Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 1 of 76 PageID 10
`
`
`Exhibit A
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 2 of 76 PageID 11
`Case 6:16-CV-00680-RBD-GJK Documen"|||fl""|m“"n|m||mm| 11
`
`US00820l 968B2
`
`(12) United States Patent
`Maxik et al.
`
`(10) Patent No.:
`
`(45; Date of Patent:
`
`US 8,201,968 B2
`Jun. 19, 2012
`
`(54) LOW PROFILE LIGHT
`
`(56)
`
`References Cited
`
`(75)
`
`Inventors: Fredric S. Nlaxik. lndialaittie. l-‘I. (US);
`Raymond A. Reynolds. Satellite Beach.
`FL (US): Addy S. Widjaja. Palm Bay.
`FL (US): Mark Penley Boomgaardcn.
`Indian I-larbour Beach. F1., (US): Robert
`Rafael Soler, Cocoa Beach. FL {US}:
`James I.. Sehellaek, Cocoa Beach. I"-‘I.
`(us)
`
`U.S. P/\'l"l‘iN'l' l)()(.'lJMl*lN'l‘S
`2009-"UU864'i'4 Al‘
`432009 Chou
`2009.-0141506 Al‘°‘
`6.-‘Z009
`l.a.n elal.
`
`362230
`362-"351
`
`lil’
`W0
`
`I-'0Rl3lGN l’A’l‘l-_iN'I‘ D0(_‘lJMl3N’l'S
`[$150491 .v’\I
`T2008
`2UOS|3?T32 A1
`II-"2003
`
`OTHER PUBLICATIONS
`
`(73) Assignee: Lighting Science Group Corporation.
`Satellite Beach. FL (US)
`
`LP International Search Report
`Dated Dec. I4. 2UlU_
`
`for Application No.
`
`i0l'?4449.8;
`
`( "‘ ) Notice:
`
`Subject to any disclairner. the term oftltis
`patent is extended or zidjusted under 35
`U.S.(.‘. l54(b) by 98 days.
`
`(21) Appl.No.: 121775.310
`
`(22)
`
`Filed:
`
`May 6, 2:110
`
`(65)
`
`Prior Publication Data
`
`US 201 le’008()'i'27 Al
`
`Apr. 7. 2011
`
`Related U.S. Application Data
`
`(60) Provisional application No. 6]f248.6(i5. filed on Oct.
`5. 2009.
`
`(51)
`
`Int. Cl.
`(2006.01)
`F2! V 1700
`(2006.01)
`F21 V29/00
`362;‘235; 362094: 362.047: 3621373
`(52) U.S. Cl.
`(58) Field of (flassitieation Search ................ .. 362;’ 147
`362E148. I49. 150. 404. 294. 373. 547. 363
`See application tile for complete search ltislory.
`
`* cited by examiner
`
`Pr'.iumr_i-' E.\'t2nii'm.’r — Ali Alavi
`(74) At!orr.=e_1-‘. Agent’. or First: — Cantor Colbttrtt LLP
`
`(5?)
`
`ABS’l‘RA(T'l‘
`
`A luminaire includes :.1 heal spreaderand 21 heat sink thermally
`coupled to and disposed diametrically outboard of the heat
`spreader. an outer optic securely retained relative to at least
`one of the heat spreader and the heat sink. and a light source
`disposed in thermal contnnlnicatiori with the heat spreader.
`the light source liaving a plurality of light emitting diodes
`(I._.lEDs). The heat spreader. the lteat sink and the outer optic.
`in combination. liave an overall height I-1 and an overall out-
`side dimension D such that the ratio ofllfl) is equal to or less
`than 0.25. The combination defined by the heat spreader. the
`heat sink and the outer optic. is so dimensioned as to: cover an
`opening defined by a nominally sized four—inch can light
`fixture: and. cover an opening, dellned by a noniinally sized
`l'o1tr-inch electrical junction box.
