Source: https://patents.justia.com/patent/20090080189
Timestamp: 2020-08-09 15:23:50
Document Index: 788137633

Matched Legal Cases: ['§ 119', 'Application No. 60', 'Application No. 61', 'Application No. 61', 'Application No. 61', 'Application No. 29']

US Patent Application for Optic Coupler for Light Emitting Diode Fixture Patent Application (Application #20090080189 issued March 26, 2009) - Justia Patents Search
Justia Patents With ModifierUS Patent Application for Optic Coupler for Light Emitting Diode Fixture Patent Application (Application #20090080189)
Optic Coupler for Light Emitting Diode Fixture
Sep 22, 2008 - Cooper Technologies Company
This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 60/994,792, titled “Light Emitting Diode Downlight Can Fixture,” filed Sep. 21, 2007, U.S. Provisional Patent Application No. 61/010,549, titled “Diverging Reflector for Light Emitting Diode or Small Light Source,” filed Jan. 9, 2008, U.S. Provisional Patent Application No. 61/065,914, titled “Dimmable LED Driver,” filed Feb. 15, 2008, and U.S. Provisional Patent Application No. 61/090,391, titled “Light Emitting Diode Downlight Can Fixture,” filed Aug. 20, 2008. In addition, this application is related to co-pending U.S. patent application Ser. No. ______, titled “Diverging Reflector,” filed Sep. 22, 2008, U.S. patent application Ser. No. ______, titled “Thermal Management for Light Emitting Diode Fixture,” filed Sep. 22, 2008, U.S. patent application Ser. No. ______, titled “Light Emitting Diode Recessed Light Fixture,” filed Sep. 22, 2008, and U.S. Design Pat. Application No. 29/305,946, titled “LED Light Fixture,” filed Mar. 31, 2008. The complete disclosure of each of the foregoing priority and related applications is hereby fully incorporated herein by reference.
The distance between the supports or joists can vary to a considerable degree. Therefore, in certain exemplary embodiments, the hanger bars 105 can have adjustable lengths. Each hanger bar 105 includes two inter-fitting members 105a and 105b that are configured to slide in a telescoping manner to provide a desired length of the hanger bar 105. A person of ordinary skill in the art having the benefit of the present disclosure will recognize that many other suitable means exist for providing adjustable length hanger bars 105. For example, in certain alternative exemplary embodiments, one or more of the hanger bars described in U.S. Pat. No. 6,105,918, titled “Single Piece Adjustable Hanger Bar for Lighting Fixtures,” the complete disclosure of which is hereby fully incorporated herein, may be utilized in the lighting fixture 100 of FIG. 1.
The plaster frame 110 extends between the hanger bars 105 and includes a generally rectangular, flat plate 110a with upturned edges 110b. For example, the flat plate 110a can rest on a top surface of the ceiling. The junction box 120 is mounted to a top surface 110aa of the flat plate 110a. The junction box 120 is a box-shaped metallic container that typically includes insulated wiring terminals and knock-outs for connecting external wiring (not shown) to an LED driver (not shown) disposed within the can 115 of the light fixture 100 or elsewhere within the light fixture 100.
In certain exemplary embodiments, the plaster frame 110 includes a generally circular-shaped aperture 110c sized for receiving at least a portion of the can 115 therethrough. The can 115 typically includes a substantially dome-shaped member configured to receive an LED module (not shown) that includes at least one LED light source (not shown). The aperture 110c provides an illumination pathway for the LED light source. A person of ordinary skill in the art having the benefit of the present disclosure will recognize that, in certain alternative exemplary embodiments, the aperture 110c can have another, non-circular shape that corresponds to an outer profile of the can 115.
The LEDs in the LED package 305 are attached to the substrate 306 by one or more solder joints, plugs, epoxy or bonding lines, and/or other means for mounting an electrical/optical device on a surface. Similarly, the substrate 306 is mounted to a bottom surface 310a of the heat sink 310 by one or more solder joints, plugs, epoxy or bonding lines, and/or other means for mounting an electrical/optical device on a surface. For example, the substrate 306 can be mounted to the heat sink 310 by a two-part arctic silver epoxy.
