Source: https://patents.google.com/patent/US8136965?oq=6%2C993%2C661
Timestamp: 2018-04-25 04:02:01
Document Index: 132266093

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', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 61']

US8136965B2 - Light fixtures and lighting devices - Google Patents
US8136965B2
US8136965B2 US12116346 US11634608A US8136965B2 US 8136965 B2 US8136965 B2 US 8136965B2 US 12116346 US12116346 US 12116346 US 11634608 A US11634608 A US 11634608A US 8136965 B2 US8136965 B2 US 8136965B2
US12116346
US20080278950A1 (en )
A lighting device comprises a heat sink, a housing mounted to and/or thermally coupled to the heat sink, a basket assembly attached to the housing, a solid state light emitter thermally coupled to the heat sink, and a baffle assembly attached to the housing. Also, a lighting device comprising a basket assembly and a baffle assembly. In some embodiments, the basket assembly comprises a first member defining a first opening, a second member, a space between the first and second members, and lenses in the opening and in the space. In some embodiments, the heat sink extends farther in a first direction in a first plane than a largest dimension of the housing in any plane which is parallel to the first plane. In some embodiments, at least one additional component (e.g., a power supply module or a junction box) is in contact with the heat sink element.
The present inventive subject matter relates to a light fixture. In some aspects, the present inventive subject matter relates to a light fixture for use with solid state light emitters, e.g., light emitting diodes (LEDs).
One particular type of light fixture is known as a lay-in luminaire, or a troffer. The lensed troffer is the most popular lay-in sold today. It is a commodity that is sold for use in applications where price is the primary buying consideration. For many decades, the recessed parabolic was the standard for high performance applications such as offices. The “parabolic” style troffer utilizes aluminum baffles to shield the light and maximize high angle shielding while sacrificing light on the walls. In recent years, the market has been moving away from the parabolics towards troffers with broader distributions for high performance applications.
A troffer is typically installed within a suspended ceiling grid system where one or more ceiling tiles are replaced with the troffer. Thus, the exterior dimensions of the troffer are typically sized to fit within the regular spacing of the ceiling tiles. In the United States, the spacing of the ceiling grid is often 2 foot (61 cm) by 2 foot (61 cm) and, therefore, troffers will typically have a dimension that is a multiple of 2 feet (61 cm). For example, many troffers are 2′ (61 cm)×2′ (61 cm) or 2′ (61 cm)×4′ (122 cm). Similar regular spacing is also provided in Europe but is provided in a metric unit of measure.
It would be desirable to provide a luminaire which ensures that the luminous surfaces are revealed in a controlled and comfortable way from all potential viewing angles. In addition, it would be desirable to provide a luminaire in which maximum luminances are not greater than amounts that will create discomfort glare. In addition, it would be desirable to provide a luminaire wherein as an observer moves closer to or further from a luminaire, the changes in luminances of the fixture occur gradually to ensure comfort and to minimize striations or hot spots projected on walls. Further, it would be desirable to provide a luminaire wherein luminance ratios of the luminaire when viewed while stationary are balanced, and significant changes do not happen over relatively small distances. In accordance with some aspects of the present inventive subject matter, there are provided devices with such properties.
a baffle assembly attached to the upper housing,
the heat sink element extending farther in a first direction which is in a first plane than a largest dimension of the upper housing in any plane which is parallel to the first plane.
In some lighting devices according to the present inventive subject matter, efforts are made to maximize the heat transfer area of the lighting device and/or the overall heat capacity of the lighting device, in particular, by maximizing the area of the components with which the heat sink (which is thermally coupled to the solid state light emitter(s)) is thermally coupled. The expression “thermally coupled”, as used herein, refers to components which readily transfer heat therebetween, e.g., components which are in contact with each other via a heat transfer gasket, thermal grease and/or thermal adhesive.
FIG. 1 is a top view of a first embodiment of a luminaire incorporating the present inventive subject matter.
Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe one element's relationship to another element(s) as illustrated in the Figures. Such relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in the Figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The exemplary term “lower”, can therefore, encompass both an orientation of “lower” and “upper,” depending on the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The exemplary terms “below” or “beneath” can, therefore, encompass both an orientation of above and below.