`
`23 Claims, 13 Drawing Sheets
`
`
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 3 of 76 PageID 12
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`
`US. Patent
`
`Jun. 19,2012
`
`Sheet 1 of 13
`
`US 8,201,968 B2
`
`115
`
`100’\
`
` 110
`
`‘wt.--4"
`
`FIG. 1
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 4 of 76 PageID 13
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`
`U.S. Patent
`
`Jun. 19, 2012
`
`Sheet 2 of 13
`
`US 8,201,968 B2
`
`
`
`FIG. 3
`
`
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 5 of 76 PageID 14
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`
`US. Patent
`
`Jun. 19,2012
`
`Sheet 3 of 13
`
`US 8,201,968 B2
`
`115
`
`
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 6 of 76 PageID 15
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`
`U.S. Patent
`
`Jun. 19, 2012
`
`Sheet 4 of 13
`
`US 8,201,968 B2
`
` 35
`
`FIG. 7
`
`FIG. 9
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 7 of 76 PageID 16
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`
`U.S. Patent
`
`Jun. 19,2012
`
`Sheet 5 of 13
`
`US 8,201,968 B2
`
`145
`
`
`
`FIG. 11
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 8 of 76 PageID 17
`Case 6:16—cv—OO680—RBD—GJK Document 1-2 Filed 04/21/16 Page 8 of 76 Page|D 17
`
`US. Patent
`
`Jun. 19,2012
`
`Sheet 6 of 13
`
`US 8,201,968 B2
`
`100’\‘
`
`
`140,160
`130
`
`200
`
`
`
`20°
`
`105
`
`135
`
`
`
`“&*“~ - ‘({‘\\‘"-
`
`
`
`‘
`
`110
`
`
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 9 of 76 PageID 18
`Case 6:16—cv—OO680—RBD—GJK Document 1-2 Filed 04/21/16 Page 9 of 76 Page|D 18
`
`U.S. Patent
`
`Jun. 19, 2012
`
`Sheet 7 of 13
`
`US 8,201,968 B2
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 10 of 76 PageID 19
`Case 6:16—cv—OO680—RBD—GJK Document 1-2 Filed 04/21/16 Page 10 of 76 Page|D 19
`
`U.S. Patent
`
`Jun. 19, 2012
`
`Sheet 8 of 13
`
`US 8,201,968 B2
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 11 of 76 PageID 20
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`
`U.S. Patent
`
`Jun. 19,2012
`
`Sheet 9 of 13
`
`US 8,201,968 B2
`
`140'
`
`105
`
`FIG. 22
`
`
`
`FIG. 23
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 12 of 76 PageID 21
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`
`US. Patent
`
`Jun. 19, 2012
`
`Sheet 10 of 13
`
`US 8,201,968 B2
`
`145"\«
`
`145'
`
`FIG. 25
`
`215'
`
`FIG. 26
`
`

`
`mem
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 13 of 76 PageID 2222
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`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 14 of 76 PageID 23
`
`US 8,201,968 B2
`
`FIG. 28
`
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`
`FIG. 29
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`
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`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 15 of 76 PageID 24
`Case 6:16—cv—OO680—RBD—GJK Document 1-2 Filed 04/21/16 Page 15 of 76 Page|D 24
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`U.S. Patent
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`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 16 of 76 PageID 25
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`
`US 8,201,968 B2
`
`2
`
`1
`LOW PROFILE LIGHT
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`This application claims the benefit of U.S. Provisional
`Application Scr. No. 613248.665. filed Oct. 5. 2009, which is
`incorporated herein by reference in its entirety.
`
`BACKGROUND OF 'l'l-IE lN\«’ENTION
`
`Ill
`
`The present disclosure relates generally to lighting. par-
`ticularly to low profile ligltting. and more particularly to low
`profile downlighting for retrofit applications.
