Source: https://patents.google.com/patent/US8827507
Timestamp: 2018-02-19 10:42:35
Document Index: 101280197

Matched Legal Cases: ['Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60']

US8827507B2 - Lighting assemblies, methods of installing same, and methods of replacing lights - Google Patents
US8827507B2
US8827507B2 US11859048 US85904807A US8827507B2 US 8827507 B2 US8827507 B2 US 8827507B2 US 11859048 US11859048 US 11859048 US 85904807 A US85904807 A US 85904807A US 8827507 B2 US8827507 B2 US 8827507B2
US11859048
US20080084701A1 (en )
F21V29/2275—
F21V29/24—
A lighting assembly comprising a light engine housing, a circuit board, a heat transfer material, an electrically conductive leg and a solid state light emitter. The emitter is in contact with a first end of the leg. The leg extends through the circuit board. A second end of the leg extends into the heat transfer material. Also, a lighting assembly as described above, which further comprises a fixture housing, in which the heat transfer material is in contact with the light engine housing and the light engine housing is connected to the fixture housing. In addition, a method of installing a lighting assembly, comprising connecting an electrical conductor and inserting the lighting assembly through a hole in a construction element such that clips attached to a fixture housing engage the construction element. Also, a method of changing a light emitter in a lighting assembly.
This application claims the benefit of U.S. Provisional Patent Application No. 60/846,222, filed Sep. 21, 2006, the entirety of which is incorporated herein by reference.
The present invention relates to lighting assemblies for emitting light, methods of installing lighting assemblies and methods of replacing light emitters included in lighting assemblies. In some embodiments, the present invention relates to lighting assemblies which include solid state light emitters, for example, light emitting diodes.
In accordance with a first aspect according to the present invention, there is provided a lighting assembly, comprising:
a heat transfer material;
at least a first electrically conductive leg; and
at least a first solid state light emitter,
the first solid state light emitter being in contact with a first end of the first electrically conductive leg,
the first electrically conductive leg extending through the circuit board,
a second end of the first electrically conductive leg extending into the heat transfer material,
the heat transfer material being in contact with the light engine housing,
the light engine housing being connected to the fixture housing.
In some embodiments according to this aspect of the present invention, the first solid state light emitter is an LED.
In accordance with a second aspect according to the present invention, there is provided a lighting assembly, comprising:
a second end of the first electrically conductive leg extending into the heat transfer material.
In accordance with a third aspect according to the present invention, there is provided a method of installing a lighting assembly, comprising:
connecting an electrical conductor on a lighting assembly to an electrical supply component, the lighting assembly comprising a fixture housing and at least two clips attached to the fixture housing and extending away from a periphery of the fixture housing; and
inserting the lighting assembly through a hole in a construction element such that the clips engage the construction element.
In some embodiments according to this aspect of the present invention, the first emitter is a solid state light emitter.
In some embodiments according to this aspect of the present invention, solid state light emitter is an LED.
In accordance with a fourth aspect according to the present invention, there is provided a method of changing a light emitter in a lighting assembly, comprising:
retracting clips attached to a fixture housing out of contact with a construction element;
moving the lighting assembly through a hole in a construction element; and
disconnecting an electrical conductor on the lighting assembly from an electrical supply component, the lighting assembly comprising a fixture housing and at least two clips attached to the fixture housing and extending away from a periphery of the fixture housing.
In some embodiments according to this aspect of the present invention, the lighting assembly comprises a fixture housing, a light engine housing, a light engine and at least a first light emitter, the first light emitter being mounted on the light engine, the light engine being mounted on the light engine housing, and
removing the light engine housing from the fixture housing;
removing the light engine from the light engine housing;
attaching a replacement light engine to the light engine housing; and
attaching the light engine housing to the fixture housing.
In some such embodiments, the method further comprises inserting the lighting assembly through the hole in the construction element such that the clips engage the construction element.
In some embodiments according to this fourth aspect of the present invention, the lighting assembly comprises a fixture housing, a light engine housing, a light engine and at least a first light emitter, the first light emitter being mounted on the light engine, the light engine being mounted on the light engine housing, and
removing the first light emitter from the light engine;
attaching a replacement light emitter on the light engine; and
In some embodiments according to this fourth aspect of the present invention, the lighting assembly comprises:
the fixture housing;
at least a first emitter,
the first solid state light emitter is in contact with a first end of the first electrically conductive leg,
the electrically conductive leg is electrically connected to the electrical conductor,
the first electrically conductive leg extends through the circuit board,
a second end of the first electrically conductive leg extends into the heat transfer material,
the heat transfer material is in contact with the light engine housing, and
the light engine housing is connected to the fixture housing.
FIG. 1 depicts a first embodiment of a lighting assembly in accordance with the present invention.
FIG. 2 is a perspective view of a lighting assembly.
FIG. 3 is a cutaway perspective view of the lighting assembly depicted in FIG. 2.