FIG. 9 is an elevational cross-sectional top view of the exemplary heat sink 310. FIG. 10 illustrates a thermal scan of the exemplary heat sink 310 in operation. With reference to FIGS. 3-10, the bottom surface 310a of the heat sink 310 includes a substantially round member 310b with a protruding center member 310c on which the LED package 305 is mounted. In certain exemplary embodiments, the center member 310c includes two notches 310d that provide a pathway for wires (not shown) that extend between the driver 315 and the ends of the substrate 306. In certain alternative exemplary embodiments, three or more notches 310d may be included to provide pathways for wires. In certain alternative exemplary embodiments, the bottom surface 310a may include only a single, relatively flat member without any protruding center member 310c.
Fins 311 extend substantially perpendicular from the bottom surface 310a, towards a top end 310e of the heat sink 310. The fins 311 are spaced around a substantially central core 905 of the heat sink 310. The core 905 is a member that is at least partially composed of a conductive material. The core 905 can have any of a number of different shapes and configurations. For example, the core 905 can be a solid or non-solid member having a substantially cylindrical or other shape. Each fin 311 includes a curved, radial portion 311a and a substantially straight portion 311b. In certain exemplary embodiments, the radial portions 311a are substantially symmetrical to one another and extend directly from the core 905. In certain alternative exemplary embodiments, the radial portions 311a are not symmetrical to one another. Each straight portion 311b extends from its corresponding radial portion 311a, towards an outer edge 310f of the heat sink 310, substantially along a tangent of the radial portion 311a.
The radius and length of the radial portion 311a and the length of the straight portion 311b can vary based on the size of the heat sink 310, the size of the LED module 300, and the heat dissipation requirements of the LED module 300. By way of example only, one exemplary embodiment of the heat sink 310 can include fins 311 having a radial portion 311a with a radius of 1.25 inches and a length of 2 inches, and a straight portion 311b with a length of 1 inch. In certain alternative exemplary embodiments, some or all of the fins 311 may not include both a radial portion 311a and a straight portion 311b. For example, the fins 311 may be entirely straight or entirely radial. In certain additional alternative exemplary embodiments, the bottom surface 310a of the heat sink 310 may not include the round member 310b. In these embodiments, the LED package 305 is coupled directly to the core 905, rather than to the round member 310b.
As illustrated in FIG. 10, the heat sink 310 is configured to dissipate heat from the LED package 305 along a heat-transfer path that extends from the LED package 305, through the bottom surface 310a of the heat sink, and to the fins 311 via the core 905. The fins 311 receive the conducted heat and transfer the conducted heat to the surrounding environment (typically air in the can 115 of the lighting fixture 100) via convection. For example, heat from the LEDs can be transferred along a path from the LED package 305 to the core 905, from the core 905 to the radial portions 311a of the fins 311, from the radial portions 311a of the fins 311 to their corresponding straight portions 311b, and from the corresponding straight portions 311b to a surrounding environment. Heat also can be transferred by convection directly from the core 905 and/or the fins 311 to one or more gaps between the fins 311.
In certain exemplary embodiments, a reflector housing 320 is coupled to the bottom surface 310a of the heat sink 310. A person of ordinary skill in the art will recognize that the reflector housing 320 can be coupled to another portion of the LED module 300 or the lighting fixture 100 in certain alternative exemplary embodiments. FIG. 11 illustrates the exemplary reflector housing 320. With reference to FIGS. 3-8 and 11, the reflector housing 320 includes a substantially round member 320a having a top end 320b and a bottom end 320c. Each end 320b and 320c includes an aperture 320ba and 320ca, respectively. A channel 320d extends through the reflector housing 320 and connects the apertures 320ba and 320ca.
The top end 320b includes a substantially round top surface 320bb disposed around at least a portion of the channel 320d. The top surface 320bb includes one or more holes 320bc capable of receiving fasteners that secure the reflector housing 320 to the heat sink 310. Each fastener includes a screw, nail, snap, clip, pin, or other fastening device known to a person of ordinary skill in the art having the benefit of the present disclosure. In certain alternative exemplary embodiments, the reflector housing 320 does not include the holes 320bc. In those embodiments, the reflector housing 320 is formed integrally with the heat sink 310 or is secured to the heat sink 310 via means, such as glue or adhesive, that do not require holes for fastening. In certain exemplary embodiments, the reflector housing 320 is configured to act as a secondary heat sink for conducting heat away from the LEDs. For example, the reflector housing 320 can assist with heat dissipation by convecting cool air from the bottom of the light fixture 100 towards the LED package 305 via one or more ridges 321.