As used herein, the term “substantially,” e.g., in the expressions “substantially planar”, “substantially frustopyramidal”, or “substantially square” means at least about 95% correspondence with the feature recited, e.g.:
the expression “substantially planar” means that at least 95% of the points in the surface which is characterized as being substantially planar are located on one of or between a pair of planes which are parallel and which are spaced from each other by a distance of not more than 5% of the largest dimension of the surface.
the expression “substantially frustopyramidal”, as used herein, means that at least 95% of the points in the surface which is characterized as being substantially frustopyramidal are located on one of or between a pair of imaginary frustopyramidal structures which are spaced from each other by a distance of not more than 5% of their largest dimension;
the expression “substantially square” means that a square shape can be identified, wherein at least 95% of the points in the item which is characterized as being substantially square fall within the square shape, and the square shape includes at least 95% of the points in the item.
(2) U.S. Patent Application No. 60/793,524, filed on Apr. 20, 2006, entitled “LIGHTING DEVICE AND LIGHTING METHOD” (inventors: Gerald H. Negley and Antony Paul van de Ven) and U.S. patent application Ser. No. 11/736,761, filed Apr. 18, 200 7(now U.S. Patent Publication No. 2007/0278934), the entireties of which are hereby incorporated by reference;
(3) U.S. Patent Application No. 60/793,518, filed on Apr. 20, 2006, entitled “LIGHTING DEVICE AND LIGHTING METHOD” (inventors: Gerald H. Negley and Antony Paul van de Ven) and U.S. patent application Ser. No. 11/736,799, filed Apr. 18, 2007 (now U.S. Patent Publication No. 2007/0267983), the entireties of which are hereby incorporated by reference;
(4) U.S. Patent Application No. 60/857,305, filed on Nov. 7, 2006, entitled “LIGHTING DEVICE AND LIGHTING METHOD” (inventors: Antony Paul van de Ven and Gerald H. Negley; and U.S. patent application Ser. No. 11/936,163, filed Nov. 7, 2007 (now U.S. Patent Publication No. 2008/0106895), the entireties of which are hereby incorporated by reference;
(5) U.S. Patent Application No. 60/916,596, filed on May 8, 2007, entitled “LIGHTING DEVICE AND LIGHTING METHOD” (inventors: Antony Paul van de Ven and Gerald H. Negley), the entirety of which is hereby incorporated by reference;
(6) U.S. Patent Application No. 60/916,607, filed on May 8, 2007, entitled “LIGHTING DEVICE AND LIGHTING METHOD” (inventors: Antony Paul van de Ven and Gerald H. Negley), the entirety of which is hereby incorporated by reference;
(7) U.S. Patent Application No. 60/839,453, filed on Aug. 23, 2006, entitled “LIGHTING DEVICE AND LIGHTING METHOD” (inventors: Antony Paul van de Ven and Gerald H. Negley) and U.S. patent application Ser. No. 11/843,243, filed Aug. 22, 2007 (now U.S. Patent Publication No. 2008/0084685), the entireties of which are hereby incorporated by reference;
(8) U.S. Pat. No. 7,213,940, issued on May 8, 2007, entitled “LIGHTING DEVICE AND LIGHTING METHOD” (inventors: Antony Paul van de Ven and Gerald H. Negley), the entirety of which is hereby incorporated by reference;
(9) U.S. Patent Application No. 60/868,134, filed on Dec. 1, 2006, entitled “LIGHTING DEVICE AND LIGHTING METHOD” (inventors: Antony Paul van de Ven and Gerald H. Negley), the entirety of which is hereby incorporated by reference;
(10) U.S. patent application Ser. No. 11/948,021, filed on Nov. 30, 2007 (now U.S. Patent Publication No. 2008/0130285), entitled “LIGHTING DEVICE AND LIGHTING METHOD” (inventors: Antony Paul van de Ven and Gerald H. Negley), the entirety of which is hereby incorporated by reference;
(11) U.S. Patent Application No. 60/868,986, filed on Dec. 7, 2006, entitled “LIGHTING DEVICE AND LIGHTING METHOD” (inventors: Antony Paul van de Ven and Gerald H. Negley), and U.S. patent application Ser. No. 11/951,626, filed Dec. 6, 2007 (now U.S. Patent Publication No. 2008/0136313), the entireties of which are hereby incorporated by reference;
(12) U.S. Patent Application No. 60/916,597, filed on May 8, 2007, entitled “LIGHTING DEVICE AND LIGHTING METHOD” (inventors: Antony Paul van de Ven and Gerald H. Negley) and U.S. Patent Application No. 60/944,848, filed Jun. 19, 2007, the entireties of which are hereby incorporated by reference; and
(13) U.S. Patent Application No. 60/990,435, filed on Nov. 27, 2007, entitled “WARM WHITE ILLUMINATION WITH HIGH CRI AND HIGH EFFICACY” (inventors: Antony Paul van de Ven and Gerald H. Negley), the entirety of which is hereby incorporated by reference.