FIG. 4 is a sectional view of the lighting assembly depicted in FIG. 2.
FIG. 5 is a cutaway perspective view of a portion of the lighting assembly depicted in FIG. 2.
FIGS. 6 and 7 are perspective views of sub-assemblies of the lighting assembly depicted in FIG. 2.
FIG. 8 is a perspective view of the fixture housing of the lighting assembly depicted in FIG. 2, with clips attached thereto and with gaps 42 formed therein.
FIG. 9 is a perspective view showing a portion of a clip, a portion of a rim, a portion of a lens and a portion of a fixture housing.
FIG. 10 is a perspective view showing a portion of a clip and a portion of a fixture housing.
FIG. 11 is a perspective view showing a clip.
As used herein, the term “substantially,” e.g., in the expressions “substantially conical”, “substantially parallel”, “substantially frustoconical”, “substantially cylindrical”, “substantially co-linear”, “substantially coaxial”, “substantially semi-elliptical”, means at least about 90% correspondence with the feature recited, e.g.,
“substantially parallel” means that two lines (or two planes) diverge from each other at most by an angle of 10% of 90 degrees, i.e., 9 degrees;
“substantially semi-elliptical” means that a semi-ellipse can be drawn having the formula x2/a2+y1/b2=1, where y≧0, and imaginary axes can be drawn at a location where the y coordinate of each point on the structure is within 0.90 to 1.10 times the value obtained by inserting the x coordinate of such point into such formula;
the expression “substantially coaxial” means that the axes of the respective surfaces come to within a distance of not more than 10% of the largest dimension of the respective surfaces, and that the respective axes define an angle of not greater than 10 degrees;
the expression “substantially conical”, as used herein, means that at least 90% of the points in the surface which is characterized as being substantially conical are located on one of or between a pair of imaginary conical structures which are spaced from each other by a distance of not more than 10% of their largest dimension;
the expression “substantially frustoconical”, as used herein, means that at least 90% of the points in the surface which is characterized as being substantially frustoconical are located on one of or between a pair of imaginary frustoconical structures which are spaced from each other by a distance of not more than 10% of their largest dimension; and
the expression “co-linear”, as used herein, means that two lines which are described as being co-linear are spaced from each other by not more than 10% of a largest dimension of any structure being described, and that coordinate axes can be defined such that respective x-y slopes of the two lines differ by not more than 10%, and respective x-z slopes of the two lines differ by not more than 10%.
As noted above, in a first aspect of the present invention, there is provided a lighting assembly, comprising:
at least a first solid state light emitter.
The housing can be formed of any material which can be molded and/or shaped, a wide variety of which are well-known and readily available. Preferably, the housing is formed of a material which is an effective heat sink (i.e., which has high thermal conductivity and/or high heat capacity) and/or which is reflective (or which is coated with a reflective material). A representative example of a material out of which the fixture housing can be made is sheet metal.
The fixture housing can be any desired shape. A representative shape for the fixture housing is hollow cylindrical, e.g., as in conventional “can” light fixtures. Other representative shapes include hollow conical (or substantially conical), hollow frustoconical (or substantially frustoconical) and hollow semi-elliptical (or substantially semi-elliptical), or any shape which includes one or more portions which are individually selected from among hollow conical (or substantially conical), hollow frustoconical (or substantially frustoconical), hollow cylindrical (or substantially cylindrical) and hollow semi-elliptical (or substantially semi-elliptical).
In some embodiments, the fixture housing can include a reflective element (and/or one or more of its surfaces are reflective), so that light from some or all of the solid state light emitters is reflected by such reflective surfaces. Such reflective elements (and surfaces) are well-known and readily available to persons skilled in the art. A representative example of a suitable material out of which a reflective element can be made is a material marketed by Furukawa (a Japanese corporation) under the trademark MCPET®.
In some embodiments according to the present invention, the fixture housing is cylindrical and includes serrations, whereby a hole can be formed in a construction element (e.g., a wall, a floor or a ceiling) in which the fixture housing is being mounted by holding the fixture housing in contact with the construction element and rotating the fixture housing about its cylindrical axis so as to cut a hole in the construction element, the hole having about the same diameter as the fixture housing.
The light engine housing is connected to the fixture housing, and it can be made of any suitable material, a wide variety of which are well-known and readily available. Representative examples of materials out of which the light engine housing can be made are die cast aluminum, liquid crystal polymer, polyphenylene sulfide (PPS) or a composite material.
The light engine housing can be any desired shape. A representative shape for the light engine housing is cylindrical.
The circuit board can be made of any suitable material, a wide variety of which are well-known and readily available. Skilled artisans are very familiar with a wide variety of ways to construct circuit boards, and they have access to the materials needed to make such circuit boards. In addition, skilled artisans can readily design the conductive features needed to provide all of the electrical connections needed to operate any of the light engines described herein. Representative well-known types of circuit boards include layers of insulating material and conductive material, in which the insulating material is, for example, FR-4 (fiberglass impregnated with epoxy resin) or FR-2 (paper impregnated with phenolic resin) and/or polyimide, and in which the conductive material is etched copper sheets.