The reflector housing 320 is configured to receive a reflector 1205 (FIG. 12) composed of a material for reflecting, refracting, transmitting, or diffusing light emitted by the LED package 305. The term “reflector” is used herein to refer to any material configured to serve as an optic in a light fixture, including any material configured to reflect, refract, transmit, or diffuse light. FIG. 12 is a perspective side view of the exemplary reflector 1205 being inserted in the channel 320d of the reflector housing 320, in accordance with certain exemplary embodiments. With reference to FIGS. 3-8, 11, and 12, when the reflector 1205 is installed in the reflector housing 320, outer side surfaces 1205a of the reflector 1205 are disposed along corresponding interior surfaces 320e of the reflector housing 320. In certain exemplary embodiments, a top end 1205b of the reflector 1205 abuts an edge surface 330a of an optic coupler 330, which is mounted to a bottom edge 310a of the top surface 320bb. The reflector 1205 is described in more detail below with reference to FIG. 20. The optic coupler 330 includes a member configured to cover the electrical connections at the substrate 306, to allow a geometric tolerance between the LED package 305 and the reflector 1205, and to guide light emitted by the LED package 305. The optic coupler 330 and/or a material applied to the optic coupler 330 can be optically refractive, reflective, transmissive, specular, semi-specular, or diffuse. The optic coupler 330 is described in more detail below with reference to FIGS. 17-19.
The bottom end 320c of the reflector housing 320 includes a bottom surface 320ca that extends away from the channel 320d, forming a substantially annular ring around the channel 320d. The surface 320ca includes slots 320cb that are each configured to receive a corresponding tab 1305a from a trim ring 1305 (FIG. 13). FIG. 13 illustrates a portion of the trim ring 1305 aligned for installation with the reflector housing 320. With reference to FIGS. 3-8 and 11-13, proximate each slot 320cb, the surface 320ca includes a ramped surface 320cc that enables installation of the trim ring 1305 on the reflector housing 320 via a twisting maneuver. Specifically, the trim ring 1305 can be installed on the reflector housing 320 by aligning each tab 1305a with its corresponding slot 320cb and twisting the trim ring 1305 relative to the reflector housing 320 so that each tab 1305a travels up its corresponding ramped surface 320cc to a higher position along the bottom surface 320ca. Each ramped surface 320cc has a height that slowly rises along the perimeter of the housing 320.
The trim ring 1305 provides an aesthetically pleasing frame for the lighting fixture 100. The trim ring 1305 may have any of a number of colors, shapes, textures, and configurations. For example, the trim ring 1305 may be white, black, metallic, or another color and may also have a thin profile, a thick profile, or a medium profile. The trim ring 1305 retains the reflector 1205 within the reflector housing 320. In particular, when the reflector 1205 and trim ring 1305 are installed in the light fixture 100, at least a portion of a bottom end 1205b of the reflector 1205 rests on a top surface 1305b of the trim ring 1305.
Referring now to FIGS. 3-8, a bracket 325 couples torsion springs 340 to opposite side surfaces 310f of the heat sink 310. The bracket 325 includes a top member 325a and opposing, elongated side members 325b that extend substantially perpendicularly from the top member 325a, towards the bottom end 320c of the reflector housing 320c. The bracket 325 is coupled to the heat sink 310 via one or more screws, nails, snaps, clips, pins, and/or other fastening devices known to a person of ordinary skill in the art having the benefit of the present disclosure.
Each side member 325b includes an aperture 325c configured to receive a rivet 325d or other fastening device for mounting one of the torsion springs 340 to the heat sink 310. Each torsion spring 340 includes opposing bracket ends 340a that are inserted inside corresponding slots (not shown) in the can 115 of the light fixture 100. To install the LED module 300 in the can 115, the bracket ends 340a are squeezed together, the LED module 300 is slid into the can 115, and the bracket ends 340a are aligned with the slots and then released such that the bracket ends 340a enter the slots.