`Light fixtures come in many shapes and sizes. with some
`being configured for new work installations while others are
`configured for old work installations. New work installations
`are not limited to as many constraints as old work installa-
`tions. which must take into account the type of electrical
`fixtltrefericlosure orjuttction box existing behind a ceiling or
`wall panel material. With recessed ceiling lighting. sheet
`metal can-type light fixtures are typically used. while surface-
`mounted ceiling and wall lighting typically use metal or plas-
`ticjunction boxes of a variety ofsizes and depths. With the
`advent of LED (light emitting diode) lighting. there is a great
`need to not only provide new work l.lT.l') light fixtures. but to
`also provide I.F.I) light fixtures that are suitable for old work
`applications. thereby enabling retrofit installations. One way
`of providing old work LED lighting is to configure an LED
`luminaire in such a manner as to utilize the volume of space
`available within an existing fixture (can-type fixture or junc-
`tion box). However. such configurations typically result in
`unique designs for each type and size of fixture. Accordingly,
`there is a need in the art for an I.F.D lighting apparatus that
`overcomes these drawbacks.
`This background information is provided to reveal infor-
`mation believed by the applicant to be ofpossible relevance to
`the present invention. No admission is necessarily intended.
`nor should be construed. that any of the preceding inl'omia-
`tion constitutes prior art against the present invention.
`
`BRIEF DESCRIPTION OF THE INVENTION
`
`An embodiment ofthe invention includes a luminaire hav-
`ing a heat spreader and a heat sink thermally coupled to and
`disposed diametrically outboard of the heat spreader. an outer
`optic securely retained relative to at least one of the heat
`spreader and the heat sink. and a light source disposed in
`thermal communication with the heat spreader. the light
`source having a plurality of light emitting diodes (I_EDs ). The
`heat spreader. the heat sink and the outer optic. in combina-
`tion. have an overall height I-l and an overall outside dimen-
`sion D such that the ratio of l-li'D is equal to or less than 0.25.
`The combination defined by the heat spreader. the heat sink
`and the outer optic. is so dimensioned as to: cover an opening
`defined by a nominally sized four-inch can light fixture: and.
`cover an opening defined by a nominally sized four—inch
`electrical junction box.
`An embodiment of the invention includes a luminaire hav-
`
`ing a heat spreader and a heat sink thennally coupled to and
`disposed diametrically outboard of the heat spreader. An
`outer optic is securely retained relative to at least one of the
`heat spreader and the heat sink. A light source is disposed in
`thermal communication with the heat spreader. the light
`source having a plurality of light emitting diodes (LEDs). A
`power conditioner is disposed i11 electrical comnlunication
`with the light source. the power conditioner being configured
`
`3h
`
`35
`
`4t":
`
`45
`
`50
`
`55
`
`60
`
`to receive AC voltage lrom an electrical supply line and to
`deliver DC voltage to the plurality of Ll-3l)s_. the power con-
`ditioner being so dimensioned as to fit within at least one of:
`a nominally sized four-inch can light fixture; and, a nominally
`sized l‘our-inch electrical junction box.
`A11 embodiment of the invention includes a lurninairc hav-
`ing a heat spreader. a heat sink thermally coupled to and
`dis posed diametrically outboard ofthe heat spreader. an outer
`optic securely retained relative to at least one of the heat
`spreader and the heat sink, a light source disposed in thennal
`cormnunjcation with the heat spreader, and an electrical sup-
`ply line disposed in electrical communication with the light
`source. The heat spreader. heat sink and outer optic. in com-
`bination. have an overall height H and an overall outside
`dimension D such that the ratio of I-DD is equal to or less than
`0.25. The defined combination is so dimensioned as to: cover
`an opening defined by a nominally sized four—inch can light
`fixture: and. cover an opening defined by a nominally sized
`four—inch electrical junction box.
`An embodiment olthe invention includes a luminaire hav-
`ing a housing with a light unit and a trim unit. The light unit
`includes a light source. and the trim unit is mechanically
`separable from the light unit. A means lhr mechanically sepa-
`rating the trim unit from the light unit provides a thermal
`conduction path therebetween. The light unit has sufficient
`thenual mass to spread heat generated by the light source to
`the means for mechanically separating. and the trim unit has
`sulficient thermal mass to serve as a heat sink to dissipate heat
`generated by the light source.
