector  105  is shown as also comprising a plurality of Tabs  175  that extend from the Upper Opening  135  of the Reflector  105 . More specifically, the plurality of Tabs  175  may extend from a peripheral edge of the Upper Opening  135 . Each of the plurality of Tabs  175  is shown as extending substantially normally to the Upper Opening (also relative to a Centerline C of the Reflector  105  as shown in  FIG. 6C ). The plurality of Tabs  175  may be utilized to associate and/or join the Reflector  105  to the Substrate  155  of the LED Sub-Assembly  110 . In some embodiments, the Upper Opening  135  of the Reflector  105  encircles the LED Array  150 . 
         [0038]    FIGS.  7  and  8 A-C collectively illustrate various views of the Mounting Sub-Assembly  115  and the Reflector  105  of the assembly  100 . The Mounting Sub-Assembly  115  is shown as comprising a Mounting Plate  160  having a substantially annular shape, along with a plurality of Fasteners  165 . According to some embodiments, the Mounting Plate  160  may be sized to be matingly received within a housing assembly of a standard luminaire (see  FIGS. 10A-B ), as will be discussed in greater detail infra. As best illustrated in  FIG. 8A , the Mounting Plate  160  is shown as comprising a Notch  195  that allows for electrical wiring (not shown) that electrically couples the LED Array  150  with the Power Source  125  (see  FIGS. 2 ,  4 , and  5 ) to pass through the Mounting Plate  160 . The Mounting Plate  160  may comprise an Aperture  185  that is sized to receive at least a portion of a Heat Sink  170 , as will be described in greater detail below. 
         [0039]      FIGS. 9A and 9B  are alternative views of the Mounting Plate  160 , providing additional dimensional details regarding some embodiments of the Mounting Sub-Assembly  110 . It is noteworthy that the dimensions of  FIGS. 9A-B  are merely exemplary and are thus not limiting in any way. 
         [0040]    As mentioned briefly above, electrical wiring (not shown) may be utilized to electrically couple the LED Array  150  to the Power Source directly. In some instances, the LED Array  150  may be electrically coupled to the Substrate  155  such that the LED Array is indirectly electrically coupled to the Power Source via the Substrate  155 . Also, it is noteworthy that the Power Source  125  may be mounted to the Thermal Transfer Sub-Assembly  120  in some instances. 
         [0041]    The Thermal Transfer Sub-Assembly  120  may, in some embodiments, include a Heat Sink  170  (also known as a “cooling device  170 ”). According to some embodiments, the Heat Sink  170  may comprise a body portion and a plurality of fins  180  that extend radially from the body portion. In some instances the Heat Sink  170  may comprise a Mounting Surface  190  that mates with the Aperture  185  of the Mounting Plate  160 . In some embodiments, the Substrate  155  of the LED Sub-Assembly  110  is attached to the Mounting Surface  190  of the Heat Sink  170 . 
         [0042]    In some instances, the Power Source  125  may be disposed behind the Thermal Transfer Sub-Assembly  120 . As already mentioned previously, the Power Source  125  may be preferably electrically coupled with the LED Array  150  of the LED Sub-Assembly  110  either directly or indirectly. The Power Source  125  may comprise any type of power generating, converting, and/or delivery device that is designed to provide power to a lighting unit such as an LED Array  150 . 
         [0043]      FIGS. 10A-B  illustrate a process for retrofitting a standard luminaire such as a  575  Watt ETC Source Four® stage light  200  manufactured by Electronic Theater Controls, Inc. Initially, a handle  230  of the stage light (“luminaire  200 ”) is removed. Next, fasteners that join two sections of the housing  205  assembly of the luminaire  200  are removed to allow the two sections  210  and  215  of the housing  205  to be separated from one another. Additionally, the lens end  220  of the luminaire  200  is also removed from the end of the housing  205 . While not shown, the standard HID or HPL lamp assembly may be removed from within the housing assembly. The standard lamp assembly may comprise a lamp, a heat transfer unit (such as a heat sink), and a power source. In some instances, the existing lighting assembly of the luminaire  200  comprises any of a high intensity discharge lamp, a high performance lamp, an incandescent lamp, a halogen lamp, a fluorescent lamp, and combinations thereof. 