A mounting bracket 335 is coupled to the top member 325a and/or the top end of heat sink 310 via one or more screws, nails, snaps, clips, pins, and/or other fastening devices known to a person of ordinary skill in the art having the benefit of the present disclosure. The mounting bracket 335 includes a substantially round top member 335a and protruding side members 335b that extend substantially perpendicular from the top member 335a, towards the bottom end 320c of the reflector housing 320. In certain exemplary embodiments, the mounting bracket 335 has a profile that substantially corresponds to an interior profile of the can 115. This profile allows the mounting bracket 335 to create a junction box (or “j-box”) in the can 115 when the LED module 300 is installed in the light fixture 100. In particular, as described in more detail below with reference to FIG. 14, electrical junctions between the light fixture 100 and the electrical system (not shown) at the installation site may be disposed within the substantially enclosed space between the mounting bracket 335 and the top of the can 115 (the junction box), when the LED module 300 is installed.
In certain exemplary embodiments, the driver 315 and an Edison base socket bracket 345 are mounted to a top surface 350c of the top member 350a of the mounting bracket 335. Alternatively, the driver 315 can be disposed in another location in or remote from the light fixture 100. As set forth above, the driver 315 supplies electrical power and control to the LED package 305. As described in more detail below with reference to FIGS. 14-16, the Edison base socket bracket 345 is a bracket that is configured to receive an Edison base socket 1505 (FIGS. 15-16) and an Edison base adapter 1520 (FIGS. 15-16) in a retrofit installation of the LED module 300 in an existing, non-LED fixture. This bracket 345 allows the LED module 300 to be installed in both new construction and retrofit applications. In certain alternative exemplary embodiments, the bracket 345 may be removed for a new construction installation.
In step 1435, the person squeezes the torsion springs 340 so that the bracket ends 340a of each torsion spring 340 move towards one another. The person slides the LED module 300 into a can 115 of the existing light fixture, aligns the bracket ends 340a with slots in the can 115, and releases the bracket ends 340a to install the bracket ends 340a within the can 115, in step 1440. In step 1445, the person routes any exposed wires (not shown) into the existing fixture and pushes the LED module 300 flush to a ceiling surface.
Returning to step 1410, if the installation will be Title 24 compliant, then the “yes” branch is followed to step 1450, where the person cuts wires in the existing fixture to remove the Edison base, including the Edison base socket 1505, from the existing fixture. In step 1455, the person cuts wires 1520a on the Edison base adapter 1520 to remove an Edison screw-in plug 1520b on the adapter 1520. The person connects the wires 1520a from the Edison base adapter 1520 to wires (not shown) in the existing fixture, and plugs wiring 1530 from the LED module 300 into a connector 1520c on the adapter 1520, in step 1460. These connections complete an electrical circuit between a power source at the installation site, the Edison base adapter 1520, and the LED module 300, without using an Edison base socket 1505. In step 1465, the person mounts the Edison base adapter 1520 to the mounting bracket 335 on the LED module 300, substantially as described above in connection with step 1430.
In certain exemplary embodiments, the optic coupler 330 includes a center member 330b having a top surface 330ba and a bottom surface 330bb. Each surface 330ba and 330bb includes an aperture 330ca and 330cb, respectively. The apertures 330ca and 330cb are parallel to one another and are substantially centrally disposed in the center member 330b. A side member 330bc defines a channel 330d that extends through the center member 330b and connects the apertures 330ca and 330cb. In certain exemplary embodiments, the side member 330bc extends out in a substantially perpendicular direction from the top surface 330ba. Alternatively, the side member 330bc can be angled in a conical, semi-conical, or pyramidal fashion.
When the optic coupler 330 is installed in the LED module 300, the apertures 330ca and 330cb are aligned with the LEDs of the LED package 305 so that all of the LEDs are visible through the channel 330d. In certain exemplary embodiments, the geometry of the side member 330bc and/or one or both of the apertures 330ca and 330cb substantially corresponds to the geometry of the LEDs. For example, if the LEDs are arranged in a substantially square geometry, as shown in FIGS. 7 and 8, the side member 330bc and the apertures 330ca and 330cb can have substantially square geometries, as shown in FIGS. 17 and 18. Similarly, if the LEDs are arranged in a substantially round geometry, the side member 330bc and/or one or both of the apertures 330ca and 330cb can have a substantially round geometry. In certain exemplary embodiments, the optic coupler 330d is configured to guide light emitted by the LED package 305. For example, the emitted light can travel through the channel 330d and be reflected, refracted, diffused, and/or transmitted by the side member 330bc and/or the bottom surface 330bb of the center member 330b.