The heat transfer material can be made of any suitable material, a wide variety of which are well-known and readily available. A representative example of a suitable heat transfer material is a composition containing 50 to 85 percent by weight epoxy and 15 to 50 percent by weight SiC (silicon carbide)(e.g., #400 SiC).
The heat transfer material is in contact with the light engine housing, and can be in any desired shape. In some embodiments according to the present invention, the light engine housing and the circuit board together define a heat transfer space in which the heat transfer material is positioned (in some cases, the heat transfer material substantially or completely fills the heat transfer space, except for the space(s) occupied by leg(s) extending from the solid state light emitter(s) described below).
The one or more solid state light emitter can be any suitable solid state light emitter, a wide variety of which are well-known and readily available to persons skilled in the art. Solid state light emitters include inorganic and organic light emitters. Examples of types of such light emitters include a wide variety of light emitting diodes (inorganic or organic, including polymer light emitting diodes (PLEDs)), laser diodes, thin film electroluminescent devices, light emitting polymers (LEPs), a variety of each of which are well-known in the art (and therefore it is not necessary to describe in detail such devices, and/or the materials out of which such devices are made). The expression “solid state light emitter”, as used herein, can refer to a component including one or more solid state light emitter or a component including one or more solid state light emitter as well as one or more lumiphor. In some embodiments according to the present invention, a lighting assembly includes one or more solid state light emitters which include at least one solid state light emitter and at least one lumiphor which emits light, at least a portion of such light emitted by the luminescent element being emitted in response to luminescent material in the luminescent element being excited by light emitted by the at least one solid state light emitter.
(1) U.S. Patent Application No. 60/753,138, filed on Dec. 22, 2005, entitled “Lighting Device” (inventor: Gerald H. Negley), the entirety of which is hereby incorporated by reference, and U.S. patent application Ser. No. 11/614,180, filed Dec. 21, 2006 (now U.S. Patent Publication No. 2007/023611);
(2) U.S. Patent Application No. 60/794,379, filed on Apr. 24, 2006, entitled “Shifting Spectral Content in LEDs by Spatially Separating Lumiphor Films” (inventors: Gerald H. Negley and Antony Paul van de Ven), the entirety of which is hereby incorporated by reference, and U.S. patent application Ser. No. 11/624,811, filed Jan. 19, 2007 now U.S. Patent Publication No. 2007/0170447);
Some embodiments according to the present invention include at least a first LED and at least a first lumiphor. In some such embodiments, the light emitted from the first LED has a peak wavelength in a range of from 430 nm to 480 nm, and the light emitted from the first lumiphor has a dominant wavelength in a range of from about 555 nm to about 585 nm.
Some embodiments according to the present invention include at least a first LED, at least a first lumiphor and at least a second LED. In some such embodiments, the light emitted from the first LED has a peak wavelength in a range of from 430 nm to 480 nm, and the light emitted from the first lumiphor has a dominant wavelength in a range of from about 555 nm to about 585 nm, and the light emitted from the second LED has a dominant wavelength in a range of from 600 nm to 630 nm.
Some embodiments according to the present invention include at least a first solid state light emitter (which, in some such embodiments includes at least a first LED and at least a first lumiphor) which, if illuminated, emits light which has x, y color coordinates which define a point which is within an area on a 1931 CIE Chromaticity Diagram enclosed by first, second, third, fourth and fifth line segments, the first line segment connecting a first point to a second point, the second line segment connecting the second point to a third point, the third line segment connecting the third point to a fourth point, the fourth line segment connecting the fourth point to a fifth point, and the fifth line segment connecting the fifth point to the first point, the first point having x, y coordinates of 0.32, 0.40, the second point having x, y coordinates of 0.36, 0.48, the third point having x, y coordinates of 0.43, 0.45, the fourth point having x, y coordinates of 0.42, 0.42, and the fifth point having x, y coordinates of 0.36, 0.38.
In general, light of any number of colors can be mixed by the lighting assemblies according to the present invention. Representative examples of blends of light colors are described in:
The lighting assemblies according to the present invention can comprise any desired number of solid state emitters. For example, a lighting assembly according to the present invention can include 50 or more light emitting diodes, or can include 100 or more light emitting diodes, etc. In general, with current light emitting diodes, greater efficiency can be achieved by using a greater number of smaller light emitting diodes (e.g., 100 light emitting diodes each having a surface area of 0.1 mm2 vs. 25 light emitting diodes each having a surface area of 0.4 mm2 but otherwise being identical).
Analogously, light emitting diodes which operate at lower current densities are generally more efficient. Light emitting diodes which draw any particular current can be used according to the present invention. In some embodiments of the present invention, light emitting diodes which each draw not more than 50 milliamps are employed.