The basket assembly 18, the upper housing 16 and the light emitter board 14 provide a mixing chamber in which light emitted from the LEDs is mixed by a combination of reflection within the chamber and the optical properties of the diffusing structures and/or films of the basket assembly 18. Additionally, the interior surfaces of the mixing chamber may be covered in a reflective material, such as MCPET® from Furakawa Industries or any other reflective material, a wide variety of which are known by and available to persons skilled in the art (in some embodiments, particularly preferred reflective material is diffuse reflective material). Alternatively or additionally, any of the surfaces which light contacts can, in some embodiments, be coated with textured paint in order to alter brightness characteristics and/or patterns as desired.
Additionally, because the light emitter board 14 has a smaller area than the basket assembly 18, the configuration of the basket assembly 18 and the upper housing 16 may be such as to spread the light from the LEDs across visible surfaces of the basket assembly 18 so as to avoid abrupt changes in luminance of the basket assembly 18 and the baffle assembly 20. This may be accomplished, for example, with the mechanical configuration of the basket as described in U.S. Provisional Patent Application Ser. No. 60/916,407 filed May 7, 2007, the disclosure of which is incorporated herein as if set forth in its entirety, or by the optical properties of the lens(es) of the basket assembly as described below.
Films and/or lenses can be made by any desired method, a wide variety of which are well-known to those of skill in the art. For example, in some embodiments, lenses with one or more films attached thereto can be made by film insert molding (e.g., as described in U.S. Patent Application No. 60/950,193, filed on Jul. 17, 2007, entitled “OPTICAL ELEMENTS WITH INTERNAL OPTICAL FEATURES AND METHODS OF FABRICATING SAME” (inventors: Gerald H. Negley and Paul Kenneth Pickard; and U.S. Patent Application No. 61/023,973, filed on Jan. 28, 2008, the entireties of which are hereby incorporated by reference) or by coextrusion.
Returning to FIG. 2, in some embodiments of the present inventive subject matter, the overall depth “d” of the luminaire 10 is about 5 inches (12.7 cm) or less. Such a shallow depth may present difficulties with providing sufficient heat sink area to adequately dissipate heat from the LEDs to maintain junction temperatures of the LEDs in a desired range. Thus, as seen in FIG. 2, rather than extending the heights of the fins of the heat sink 12 to increase the surface area of the heat sink 12, the lengths (i.e., lateral dimensions) of the fins of the heat sink 12 are extended past the periphery of the upper housing 16 so as to overhang the upper housing 16 (and/or additional fins are provided, e.g., parallel to the depicted fins, so that the heat transfer area is increased in a direction perpendicular to the planes defined by the major surfaces of the fins). Such an overhanging heat sink 12 takes advantage of the relatively small size of the lighted portion of the luminaire 10 formed by the upper housing 16 and the basket 18 in comparison to the overall size of the luminaire 10 as defined by the periphery of the baffle assembly 20. Furthermore, where a slanted baffle assembly 20 and a slanted upper housing 16 are provided, extending the heat sink 12 beyond the upper housing 16 so as to overhang the baffle 20 provides sufficient clearance to allow additional components to be mounted to the heat sink 12 without extending beyond the top of the heat sink, thereby increasing the overall depth of the luminaire 10. Thus, for example, the power supply module 22 may be mounted to the heat sink 12 without increasing the overall depth “d” of the luminaire 10.