`An embodiment of the invention includes a luminaire for
`retrofit connection to an installed light fixture having a con-
`cealed in-use housing. The luminaire includes a housing hav-
`ing a light unit and a trim unit. the light unit having a light
`source. and the trim unit being mechanically separable front
`the light unit. The trim unit defines a heat sinking thermal
`management element. configured to dissipate heat generated
`by the light source. that is completely 100% external ofthe
`concealed in-use housing of the installed light fixture.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`Referring to the exemplary drawings wherein like elements
`are numbered alike in the accompanying Figures. abbreviated
`in each illustration as “Fig.“:
`FIG.
`1 depicts an isometric top view of a luniinaire in
`accordance with an embodiment of the invention:
`
`FIG. 2 depicts atop view ofthe luminaire of FIG. 1:
`FIG. 3 depicts a bottom view olthe luminaire ol'FIG. 1:
`FIG. 4 depicts a side view ofthe luminaire ofFIG. 1:
`FIG. 5 depicts a top view ofa heat spreader assembly. a heat
`sink. and an outer optic in accordance with an embodiment of
`the invention;
`FIG. 6 depicts an isometric view of the heat spreader of
`FIG. 5:
`FIG. 7 depicts a partial isometric view ofthe heat sink oi‘
`FIG. 5:
`
`FIG. 8 depicts a top view ofan alternative heat spreader
`assembly in accordance with an embodiment ofthe invention:
`FIG. 9 depicts a top view of another alternative heat
`spreader assembly in accordance with an enihodirnent ofthe
`invention:
`
`FIG. 10 depicts a top view ofyet another altemative heat
`spreader assembly in accordance with an embodiment ofthe
`invention;
`FIG. 11 depicts a bottom view ofa heat spreader having a
`power conditioner in accordance with an cmbodirnent ofthe
`invention;
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 1-2 Filed 04/21/16 Page 17 of 76 PageID 26
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`3
`
`4
`
`US 8,201,968 B2
`
`FIG. 12 depicts a section view ofa luminaire in accordance
`with an embodiment of the invention;
`FIG. 13 depicts a bottom view of a heat sink having
`recesses in accordance with an embodiment of the invention:
`
`FIGS. 14-18 depict isometric views ofexisting electrical
`can-type light fixtures and elcctricaljunction boxes for use i11
`accordance with an embodiment cfthe invention:
`
`FIGS. 19-21 depict a side view. top view and bottom view.
`respectively. ofa luminaire similar but alternative to that of
`FIGS. 2-4. in accordance with an embodiment of the inven-
`tion;
`FIGS. 22-23 depict top and bottom views. respectively. of
`a heat spreader having an alternative power conditioner in
`accordance with an embodiment of the invention:
`FIG. 24-26 depict it1 isometric. top and side views. respec-
`tively, an altemative reflector to tl1at depicted in FIGS. 10 and
`12:
`FIG. 2'! depicts an exploded assembly view of an alterna-
`tive luminairc in accordance with an embodiment of the
`invention:
`FIG. 28 depicts a side view of the luminaire ofFlG. 27;
`FIG. 29 depicts a back view of the luminaire of FIG. 27:
`and
`FIG. 30 depicts a cross section view of the ltuninaire of
`FIG. 27. and more particularly depicts a cross section view of
`the outer optic used in accordance with an embodiment of the
`invention.
`
`DETAILED DESCRIPTION OF THE INVENTION
`
`Although the following detailed description contains many
`specifics for the purposes of illustration. anyone of ordinary
`skill in the art will appreciate that many variations and alter-
`ations to the following details are within the scope of the
`invention. Accordingly, the following preferred embodiments
`ofthe invention are set forth without any loss of generality to.
`and without imposing limitations upon. the claimed inven-
`tion.
`An embodiment of the invention. as shown and described
`
`by the various figures and accompanying text. provides a low
`profile downlight. more generally referred to as a Iuminaire.
`having an LED light source disposed on a heat spreader.
`which in tum is thennally coupled to a heat sink that also
`serves as the trim plate of the Iuminaire. The lutninaire is
`configured and dimensioned for retrofit installation on stan-
`dard can-type light fixtures used for recessed ceiling lighting.