As indicated above, some embodiments of the lighting assemblies according to the present invention can include lumiphors (i.e., luminescence region or luminescent element which comprises at least one luminescent material). The expression “lumiphor”, as used herein, refers to any luminescent element, i.e., any element which includes a luminescent material.
Each solid state light emitter typically is attached to one or two electrically conductive legs. In accordance with this aspect of the present invention, at least one solid state light emitter has at least one electrically conductive leg which extends through the circuit board and at least partially (e.g., 50%, 75%, 90% or more of the distance from the circuit board to a surface of the light engine housing which is opposite the circuit board relative to the heat transfer material) into the heat transfer material. The one or more electrically conductive legs are electrically connected to the circuit board by any suitable method, e.g., by soldering. The electrically conductive leg(s) can be formed in any suitable shape from any suitable material, a wide variety of which are well-known and available to persons skilled in the art. A representative material out of which the legs can be made is silver-plated copper (or silver-plated mild steel).
In some embodiments of this aspect of the invention, an axis of symmetry of the fixture housing is substantially co-linear with an axis of symmetry of the light engine housing. In some such embodiments, an axis of symmetry of the first leg is substantially parallel to the axis of symmetry of the light engine housing, and/or an axis of symmetry of the first solid state light emitter is substantially parallel to the axis of symmetry of the light engine housing.
In some embodiments of this aspect of the invention, the first solid state light emitter is an LED.
In some embodiments of this aspect of the invention, heat sink fins are provided, which extend from the light engine housing away from the heat transfer material. Such heat sink fins can be made of any suitable material, a wide variety of which will be readily apparent to persons skilled in the art.
In some embodiments of this aspect of the invention, the lighting assembly further includes at least two clips attached to the fixture housing and extending away from a periphery of the fixture housing. Such clips are designed such that the lighting assembly can, for example, be inserted through an opening in a construction element whereby the clips engage the construction element (or some other construction element) so that the lighting assembly is held in place.
In some embodiments of this aspect of the invention, the lighting assembly further comprises a rim which has an external surface which faces an internal surface of the fixture housing.
In some embodiments of this aspect of the invention, the lighting assembly further comprises clips as described above and at least a first drawstring which, when pulled, causes the clips to retract toward the periphery of the fixture housing in order to enable the lighting assembly to be released and removed from the construction element(s). In some such embodiments, the lighting assembly further comprises a rim as described above which obstructs the first drawstring from view through an opening defined by an internal surface of the rim.
In some embodiments of this aspect of the invention, the lighting assembly further comprises at least a first control device (e.g., a switch) attached to the fixture housing and a rim as described above, in which the rim obstructs the first control device from view through an opening defined by an internal surface of the rim.
In some embodiments of this aspect of the invention, the lighting assembly further comprises a rim as described above and one or more mounting screws which connect the fixture housing to a construction element, wherein an internal surface of the rim defines an opening through which light from the one or more solid state light emitter can pass, the rim obstructing the mounting screws from view through the opening.
As noted above, in a second aspect of the present invention, there is provided a lighting assembly, comprising:
the first electrically conductive leg extending through the circuit board, and
The discussion above regarding the light engine housings, the circuit boards, the heat transfer materials, the electrically conductive legs and the solid state light emitter which can be employed in accordance with the first aspect of the present invention apply to those items in accordance with the second aspect of the present invention.
As noted above, in a third aspect of the present invention, there is provided a method of installing a lighting assembly, comprising:
connecting an electrical conductor on a lighting assembly to an electrical supply component (e.g., an electrical wire), the lighting assembly comprising a fixture housing and at least two clips attached to the fixture housing and extending away from a periphery of the fixture housing; and
inserting the lighting assembly through a hole in a construction element (e.g., a wall, a floor or a ceiling) such that the clips engage the construction element.
In some embodiments of this aspect of the invention, the method further comprises positioning a lens in the fixture housing and turning the lens, whereby the lens becomes engaged with the fixture housing and is held in place. In some such embodiments, the lens is turned by rotating the lens about an axis substantially coaxial with an axis of the fixture housing. Persons of skill in the art are familiar with a variety of lenses for lighting assemblies, a representative example being a standard diffusing element, e.g., a glass or plastic diffusing element about 0.2 mm thick.
In some embodiments of this aspect of the invention, the method further comprises positioning a rim such that an external surface of the rim faces an internal surface of the fixture housing. The discussion above regarding the rims which can be employed in accordance with the first aspect of the present invention applies to the rims which can be employed in accordance with the third aspect of the present invention.
In some embodiments of this aspect of the invention, the lighting assembly comprises:
the light engine housing is connected to the fixture housing. In some such embodiments, the first emitter is a solid state light emitter, e.g., an LED.