With regard to the baffle assembly 20 of FIG. 2, the baffle assembly 20 includes a flat lip portion 30 that engages the grid of the suspended ceiling. The lip portion 30 may extend a distance “1” from the periphery of the luminaire 10. If the distance 1 is too great, then a dark area may be perceived about the periphery of the luminaire 10 as the lip portion 30 is spaced from but substantially parallel with the light emitting lens of the basket assembly 18 and, therefore, little light will be incident on the lip portion 30. If the distance 1 is too small, then the angled portion of the baffle may extend onto the ceiling grid which may not be aesthetically pleasing. Thus, in some embodiments, the distance 1 may be from about 0.5 inches (1.25 cm) to about 2 inches (5.1 cm).
Additionally, the baffle assembly 20 recesses the light generation portion of the luminaire 10 above the plane of the ceiling tile. The light generation portion of the luminaire 10 is recessed above the ceiling tile such that the luminaire 10 is perceived as dimmer the farther away an occupant is from the luminaire 10. Recessing the light generation portion creates a cutoff angle such that at a sufficient distance from the luminaire 10, the light generation portion is no longer directly visible. However, recessing the light generation portion may also limit the ability of the luminaire to provide a wide distribution of light into the room. Furthermore, recessing the light generation portion above the ceiling tile may limit the distance available for mixing light from the LEDs inasmuch as the luminaire 10 must be no deeper than the depth “d.”
The degree to which the baffle assembly 20 is illuminated will depend on the degree of slant of the wall of the baffle assembly 20, the extent to which the basket assembly 18 extends beyond the baffle assembly 20 and the light distribution pattern from the basket assembly 18. Thus, the width “w” and the height “h” of the slanted portion of the baffle section define the relationship between the recess of the light generating portion of the luminaire 10 and the baffle assembly 20. If the degree of slant (i.e., angle) is too great for a given depth of recess, then too much light is lost on the baffle assembly and luminaire efficiency is unduly decreased. If the degree of slant is not great enough for a given depth of recess, then the basket assembly 18 is not sufficiently recessed above the ceiling and/or the baffle assembly 20 will appear dark, which can be aesthetically displeasing. Accordingly, in some embodiments of the present inventive subject matter, the ratio of w to h is from about 2 to about 3 and in some embodiments about 2.3. In particular embodiments, the width w is from about 130 to about 140 mm and the height h is from about 50 to about 60 mm. In some embodiments of the present inventive subject matter, the angle of slant is in the range of from about 20 degrees to about 40 degrees (i.e., the ratio of w to h is from about 2.75 to about 1.19). In some embodiments of the present inventive subject matter, the angle of slant is about 22 degrees (i.e., the ratio of w to h is about 2.48). In some embodiments of the present inventive subject matter, the angle of slant is about 28 degrees (i.e., the ratio of w to h is about 1.88). In some embodiments of the present inventive subject matter, the angle of slant is about 34 degrees (i.e., the ratio of w to h is about 1.48).
FIGS. 8 and 9 are more detailed cross-sectional view of the luminaire 10 without the baffle assembly 20. As seen in FIG. 8, the upper housing 16 is mounted to the heat sink 12. The upper housing 16 has an opening adjacent the heat sink 12 through which a PC board 60 having LEDs 62 mounted thereon extends. As discussed above, the PC board may be a metal core PC board and it may be thermally and mechanically coupled to the heat sink 12. A layer of MCPET® 56 is provided on all exposed internal faces of the upper housing 16, the PC board 60 and heat sink 12 and the basket assembly 18.
As discussed above, one or more films or other diffusing structures 58 may be provided on or as part of the first lens 52. The one or more films may, for example, be held in place by one or more tabs on each edge of the film 58 that is folded and extends onto the internal frame member 70. The tab may then be held in place by the MCPET® reflector 56 that is adhesively secured to the exposed surface of the internal frame member 70, thereby capturing the tab between the MCPET® 56 and the internal frame member 70.