`and on standard ceiling or wall junction boxes [J-boxes} used
`for ceiling or wall mounted lighting. The luminaire is also
`suitable for new work installation.
`While embodiments of the invention described and illus-
`
`trated herein depict an example luminaire for use as a down-
`light when disposed upon a ceiling. it will be appreciated that
`embodiments of the invention also encompass other lighting
`applications. such as a wall sconce for example.
`While embodiments of the invention described and illus-
`trated herein depict example power conditioners having visu-
`ally defined sizes. it will be appreciated that embodiments of
`the invention also encompass other power conditioners hav-
`ing other sizes as long as the power conditioners fall within
`the ambit of the invention disclosed herein.
`
`Referring to FIGS. 1-26 collectively, a luminaire 100
`includes a heat spreader 195. a heat sink 110 thermally
`coupled to and disposed diametrically outboard ofthe heat
`spreader. an outer optic 115 securely retained relative to at
`least one of the heat spreader 105 and the heat sink 110, a light
`source 120 disposed in thermal commttnication with the heat
`spreader 105. and an electrical supply line 125 disposed in
`
`III
`
`3n
`
`3.‘-
`
`4t":
`
`45
`
`50
`
`55
`
`60
`
`electrical cottununication with the light source 120. To pro-
`vide for a low profile luminaire 100. the combination of the
`heat spreader 105. heat sink 110 and outer optic 115. have an
`overall height H and an overall outside dimension D such that
`the ratio ofllfl) is equal to or less than 0.25. In an example
`embodi111enI.hcight I I is I .5-inches. and otttside diniensiort 1)
`is a diameter of 7-incltes. Other dimensions for ii and I) are
`
`contemplated such that the combination of the heat spreader
`I05. heat sink 110 and outer optic 115. are configured and
`sized so as to: (i) cover an opening defined by an industry
`standard can-type light fixture having nominal sizes from
`three—inches to six-inches {see FIGS. 14 and 15 for example):
`and. (ii) cover an opening defined by an industry standard
`electrical junction box having nominal sizes from three-
`inchcs to six-inches (see FIGS. 16 and 17 for example). Since
`can-type light fixtures and ceilingfwall mottntjttnction boxes
`are designed for placement behind a ceiling or wall material.
`an example luminaire has the back surface of the heat
`spreader 105 substantially Planar with the back surface o fthc
`heat sink 110. thereby permitting the luminaire 100 to sit
`substantially flush on the surface ofthe ceilingfwall material.
`Alternatively. small standoifs 200 (see FIG. 12 for example]
`may be used to promote air movement around the luminaire
`100 for improved heat transfer to ambient. which will be
`discussed further below. Secnrement ol'the ltuuinaire 100 to
`
`a junction box may be accomplished by using suitable fas-
`teners through appropriately spaced holes 150 (see FIG. 8 for
`example). and securement of the luminaire 100 to a can—type
`fixture may be accomplished by using extension springs 205
`fastened at one end to the heat spreader 105 [see FIG. 12 for
`example) and then hooked at the other end onto an interior
`detail of the can-type fixture.
`In an cmbodi ment. the light source 120 includes a plurality
`oflight emitting diodes (LEDs) (also herein referred to as an
`LED chip package), which is represented by the “checkered
`box" in FIGS. 5. 6 and 8-10. I11 application. the LED chip
`package generates heat at the junction of each LIED die. To
`dissipate this heat. the LED chjp package is disposed in
`suitable thennal conununication with the heat spreader 105.
`which in an embodiment is made using aluminum. and the
`heat spreader is disposed in suitable thermal conununication
`with the heat sink 110. which in an embodiment is also made
`
`using aluminum. To provide for suitable heat transfer from
`the heat spreader 105 to the heat sink 110, an embodiment
`employs a plurality of interconnecting threads 130. 135.
`which when tightened provide suitable surface area for heat
`transfer thereacross.