         [0044]    Once the luminaire  200  has been disassembled and the standard lamp assembly removed, an exemplary lighting assembly  100  constructed in accordance with the present technology may be installed within the housing  205 . The exemplary lighting assembly may be installed by fitting the edge of the Mounting Plate  160  within a groove  225  of the housing  205  of the luminaire  200 . Note that the edge of the Mounting Plate  160  may contact an inner surface  230  of the housing  205  of the luminaire  200 . In some instances, the Mounting Plate  160  may be sized to fit within an existing track/channel (see groove  225 ) fabricated into the inner surface of the housing  205 . Fasteners, adhesives, and/or other securing means may be utilized to affix the lighting assembly within the housing  205 . In other embodiments, when the two sections  210  and  215  of the housing  205  are secured together, the two sections  210  and  215  may exert compressive forces on the Mounting Plate  160  to secure the lighting assembly  100  within the housing  205 . It is noteworthy that the Reflector  105  of the assembly  100  may be completely covered by the housing  205  to ensure that light emitted by the LED Array  150  is directed towards and through the lens end  220  of the luminaire  200 . 
         [0045]    To reassemble the housing  205 , the two sections  210  and  215  of the housing  205  are joined together via fasteners. Also, the lens end  220  and handle  230  are re-secured to the housing  205  of the luminaire, as shown in  FIG. 10B . 
         [0046]    It will be understood that while  FIGS. 10A  and B illustrate the use of a lens end  220 , advantageously, the use of a Reflector  105  allows for the creation of luminaires that do not require the use of a lens. That is, all standard luminaires require the use of a lens to properly focus light that is emitted from the existing lighting assembly, otherwise, the light emitted from the existing lighting assembly would diffuse in a completely unusable manner. To change the focus or light dispersal pattern of the luminaire, the user may interchange the lens of the luminaire. For example, if the user desires a natural light effect or a spotlight effect, two separate lenses are required to produce these different effects. 
         [0047]    Lenses are costly and interchanging lenses is a difficult process since most luminaires are suspended high above the ground. The use of a reflector in place of a lens is a cost effective modification to an existing (or new) luminaire. Also, the process of exchanging reflectors, rather than lenses, is a much safer process, which does not require the presence of multiple operators or users. An exemplary lens-free luminaire could be created from retrofitting a standard luminaire, such as the standard luminaire shown in  FIG. 10A , where the Lens End  220  is removed and discarded, rather than being replaced as shown in  FIG. 10B . The removal of the lens from the luminaire allows for luminaires of varying size and shape to be created. That is, since the lens end was a requirement of a standard luminaire, and such lenses were necessarily round to effectuate their desired light focusing function, standard luminaires have accommodating round shaped housing assemblies. 
         [0048]      FIGS. 12A  and B illustrate the use of a Mounting bracket  1200  that allows for quick removal and replacement of reflectors, such as the Reflector  1220  of  FIG. 12B . More specifically, the Mounting bracket  1200  comprises a Body  1205  that includes a cylindrical disk having a particular thickness. The Body  1205  includes a Central Aperture  1205 A that is sized to receive an LED array or light, such as the LED Array  150  of  FIGS. 3 and 4 . 
         [0049]    The body  1205  also includes apertures  1210  that accommodate fasteners such as screws. These fasteners are used to join the mounting bracket  1200  to the Substrate  155  of the LED Sub-Assembly  110  (See  FIGS. 3 and 4 ). Thus, the mounting bracket  1200 , when installed, is disposed between the Reflector  105  and the Substrate  155 . 
         [0050]    To provide a quick means for attaching and detaching various reflectors, the mounting bracket  1200  comprises a plurality of Bayonet Tabs, such as Bayonet Tab  1215 . The Bayonet Tab  1215  may comprise a protrusion that extends upwardly from Body  1205 . The Bayonet Tab  1215  is configured to lockingly engage with a Bayonet Lock  1225  (groove) that is fabricated into the base of an exemplary Reflector  1220 . 
         [0051]    Therefore, in some embodiments, the present technology contemplates the creation of a lens-free luminaire that comprises an exemplary lighting assembly, as described above. These lens-free luminaires can be created from standard luminaires that have been retrofitted with an exemplary lighting assembly of the present technology, or also luminaires which are initially manufactured with an exemplary lighting assembly of the present technology. 
         [0052]    While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. The descriptions are not intended to limit the scope of the technology to the particular forms set forth herein. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments. It should be understood that the above description is illustrative and not restrictive. To the contrary, the present descriptions are intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the technology as defined by the appended claims and otherwise appreciated by one of ordinary skill in the art. The scope of the technology should, therefore, be determined not with reference to the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents.

Technology Classification (CPC): 5