A side wall member 330e extends substantially perpendicularly from the top surface 330ba of the optic coupler 330. The side wall member 330e connects the center member 330b and an edge member 330f that includes the edge surface 330a of the optic coupler 330. The side wall member 330e has a substantially round geometry that defines a ring around the center member 330b. The edge member 330f extends substantially perpendicularly from a top end 330ea of the side wall member 330e. The edge member 330f is substantially parallel to the center member 330b.
The side wall member 330e and center member 330b define an interior region 330g of the optic coupler 330. The interior region 330g includes a space around the aperture 330ca that is configured to house the electrical connections at the substrate 306. In particular, when the optic coupler 330 is installed within the LED module 300, the optic coupler 330 covers the electrical connections on the substrate 306 by housing at least a portion of the connections in the interior region 330g. Thus, the electrical connections are not visible when the LED module 300 is installed.
FIG. 19 is a perspective top view of an optic coupler 1900 of the LED module 300, in accordance with certain alternative exemplary embodiments. The optic coupler 1900 is substantially similar to the optic coupler 330, except that the optic coupler 1900 has a wider edge member 1900f and a narrower center member 1900b that has a substantially conical or frusto-conical geometry. In particular, a bottom surface 1900ba of the center member 1900b has a larger radius than a top surface 1900bb of the center member 1900b. Each surface 1900ba and 1900bb includes an aperture 1900ca and 1900cb, respectively, that connects a channel 1900d extending through the center member 1900b. The bottom surface 1900ba has a substantially angled profile that bows outward from the channel 1900d, defining the substantially conical or frusto-conical geometry of the center member 1900b. In certain exemplary embodiments, the geometry of the center member 1900b can reduce undesirable shadowing from the optic coupler 1900. In particular, the center member 1900b does not include sharp angled edges that could obstruct light from the LED package 305.
Although FIGS. 17-18 and 19 illustrate center members 330b and 1900b with square and conical geometries, respectively, a person of ordinary skill in the art having the benefit of the present disclosure will recognize that the center members 330b and 1900b can include any geometry. For example, in certain alternative exemplary embodiments, the optic coupler 300 or 1900 can include a center member that incorporates a hemispherical or cylindrical geometry.
an optic coupler covering the at least one electrical connection at the substrate, the optic coupler comprising: a top end comprising a first opening; a bottom end comprising a second opening; and at least one wall member extending between the top end and the bottom end and defining a channel that connects the first opening and the second opening,
wherein the channel is substantially aligned with the LEDs so that the LEDs are visible through the channel.
2. The recessed light fixture of claim 1, wherein the LED package generates substantially all light emitted by the recessed light fixture.
a side member extending angularly from the bottom member, wherein the bottom member and the side member define a region that at least partially houses the at least one electrical connection at the substrate.
8. The recessed light fixture of claim 0, wherein the side member extends substantially away from the bottom end, towards a plane defined by the first opening.
12. The recessed light fixture of claim 11, wherein the engaging member is substantially parallel to the bottom member.
a reflector disposed substantially within the reflector housing, around at least a portion of the LED package; and
an optic coupler disposed substantially between the LED package and the reflector, the optic coupler comprising an engaging surface that engages a top end of the reflector such that the top end of the reflector is disposed between a side edge of the optic coupler and an inside surface of the reflector housing.
16. The recessed light fixture of claim 15, wherein the LED package generates substantially all light emitted by the recessed light fixture.
at least one wall member extending between the top member and the bottom member and defining a channel that connects the first opening and the second opening,
18. The recessed light fixture of claim 17, wherein the optic coupler further comprises:
19. The recessed light fixture of claim 18, wherein the engaging member is substantially parallel to the bottom member.
21. The recessed light fixture of claim 20, wherein the at least one electrical connection are not visible when looking into the recessed light fixture from an environment illuminated by the recessed light fixture.
an optic coupler disposed substantially between the LED package and the reflector and covering at least one electrical connection on the LED package, the optic coupler comprising an aperture through which light emitted by the LEDs is visible.
23. The recessed light fixture of claim 22, wherein the recessed light fixture further comprises a housing within which the reflector is substantially disposed, and
24. The recessed light fixture of claim 22, wherein the LED package generates substantially all light emitted by the recessed light fixture.
Publication number: 20090080189
Applicant: Cooper Technologies Company (Houston, TX)
Inventor: Scott David Wegner (Peachtree City, GA)
Application Number: 12/235,141
International Classification: F21V 1/02 (20060101); F21V 17/04 (20060101);