As noted above, in a fourth aspect of the present invention, there is provided a method of changing a light emitter in a lighting assembly, comprising:
In some embodiments of this aspect of the invention, the method further comprises inserting the lighting assembly through the hole in the construction element such that the clips engage the construction element, or some other construction element, so as to hold the lighting assembly in place.
The expression “lighting assembly”, as used herein, is not limited, except that it is capable of emitting light. That is, a lighting assembly can be a device which illuminates an area or volume, e.g., a structure, a swimming pool or spa, a room, a warehouse, an indicator, a road, a parking lot, a vehicle, signage, e.g., road signs, a billboard, a ship, a toy, a mirror, a vessel, an electronic device, a boat, an aircraft, a stadium, a computer, a remote audio device, a remote video device, a cell phone, a tree, a window, an LCD display, a cave, a tunnel, a yard, a lamppost, or a device or array of devices that illuminate an enclosure, or a device that is used for edge or back-lighting (e.g., back light poster, signage, LCD displays), bulb replacements (e.g., for replacing AC incandescent lights, low voltage lights, fluorescent lights, etc.), lights used for outdoor lighting, lights used for security lighting, lights used for exterior residential lighting (wall mounts, post/column mounts), ceiling fixtures/wall sconces, under cabinet lighting, lamps (floor and/or table and/or desk), landscape lighting, track lighting, task lighting, specialty lighting, ceiling fan lighting, archival/art display lighting, high vibration/impact lighting—work lights, etc., mirrors/vanity lighting, or any other light emitting device.
The present invention further relates to an illuminated enclosure (the volume of which can be illuminated uniformly or non-uniformly), comprising an enclosed space and at least one lighting assembly according to the present invention, wherein the lighting assembly illuminates at least a portion of the enclosure (uniformly or non-uniformly).
The present invention is further directed to an illuminated area, comprising at least one item, e.g., selected from among the group consisting of a structure, a swimming pool or spa, a room, a warehouse, an indicator, a road, a parking lot, a vehicle, signage, e.g., road signs, a billboard, a ship, a toy, a mirror, a vessel, an electronic device, a boat, an aircraft, a stadium, a computer, a remote audio device, a remote video device, a cell phone, a tree, a window, an LCD display, a cave, a tunnel, a yard, a lamppost, etc., having mounted therein or thereon at least one lighting assembly as described herein.
The lighting assemblies of the present invention can be supplied with electricity in any desired manner. Skilled artisans are familiar with a wide variety of power supplying apparatuses, and any such apparatuses can be employed in connection with the present invention. The lighting assemblies of the present invention can be electrically connected (or selectively electrically connected) to any desired power source, persons of skill in the art being familiar with a variety of such power sources.
Representative examples of apparatuses for supplying electricity to lighting assemblies and power supplies for lighting assemblies, all of which are suitable for the lighting assemblies of the present invention, are described in:
(1) U.S. Patent Application No. 60/752,753, filed on Dec. 21, 2005, entitled “Lighting Device” (inventors: Gerald H. Negley, Antony Paul van de Ven and Neal Hunter), the entirety of which is hereby incorporated by reference, and U.S. patent application Ser. No. 11/613,692, filed Dec. 20, 2006 (now U.S. Patent Publication No. 2007/0139923);
(2) U.S. Patent Application No. 60/798,446, filed on May 5, 2006, entitled “Lighting Device” (inventor: Antony Paul van de Ven), the entirety of which is hereby incorporated by reference, and U.S. patent application Ser. No. 11/743,754, filed May 3, 2007 (now U.S. Patent Publication No. 2007/0263393);
(3) U.S. Patent Application No. 60/809,959, filed on Jun. 1, 2006, entitled “Lighting Device With Cooling” (inventors: Thomas G. Coleman, Gerald H. Negley and Antony Paul van de Ven), the entirety of which is hereby incorporated by reference, and U.S. patent application Ser. No. 11/626,483, filed Jan. 24, 2007 (now U.S. Patent Publication No. 2007/0171145);
(4) U.S. Patent Application No. 60/809,595, filed on May 31, 2006, entitled “LIGHTING DEVICE AND METHOD OF LIGHTING” (inventor: Gerald H. Negley), the entirety of which is hereby incorporated by reference, and U.S. patent application Ser. No. 11/755,162, filed May 30, 2007 (now U.S. Patent Publication No. 2007/0279440); and
(5) U.S. Patent Application No. 60/844,325, filed on Sep. 13, 2006, entitled “BOOST/FLYBACK POWER SUPPLY TOPOLOGY WITH LOW SIDE MOSFET CURRENT CONTROL” (inventor: Peter Jay Myers), the entirety of which is hereby incorporated by reference.
FIG. 1 depicts a first embodiment of a lighting assembly in accordance with the present invention. Referring to FIG. 1, there is shown a lighting assembly 10 which includes a fixture housing 11, a light engine housing 12, a circuit board 13, a heat transfer material 14, a plurality of solid state light emitters 15 (in this embodiment, they are LEDs), each being in contact with a pair of electrically conductive legs 16.