`Embodiments of luminaire 100 may be powered by DC
`voltage. while other embodiments may be powered by AC
`voltage. I11 a DC—powered embodiment. the electrical supply
`lines 125, which receive DC voltage from a DC supply, are
`directly connected to the plurality of l..I-3Ds 120. I-Ioles 210
`[see FIG. 9 for example] in the heat spreader I05 permit
`passage of the supply lines 125 from the back side of the heat
`spreader 105 to the front side. In an AC—powered embodi-
`ment. a suitable power conditioner 140, 160. 165 (see FIGS.
`8. 9 and 11 for example) is used.
`In an embodiment. and with reference to FIG. 8, power
`conditioner 140 is disposed on the heat spreader 105 on a
`same side of tI1e heat spreader as the plurality ofLEDs 120. In
`an embodiment. the power conditioner 140 is an electronic
`circuit board having electronic components configured to
`receive AC voltage from the electrical supply line 125 and to
`deliver DC voltage to the plurality of LEDs through appro-
`priate electrical connections o11 either the front side or the
`back side ofthe heat spreader 105, with holes through the heat
`
`

`
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`5
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`US 8,201,968 B2
`
`6
`
`spreader or insulated electrical traces across the surface ofthe
`heat spreader being used as appropriate for the purposes.
`In an alternative embodiment. and with reference to FIG. 9.
`an arc-shaped electronic-circuit-board-mounted power con-
`ditioner 160 may be used in place of the localized power
`conditioner 140 illustrated in FIG. 8. thereby utilizing a larger
`available area of the heat spreader 105 without detracting
`from the lighting efficiency of luminaire 100.
`In a further embodiment. and with reference to FIG. 1 1. a
`block-type power conditioner 165 (electronics contained
`within a housing) may be used on the back surface of the heat
`spreader 105. where the block-type power conditioner 165 is
`configured and sized to fit within the interior space of an
`industry—standard nominally sized can—Iype light fixture or an
`industry—standard nominally sized walltceiling junction box.
`Electrical connections between the power conditioner 165
`and tire LEDs 120 are made via wires 170. which may be
`contained within the can fixture or junction box. or may be
`self‘-contained within the power conditioner housing. Electri-
`cal wires 175 receive AC voltage via electrical connections
`within the can fixture or junction box.
`Referring now to FIGS. 8-10 and 12. an embodiment
`includes a reflector 145 disposed on the heat spreader 105 so
`as to cover the power conditioner 140, 160, while permitting
`the plurality of LEDs 120 to be visible {i.e.. uncovered]
`through an aperture 215 of the reflector 145. Mounting holes
`155 in the reflector I45 align with mounting holes 150 in the
`heat spreader 105 for the purpose discussed above. The
`reflector 145 provides a reflective covering. that hides power
`conditioner 140. 160 from view when viewed from the outer
`optic side of luminaire 100. while efficiently reflecting light
`from the LEDs 120 toward the outer optic 115. FIG. 12
`illustrates a section view through luminaire I00. showing a
`stepped conliguratiott of the reflector I45. with the power
`conditioner 140. 160 hidden inside a pocket (i.e.. between the
`reflector 145 and the heat spreader 105). and with the LEDs
`120 visible through the aperture 215. In an embodiment. the
`outer optic is made using a glass-bead-impregnated-plastic
`material. In an embodiment the outer optic 115 is made of a
`suitable material to mask the presence of a pixilated light
`source 120 disposed at
`the center of the luminaire. In an
`embodiment. the halfangle power ofthe luminaire. where the
`light intensity of the light source when viewed at the outer
`optic drops to 50% ofits maximum intensity. is evident within
`a central diameter of the outer optic that is equal to or greater
`than 50% of the outer diameter of the outer optic.
`While FIG. I0 includes a reflector I45, it will be appreci-
`ated that not all embodiments of the invention disclosed
`herein may employ a reflector I45. and that when a reflector
`145 is employed it may be used for certain optical preferences
`or to mask the electronics ofthe power conditioner I40. 160.
`"the reflective surface of the reflector 145 may be white,
`reflective polished metal. or metal
`film over plastic. for
`example. and Inay have surface detail for certain optical
`effects, such as color mixing or controlling light distribution
`andtor focusing for example.