By providing the one or more second light transmitting windows about the periphery of the first light transmitting window, the transition from the bright central portion of the basket assembly 18 to the less bright baffle assembly 20 may be softened by lower luminous intensity outer windows. In addition, the one or more second light transmitting windows can provide for better illumination of the outside surface of the inner frame assembly (i.e., the light which passes through the first lens typically would not illuminate the outside surface of the inner frame assembly, such that the outside surface of the inner frame assembly might be dark or less illuminated than is desirable—in such cases, light passing through the second lens(es) can allow for better illumination of the outside surface of the inner frame assembly.
Embodiments of the present inventive subject matter may be used with differing designs of the basket assembly 18. Thus, the present inventive subject matter may be used with basket assemblies 18 that appear as described in U.S. patent application Ser. No. 29/324,488 filed Sep. 12, 2008 (now U.S. Pat. No. D592,348, U.S. patent application Ser. No. 29/324,484 filed Sep. 12, 2008 (now U.S. Pat. No. D592,347 and/or U.S. patent application Ser. No. 29/324,486 filed Sep. 12, 2008 (now U.S. Pat. No. D601,741, the disclosures of which are incorporated herein by reference as if set forth in their entirety.
While embodiments of the present inventive subject matter have been described with reference to a substantially square luminaire, other shapes, such as rectangles, may also be provided. Thus, for example, a 2′×4′ luminaire could be provided by extending the dimensions of the various components of the luminaire one dimension but not the other.
2. A lighting device as recited in claim 1, wherein the baffle assembly comprises four side walls, and the four side walls define a substantially frustopyramidal shape.
4. A lighting device as recited, in claim 3, wherein the baffle assembly comprises four side walls, and the four side walls define a substantially frustopyramidal shape.
6. A lighting device as recited in claim 1, wherein the at, least one, solid state light emitter is mounted on the heat sink.
7. A lighting device as recited in claim 1, wherein the lighting device further comprises a light emitter board mounted on the heat sink, the at least one solid state light emitter mounted on the light emitter board, the light emitter board thermally coupled to the heat sink, the at least one solid state light emitter thermally coupled to the light emitter board.
15. A lighting device as recited in claim 1, wherein the basket assembly comprises at least a first frame, the first frame comprising at least one first frame member and at least one second frame member, the first frame member defining a first opening, at least one first lens in the first opening, at least one space between the first frame member and the second frame member, at least one second lens in the space.
the first frame member defining a first opening, at least one first lens being in the first opening,
at least one space provided between the first frame member and the second frame member, at least one second lens in the space.
19. A lighting device as recited in claim 18, wherein the first frame consists of the first frame member and the second frame member, and the second lens covers an entirety of the space between the first frame member and the second frame member.
the first frame consists of the first frame member and the second frame member,
the second frame member comprises a second frame member first portion, a second frame member second portion, a second frame member third portion and a second frame member fourth portion,
a first space is located between the first-second frame member first portion and the first frame member,
a second space is located between the second frame member second portion and the first frame member,
a third space is located between the second frame member third portion and the first frame member,
a fourth space is located between the second frame member fourth portion and the first frame member,
the first opening is a central opening and is substantially square, and a second lens is in each of the first, second, third and fourth spaces.
21. A lighting device as recited in claim 18, wherein the at least one solid state light emitter is mounted on the heat sink.
22. A lighting device as recited in claim 18, wherein the lighting device further comprises a light emitter board mounted on the heat sink, the at least one solid state light emitter mounted on the light emitter board, the light emitter board thermally coupled to the heat sink, the at least one solid state light emitter thermally coupled to the light emitter board.
23. A lighting device as recited in claim 22, wherein the basket assembly, the upper housing and the light emitter board together, define a light mixing chamber.
32. A lighting device as recited in claim 31, wherein the largest dimension of the upper housing is in a second plane which is parallel to the first plane.
33. A lighting device as recited in claim 32, wherein the baffle assembly comprises a plurality of side walls and an end region, the end region defining a light exit opening, the light exit opening defining a first substantially planar area, the first plane parallel to the first substantially planar area.