The electrically conductive legs 16 extend through (and are soldered to) the circuit board 13 and into the heat transfer material 14. The heat transfer material 14 is in contact with the light engine housing 12. The light engine housing 12 is connected to the fixture housing 11 by screws 17.
Referring to FIG. 1, the heat transfer material 14 is positioned within a space defined between the light engine housing 12 and the circuit board 13.
Again referring to FIG. 1, an axis of symmetry of the fixture housing 11 is substantially co-linear with an axis of symmetry of the light engine housing 12.
Again referring to FIG. 1, axes of symmetry of the legs 16 are substantially parallel to the axis of symmetry of the light engine housing 12.
Again referring to FIG. 1, axes of symmetry of the solid state light emitters are substantially parallel to the axis of symmetry of the light engine housing 12.
The lighting assembly 10 also includes heat sink fins 18 which extend from the light engine housing 12 away from the heat transfer material 14.
The lighting assembly 10 also includes clips 19 which are attached to the fixture housing 11 and which extend away from a periphery of the fixture housing 11.
The lighting assembly 10 also includes a rim 20. The rim 20 has a rim external surface 21 and a rim internal surface 22. The fixture housing 11 has a fixture housing internal surface 23. The rim external surface 21 faces the fixture housing internal surface 23.
The lighting assembly 10 further includes a drawstring 24 which, when pulled, causes the clips 19 to retract toward the periphery of the fixture housing 11. Referring to FIG. 1, the rim 20 obstructs the drawstring 24 from view through an opening 25 defined by the rim internal surface 22.
The lighting assembly 10 further includes a control device 26 (in the form of a switch) attached to the fixture housing 11. The rim 20 obstructs the control device 26 from view through the opening 25.
The lighting assembly 10 further includes mounting screws 27 which connect the fixture housing 11 to a construction element 28. The rim 20 obstructs the mounting screws 27 from view through the opening 25.
The legs 16 extend into the heat transfer material 14 more than 90% of the distance from the circuit board 13 to the surface of the light engine housing 12 which is opposite the circuit board 13 relative to the heat transfer material 14.
FIGS. 2-11 depict a second embodiment of a lighting assembly according to the present invention. FIG. 2 is a perspective view of a lighting assembly 29, and FIG. 4 is a sectional view of the lighting assembly 29. Referring to FIG. 4, the lighting assembly 29 includes a fixture housing 30, a light engine housing 31, a circuit board 32, a heat transfer material 33, a plurality of solid state light emitters 34 (in this embodiment, they are LEDs), each being in contact with a pair of electrically conductive legs 35.
The electrically conductive legs 35 extend through the circuit board 32 and into the heat transfer material 33. The heat transfer material 33 is in contact with the light engine housing 31. The light engine housing 31 is connected to the fixture housing 30 by screws 36 (only one screw 36 is shown in FIG. 4).
The lighting assembly 29 also includes heat sink fins 37 which extend from the light engine housing 31 away from the heat transfer material 33.
The lighting assembly 29 also includes clips 38 (one of which is shown in FIG. 2) which are attached to the fixture housing 30 and which extend away from a periphery of the fixture housing 30.
The lighting assembly 29 also includes a rim 39.
The lighting assembly 29 also includes a lens 40, which can be inserted by positioning the lens 40 such that tabs which extend outward from the lens 40 engage corresponding gaps 42 in the fixture housing 30, and twisting the lens (clockwise or counter-clockwise) such that the tabs move within the gaps 42. The lens 40 can be removed by twisting in the opposite direction.
The lighting assembly 29 further includes a ballast 41 which converts AC current (e.g., 110 volts) into lower voltage DC current suitable for supplying to the solid state light emitters 34.
FIG. 3 is a cutaway perspective view of the lighting assembly 29.
FIG. 5 is a cutaway perspective view of a portion of the lighting assembly 29 (without including the heat transfer material 33, and with each solid state light emitter 34 having only a single leg 35)
FIGS. 6 and 7 are perspective views of sub-assemblies including the light engine housing 31 (with the heat sink fins 37 formed integrally thereon), the circuit board 32 (not visible in FIG. 6 or in FIG. 7), the heat transfer material 33 (also not visible in FIG. 6 or in FIG. 7), the solid state light emitters 34 (some visible in FIG. 7 and some partially visible in FIG. 6) and a ballast cover 43 (formed integrally with the light engine housing 31). The sub-assembly of FIG. 7 further includes the ballast 41.
FIG. 8 is a perspective view of the fixture housing 30, with clips 38 attached thereto and with gaps 42 formed therein.
FIG. 9 is a perspective view showing a portion of a clip 38, a portion of a rim 39, a portion of a lens 40 and a portion of a fixture housing 30.
FIG. 10 is a perspective view showing a portion of a clip 38 and a portion of a fixture housing 30.