`Referring to FIG. 12. an embodiment includes an inner
`optic 180 disposed over the plurality of LEDs 120. Employ-
`ing an inner optic 180 not only provides protection to the
`Ll-jl)s 120 during installation of the luminairc 100 to a can
`fixture or junction box, but also offers another means of
`color-mixing andfor difliising andfor color-temperature-ad-
`justing the light output frorn the LEDs 120. In alternative
`embodiments. the inner optic 180 may be a standalone ele-
`ment. or integrally formed with the reflector 145.
`111 an
`cmbodirlient. the LI il)s 120 are encapsulated in a phosphor of
`a type suitable to produce a color temperature output of 2700
`
`Ill
`
`3o
`
`35
`
`4t":
`
`45
`
`50
`
`55
`
`60
`
`deg-Kelvin. Other LEDs with or without phosphor er1capsu-
`lation may be used to produce other color temperatures as
`desired.
`
`Referring to FIG. 13. a back surface 185 of the heat sink
`110 includes a first plurality ofrecesses 190 oriented in a first
`direction. and a second plurality of recesses 195 oriented in a
`second opposing direction. each recess of the first plurality
`and the second plurality having a shape that promotes local-
`ized air movement within the respective recess due at least in
`part to localized air temperature gradients and resulting local-
`ized air pressure gtadients. Without being held to any particu-
`lar theory.
`it
`is contemplated that a teardrop-shaped recess
`190, 195 each having a narrow end and an opposing broad end
`will generate localized air temperatures hi the narrow end that
`are higher than localized air temperatures in the associated
`broad end. due to the difference of proximity of the surround-
`it1g “heated" walls of the associated recess. It is contemplated
`that the presence of such air temperature gradients. with
`resulting air pressure gradients. within a given recess 190.
`195 will cause localized air rnovcrnent within the associated
`recess. which in turn will enhance the overall heat transfer of
`the thermal system (the thermal system being the luminaire
`100 as a whole). By altemating the orientation of the recesses
`190, 195. such that the first plurality of recesses 190 and the
`second plurality ofrecesses 195 are disposed in an alternating
`fashion around the circumference ofthe back 185 of the heat
`
`sink 110. it is contemplated that further enhancements in heat
`transfer will be achieved. either by the packing density of
`recesses achievable by nesting one recess 190 adjacent the
`other 195. or by alternating the direction vectors of the local-
`ized air temperatttrefpressure gradients to enhance overall air
`movement. In an embodiment. the first plurality of recesses
`190 have a first depth into the back surface of the heat sink.
`and the second plurality of recesses 195 have a second depth
`into the back surface of the heat sink, the first depth being
`different from the second depth. which is contemplated to
`further enhance heat‘ transfer.
`FIGS. 14-18 illustrate typical industry standard can-type
`light fixtures for recessed lighting (FIGS. 14-15). and typical
`industry standard electrical junction boxes for ceiling or wall
`mounted lighting (FIGS. 16-18}. limbodinients ofthe inven-
`tion are configured and sized for use with such fixtures of
`FIGS. 14-18.
`
`FIGS. I9-21 illustrate an alternative luminaire 100‘ having
`a different form factor (flat
`top.
`flat outer optic. smaller
`appearance} as compared to luminaire 100 of FIGS. 1-4.
`FIGS. 22-23 illustrate alternative electronic power condi-
`tioners l40'. 165' having a di lferent form factor as compared
`to power conditioners 140. 165 of FIGS. 8 and 11. respec-
`tively. All alternative embodiments disclosed herein. either
`explicitly. implicitly or equivalently. are considered within
`the scope of the invention.
`FIGS. 24-26 illustrate an alternative reflector 145' to that
`
`illustrated in FIGS. 10 and 12. with FIG. 24 depicting an
`isometric view. FIG. 25 depicting a top view. and FIG. 26
`depicting a side view of alternative reflector 145'. As illus-
`trated. reflector 145' is couically—shaped with a centrally dis-
`posed aperture 2l5' for receiving the LED package 120. The
`cone of reflector 145' has a shallow form factor so as to fit in
`
`the low profile lttminaire 100. 100'. Similar to reflector 145.