35. A lighting device as recited in claim 31, wherein the lighting device further comprises a light emitter board mounted on the heat sink, the at least one solid state light emitter mounted on the light emitter board, the light emitter board thermally coupled to the heat sink, the at least one solid state light emitter thermally coupled to the light emitter board.
43. A lighting device as recited in claim 31, wherein the basket assembly comprises at least a first frame, the first frame comprising at least one first frame member and at least one second frame member, the first frame member defining a first opening, at least one first lens in the first opening, at least one space between the first frame member and the second frame member, at least one second lens in the space.
45. A lighting device as recited in claim 44, wherein the heat sink element comprises a first side and a second side, the at least one additional component and the upper housing both in contact with the first side of the heat sink element.
47. A lighting device as recited in claim 46, wherein the power supply module comprises a compartment in which there is a power supply.
51. A lighting device as recited in claim 50, wherein the heat sink element comprises a first side and a second side, the at least one additional component and the upper housing both in contact with the first side of the heat sink element.
52. A lighting device as recited in claim 50, wherein the at least, one additional component comprises at least one element selected from among a power supply module and a junction box.
55. A lighting device as recited in claim 54, wherein the at least one additional component comprises at least one element selected from among a power supply module and a junction box.
57. A lighting device as recited in claim 54, wherein the lighting device further comprises a light emitter board mounted on the heat sink, the at least one solid state light emitter mounted on the light emitter board, the light emitter board thermally coupled to the heat sink, the at least one solid state light emitter thermally coupled to the light emitter board.
66. A lighting device as recited in claim 65, wherein the at least one solid state light emitter is mounted on the heat sink.
67. A lighting device as recited in claim 65, wherein the lighting device further comprises a light emitter board mounted on the heat sink, the at least one solid state light emitter mounted on the light emitter board, the light emitter board thermally coupled to the heat sink, the at least one solid state light emitter thermally coupled to the light emitter board.
74. A lighting device as recited in claim 73, wherein the power supply module comprises a compartment in which there is a power supply.
76. A lighting device as recited in claim 72, wherein the heat sink element comprises a first side and a second side, the at least one additional component and the upper housing both in contact with the first side of the heat sink element.
the baffle assembly comprising a plurality of side walls and an end region, the end region defining a light exit opening, the light exit opening defining a first substantially planar area, at least one of the side walls of the baffle assembly extending from the end region at an angle of less than 90 degrees relative to the first substantially planar area,
a periphery of the basket assembly within a space defined by the baffle assembly.
79. A lighting device as recited in claim 78, wherein the baffle assembly comprises four side walls, and the four side walls define a substantially frustopyramidal shape.
87. A lighting device as recited in claim 78, wherein the basket assembly comprises at least a first frame, the first frame comprising at least one first frame member and at least one second frame member, the first frame member defining a first opening, at least one first lens in the first opening, at least one space between the first frame member and the second frame member, at least one second lens in the space.
the first frame member defining a first opening, at least one first lens in the first opening,
at least one space between the first frame member and the second frame member, at least one second lens in the space.
91. A lighting device as recited in claim 90, wherein the lighting device further comprises at least one light emitter.
a second space is located between the second second frame member and the first frame member,
95. A lighting device as recited in claim 90, wherein the lighting device further comprises at least one diffusing film mounted on the first lens.
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US13365618 US8789975B2 (en) 2007-05-07 2012-02-03 Light fixtures and lighting devices
US13365618 Continuation US8789975B2 (en) 2007-05-07 2012-02-03 Light fixtures and lighting devices
US20080278950A1 true US20080278950A1 (en) 2008-11-13
US8136965B2 true US8136965B2 (en) 2012-03-20
US12116346 Active 2029-07-16 US8136965B2 (en) 2007-05-07 2008-05-07 Light fixtures and lighting devices
US12116341 Active 2029-01-04 US9310035B2 (en) 2007-05-07 2008-05-07 Light fixtures and lighting devices
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US13365618 Active US8789975B2 (en) 2007-05-07 2012-02-03 Light fixtures and lighting devices
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