FIG. 11 is a perspective view showing a clip 38.
a fight engine housing;
said first solid state light emitter in contact with a first end of said first electrically conductive leg,
said heat transfer material in contact with said light engine housing,
said light engine housing having at least a first surface and a second surface,
at least a portion of said first surface exposed to an exterior of said lighting assembly,
a recess defined by said second surface of said light engine housing,
a first surface of said circuit board in contact with a portion of said second surface of said light engine housing that extends around a periphery of said recess,
said heat transfer material completely filling said recess between said light engine housing and said first surface of said circuit board,
said first electrically conductive leg extending through said circuit board,
a second end of said first electrically conductive leg extending (1) toward said portion of said light engine housing which is exposed to an exterior of said lighting assembly and (2) into said heat transfer material.
2. A lighting assembly as recited in claim 1, wherein said lighting assembly further comprises a fixture housing, and an axis of symmetry of said fixture housing is substantially co-linear with an axis of symmetry of said light engine housing.
3. A lighting assembly as recited in claim 2, wherein an axis of symmetry of said first leg is substantially parallel to said axis of symmetry of said light engine housing.
4. A lighting assembly as recited in claim 2, wherein an axis of symmetry of said first solid state light emitter is substantially parallel to said axis of symmetry of said light engine housing.
5. A lighting assembly as recited in claim 1, wherein heat sink fins extend from said light engine housing away from said heat transfer material.
6. A lighting assembly as recited in claim 1, wherein said heat transfer material comprises at least one material selected from the group consisting of epoxy and silicon carbide.
7. A lighting assembly as recited in claim 1, wherein said lighting assembly further comprises a fixture housing and at least two clips, said two clips attached to said fixture housing and extending away from a periphery of said fixture housing.
8. A lighting assembly as recited in claim 1, wherein said lighting assembly further comprises a fixture housing and a rim, said rim having a rim external surface and a rim internal surface, said fixture housing having a fixture housing internal surface, said rim external surface facing said fixture housing internal surface.
9. A lighting assembly as recited in claim 8, wherein:
said lighting assembly further comprises a fixture housing, at least two clips, and at least a first drawstring, said two clips attached to said fixture housing and extending away from a periphery of said fixture housing, and
said first drawstring, when pulled, causes said clips to retract toward said periphery of said fixture housing, said rim obstructing said first drawstring from view through an opening defined by said rim internal surface.
10. A lighting assembly as recited in claim 8, further comprising at least a first control device attached to said fixture housing, said rim obstructing said first control device from view through an opening defined by said rim internal surface.
11. A lighting assembly as recited in claim 8, further comprising mounting screws which connect said fixture housing to a construction element, said rim internal surface defining an opening through which light from said at least a first solid state light emitter can pass, said rim obstructing the mounting screws from view through said opening.
12. A lighting assembly as recited in claim 1, wherein said first electrically conductive leg extends into said heat transfer material at least 50% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.
13. A lighting assembly as recited in claim 1, wherein said first electrically conductive leg extends into said heat transfer material at least 75% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.
14. A lighting assembly as recited in claim 1, wherein said first electrically conductive leg extends into said heat transfer material at least 90% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.
a heat transfer material,
said heat transfer material completely filling said recess between said first surface of said circuit board and said light engine housing,
at least a portion of said first surface of said light engine housing exposed to an exterior of said lighting assembly,
said circuit board mounted on the light engine housing between (1) said first solid state light emitter and (2) said portion of said surface of said light engine housing which is exposed to an exterior of said lighting assembly.
16. A lighting assembly as recited in claim 15, wherein said lighting assembly further comprises at least a first electrically conductive leg, said first electrically conductive leg extending into said heat transfer material at least 50% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.
17. A lighting assembly as recited in claim 15, wherein said lighting assembly further comprises at least a first electrically conductive leg, said first electrically conductive leg extending into said heat transfer material at least 75% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.
18. A lighting assembly as recited in claim 15, wherein said lighting assembly further comprises at least a first electrically conductive leg, said first electrically conductive leg extending into said heat transfer material at least 90% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.
19. A lighting assembly as recited in claim 15, wherein said lighting assembly further comprises at least a first electrically conductive leg, and an axis of symmetry of said first leg is substantially parallel to an axis of symmetry of said light engine housing.
20. A lighting assembly as recited in claim 15, wherein an axis of symmetry of said first solid state light emitter is substantially parallel to an axis of symmetry of said light engine housing.
21. A lighting assembly as recited in claim 15, wherein said lighting assembly further comprises heat sink fins, and said heat sink fins extend from said light engine housing away from said heat transfer material.