`the refiective surface of the reflector 145' may be white.
`reflective polished metal. or metal
`lilm over plastic.
`for
`example, and may have surface detail for certain optical
`effects. such as color mixing or controlling light distribution
`andfor focusing fbr example. As discussed herein with respect
`to reflector 145. alternative reflector 145' may or may not be
`employed as required to obtain the desired optical effects.
`
`

`
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`7
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`8
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`US 8,201,968 B2
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`From the foregoing. it will be appreciated that ei11bodi-
`ments of the invention also include a luminaire 100 with a
`
`housing (collectively referred to by reference numerals 105.
`110 and 115) having a light unit (collectively referred to by
`reference numerals 105 and 115) and a trim unit I 10. the light
`unit incltlding a light source 120. tI1e trim unit being mechani-
`cally separable from the light unit. a means for mechanically
`separating 130. 135 the trim unit from the light unit providing
`a thermal conduction path therebetween. the light tinit having
`sufficient thermal mass to spread heat generated by the light
`source to the means for mechanically separating, the trim unit
`having sufficient thermal mass to serve as a heat sink to
`dissipate heat generated by the lifltl source.
`Front the foregoing, it will also be appreciated that embodi-
`ments of the invention further include a luminaire 100 for
`retrofit connection to an installed light fixture having a con-
`cealed in-use housing (see FIGS. 14-18 for example). the
`luminaire including a housing 105, 110, 115 having a light
`unit 105. 115 and a trim unit 110. the light unit comprising a
`light source 120. the trim unit being mechartically separable
`from the light unit_. the trim unit defining a heat sinking
`thermal management element configured to dissipate heat
`generated by the light source that is completely 100% exter-
`nal of the concealed in-use housing of the installed light
`fixture. As used herein, the term “concealed in-use housing"
`refers to a housing that is hidden behind a ceiling or a wall
`panel once the luminaire ol‘ the invention has been installed
`thereon.
`
`Reierence is now made to FIG. 27. which depicts an
`exploded assembly view of an alternative luminaire 300 to
`dial depicted in 1"‘l(iS. 1-12. Similar to luminaire 100 (where
`like elements are numbered alike. and similar elements are
`named alike but numbered differently).
`luminaire 300
`includes a heat spreader 305 integrally formed with :1 heat
`sink 310 disposed diametrically outboard ofthe heat spreader
`305 (the heat spreader 305 and heat sink 310 are collectively
`herein referred to as base 302). an outer optic 3l5 securely
`retained relative to at least one of the heat spreader 305 and
`the heat sink 310. a light source (LIED) 120 disposed in
`thermal communication with the heat spreader 305. and an
`electrical supply line 125 disposed in electrical communica-
`tion with the light source 120. The integrally formed heat
`spreader 305 and heat sink 310 provides for improved heat
`flow from the LED 120 to the heat sink 310 as the heat flow
`path therebetween is continuous and uninterrupted as com-
`pared to the luminaire 100 discussed above.
`To provide tiara low profile luminaire 300, the combination
`oi’ the heat spreader 305. heat sink 310 and outer optic 315.
`have an overall height H and an overall outside dimension D
`such that the ratio of HID is equal to or less than 0.25 (best
`seen by reference to FIG. 28). In an example embodiment.
`height [-1 is 1.5-incltes. and outside dimension 1) is a diameter
`of 7-inches. Other dimensions for H £u1(I I) are contemplated
`such that the combination of the heat spreader 305. heat sink
`310 and outer optic 315. are so configured and dimensioned
`as to: (i) cover an opening defined by an industry standard
`can-type light fixture having nominal sizes front three-inches
`to six-inches {see FIGS. 14 and 15 for example]: and. (ii)
`cover an opening defined by an industry standard electrical
`jttnction box having nominal sizes ii-om three-inches to six-
`inches (see FIGS. 16 and 17 for example). Since can-type
`light
`fixtures and ceiling/wall mount junction boxes are
`desig