22. A lighting assembly as recited in claim 15, wherein said heat transfer material comprises at least one material selected from the group consisting of epoxy and silicon carbide.
at least a first electrically conductive leg, and
means for transferring heat from said first solid state light emitter,
said circuit board mounted on the light engine housing between (1) said first solid state light emitter and (2) a portion of a surface of said light engine housing which is exposed to an exterior of said lighting assembly,
said means for transferring heat from said first solid state light emitter in contact with said light engine housing,
a second end of said first electrically conductive leg extending (1) toward said portion of said light engine housing which is exposed to an exterior of said lighting assembly and (2) into said means for transferring heat from said first solid state light emitter,
said heat transfer means completely filling said recess between said light engine housing and said first surface of said circuit board.
24. A method of installing a lighting assembly, comprising:
connecting an electrical conductor on a lighting assembly to an electrical supply component, said lighting assembly comprising a light engine housing, a circuit board, a heat transfer material, at least a first electrically conductive leg, and at least a first solid state light emitter, said first solid state light emitter in contact with a first end of said first electrically conductive leg, said heat transfer material in contact with said light engine housing, said light engine housing having at least one surface, at least a portion of which is exposed to an exterior of said lighting assembly,
a second end of said first electrically conductive leg extending (1) toward said portion of said light engine housing which is exposed to an exterior of said lighting assembly and (2) into said heat transfer material,
said heat transfer material completely filling said recess between said light engine housing and said first surface of said circuit board.
25. A method as recited in claim 24, wherein said construction element is selected from the group consisting of a wall, a floor and a ceiling.
26. A method as recited in claim 24, further comprising positioning a lens in said lighting assembly and turning said lens, whereby said lens becomes engaged with said lighting assembly and is held in place.
27. A method as recited in claim 26, wherein said turning said lens comprises rotating said lens about an axis substantially coaxial with an axis of said lighting assembly.
28. A method as recited in claim 24, further comprising positioning a rim such that an external surface of said rim faces an internal surface of said lighting assembly.
29. A method as recited in claim 24, wherein said electrical supply component comprises an electrical wire.
30. A method as recited in claim 24, wherein said first solid state light emitter is an LED.
31. A method of changing a light emitter in a lighting assembly, comprising:
retracting clips attached to a lighting assembly out of contact with a construction element;
moving said lighting assembly through a hole in a construction element, said lighting assembly comprising a light engine housing, a circuit board, a heat transfer material, and at least a first solid state light emitter, said light engine housing having at least a first surface and a second surface, at least a portion of said first surface exposed to an exterior of said lighting assembly, said heat transfer material in contact with said first surface, said circuit board mounted on the light engine housing between (1) said first solid state light emitter and (2) said portion of said surface of said light engine housing which is exposed to an exterior of said lighting assembly,
32. A method as recited in claim 31, wherein:
said lighting assembly comprises a fixture housing, said light engine housing, a light engine and at least a first light emitter, said first light emitter mounted on said light engine, said light engine mounted on said light engine housing, and
removing said light engine housing from said fixture housing;
removing said light engine from said light engine housing;
attaching a replacement light engine to said light engine housing; and
attaching said light engine housing to said fixture housing.
33. A method as recited in claim 32, wherein said method further comprises inserting said lighting assembly through said hole in said construction element such that said clips engage said construction element.
removing said first light emitter from said light engine;
attaching a replacement light emitter on said light engine; and
35. A method as recited in claim 34, wherein said method further comprises inserting said lighting assembly through said hole in said construction element such that said clips engage said construction element.
36. A method as recited in claim 34, wherein said method further comprises inserting said lighting assembly through a second hole in a second construction element such that said clips engage said second construction element.
37. A method as recited in claim 31, wherein:
said lighting assembly comprises:
said light engine housing;
said circuit board;
said heat transfer material;
at least said first solid state light emitter,
said first solid state light emitter is in contact with a first end of said first electrically conductive leg,
said first electrically conductive leg extends through said circuit board,
a second end of said first electrically conductive leg extends into said heat transfer material.
38. A method as recited in claim 37, wherein said first emitter is a solid state light emitter.
39. A method as recited in claim 38, wherein said solid state light emitter is an LED.
40. A lighting assembly as recited in claim 15, wherein:
said lighting assembly further comprises at least a first electrically conductive leg,
said first electrically conductive leg extends through said circuit board, and
41. A lighting assembly as recited in claim 37, wherein:
said electrically conductive leg is electrically connected to said electrical conductor,
said heat transfer material is in contact with said light engine housing, and
said light engine housing is connected to said fixture housing.
US11859048 2006-09-21 2007-09-21 Lighting assemblies, methods of installing same, and methods of replacing lights Active 2027-12-01 US8827507B2 (en)
US84622206 true 2006-09-21 2006-09-21
US11859048 US8827507B2 (en) 2006-09-21 2007-09-21 Lighting assemblies, methods of installing same, and methods of replacing lights
US20080084701A1 true US20080084701A1 (en) 2008-04-10
US8827507B2 true US8827507B2 (en) 2014-09-09
ID=39046839
US11859048 Active 2027-12-01 US8827507B2 (en) 2006-09-21 2007-09-21 Lighting assemblies, methods of installing same, and methods of replacing lights
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