Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 1 of 27 PageID 234
`
`
`
`Exhibit B
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 2 of 27 PageID 235
`
`US008672518B2
`
`(12) United States Patent
`Boomgaarden et a].
`
`(10) Patent N0.:
`(45) Date of Patent:
`
`US 8,672,518 B2
`Mar. 18, 2014
`
`(54)
`
`(75)
`
`LOW PROFILE LIGHT AND ACCESSORY KIT
`FOR THE SAME
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`Inventors: Mark Penley Boomgaarden, Satellite
`Beach, FL (US); Michael Balestracci,
`Satellite Beach, FL (US); Rick LeClair,
`Melbourne, FL (US); Wei Sun,
`Indialantic, FL (US); David Henderson,
`Indialantic, FL (US); Shane Sullivan,
`Indialantic, FL (US)
`
`6,431,728 B1* 8/2002 Fredericks et al. ......... .. 362/244
`6,719,446 B2* 4/2004 Cao .................. ..
`362/547
`2008/0037255 A1* 2/2008 Wang .......................... .. 362/294
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`(73)
`
`Assignee: Lighting Science Group Corporation,
`Satellite Beach, FL (US)
`
`EP
`WO
`
`1950491 A1
`2008137732 A1
`
`7/2008
`11/2008
`
`OTHER PUBLICATIONS
`
`Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 44 days.
`
`Appl. N0.: 13/476,388
`
`Filed:
`
`May 21, 2012
`
`Prior Publication Data
`
`US 2012/0262921 A1
`
`Oct. 18,2012
`
`Related US. Application Data
`Continuation-in-part of application No. 12/775,310,
`?led on May 6, 2010, noW Pat. No. 8,201,968.
`
`Provisional application No. 61/248,665, ?led on Oct.
`5, 2009.
`
`Int. Cl.
`F21 V29/00
`US. Cl.
`USPC ......... .. 362/294; 362/147; 362/148; 362/365;
`362/235; 362/249.02
`
`(2006.01)
`
`Field of Classi?cation Search
`USPC ........ .. 362/147, 148, 150, 404, 294, 373, 365
`See application ?le for complete search history.
`
`(21)
`
`(22)
`
`(65)
`
`(63)
`
`(60)
`
`(51)
`
`(52)
`
`(58)
`
`EP International Search Report for Application No. 101744498;
`Mail Date: Dec. 14, 2010; 8 pgs.
`(Continued)
`
`Primary Examiner * Ali Alavi
`(74) Attorney, Agent, or Firm * Cantor Colburn LLP
`
`ABSTRACT
`(57)
`A luminaire includes a heat spreader; a heat sink; an LED
`light source; a poWer supply; an electrical supply line having
`a ?rst end connected to the poWer supply, and a second end
`connected to a plug-in connector; and, an optic securely
`retained relative to the heat spreader or heat sink. An acces
`sory kit includes a ?rst pre-Wired jumper including a pair of
`insulated electrical Wires having a ?rst plug-in connector
`electrically connected at one end and an Edison base electri
`cally connected at the other end; and/or, a second pre-Wired
`jumper including a pair of insulated electrical Wires having a
`second plug-in connector electrically connected at one end
`and unconnected Wire ends at the other end. The plug-in
`connector of the ?rst pre-Wired jumper and the second pre
`Wired jumper are each con?gured to electrically engage With
`the plug-in connector of the electrical supply line.
`
`15 Claims, 17 Drawing Sheets
`
`145
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 3 of 27 PageID 236
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`US 8,672,518 B2
`Page 2
`
`(56)
`
`References Cited
`
`OTHER PUBLICATIONS
`
`US. PATENT DOCUMENTS
`_
`7/2008 Kim
`9/2008 Kim
`4/2009 Chou
`6/2009 Lan et al.
`
`2008/0170398 A1
`2008/0232116 A1
`2009/0086474 A1
`2009/0141506 A1
`
`European Of?ce Action for Application No. 10 174 449.8. Mailed on
`Apr. 8, 2013. 4 pages.
`
`* cited by examiner
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 4 of 27 PageID 237
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`US. Patent
`
`Mar. 18, 2014
`
`Sheet 1 0f 17
`
`US 8,672,518 B2
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 5 of 27 PageID 238
`
`US. Patent
`
`Mar. 18, 2014
`
`Sheet 2 0f 17
`
`US 8,672,518 B2
`
`FIG. 3
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 6 of 27 PageID 239
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`US. Patent
`
`Mar. 18, 2014
`
`Sheet 3 0f 17
`
`US 8,672,518 B2
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 7 of 27 PageID 240
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`US. Patent
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`Mar. 18, 2014
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`Sheet 4 0f 17
`
`US 8,672,518 B2
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`I
`
`140
`
`150
`
`Q”
`
`105
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 8 of 27 PageID 241
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`US. Patent
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`Mar. 18, 2014
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`Sheet 5 0f 17
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`US 8,672,518 B2
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`FIG. 10
`
`FIG. 11
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 9 of 27 PageID 242
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`US. Patent
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`Mar. 18, 2014
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`Sheet 6 0f 17
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`US 8,672,518 B2
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`100’\
`
`205
`
`200
`
`105
`
`A \
`
`215
`
`+
`
`x
`
`14O’16O 200
`
`)3“ A
`
`110
`
`M H
`
`135
`
`145
`
`180 120
`
`115
`
`FIG. 12
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 10 of 27 PageID 243
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`US. Patent
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`Mar. 18, 2014
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`Sheet 7 0f 17
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`US 8,672,518 B2
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`@N UN“ w~ .UNE
`
`@@
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 11 of 27 PageID 244
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`US. Patent
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`Mar. 18, 2014
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`Sheet 8 0f 17
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`US 8,672,518 B2
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`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 12 of 27 PageID 245
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`US. Patent
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`Mar. 18, 2014
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`Sheet 9 0f 17
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`US 8,672,518 B2
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`140'
`
`105
`
`FIG. 22
`
`FIG. 23
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 13 of 27 PageID 246
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`US. Patent
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`Mar. 18, 2014
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`Sheet 10 0f 17
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`US 8,672,518 B2
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`FIG. 24
`
`145'
`
`FIG. 25
`
`FIG. 26
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 14 of 27 PageID 247
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`US. Patent
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`Mar. 18, 2014
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`Sheet 11 0117
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`US 8,672,518 B2
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`RN 65*
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 15 of 27 PageID 248
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`US. Patent
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`Mar. 18, 2014
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`Sheet 12 0f 17
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`N
`
`FIG. 28
`
`I’. W
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`\l/ “Ly/1
`I”
`
`FIG. 29
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 16 of 27 PageID 249
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`Mar. 18, 2014
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`Sheet 13 0f 17
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`US 8,672,518 B2
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`QM ENE
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 17 of 27 PageID 250
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`Mar. 18, 2014
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`Sheet 14 0117
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`US 8,672,518 B2
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`FIG. 31
`
`505 \
`
`560
`
`550
`
`551
`
`555
`
`FIG. 32
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 18 of 27 PageID 251
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`US. Patent
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`Mar. 18, 2014
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`Sheet 15 0117
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`US 8,672,518 B2
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`
`
`J [A L /l N
`
`
`
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`
`FIG. 34
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 19 of 27 PageID 252
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`Mar. 18, 2014
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`Sheet 16 0f 17
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`US 8,672,518 B2
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`470
`
`FIG. 35
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 20 of 27 PageID 253
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`Sheet 17 0f 17
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`US 8,672,518 B2
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`
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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 21 of 27 PageID 254
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`US 8,672,518 B2
`
`1
`LOW PROFILE LIGHT AND ACCESSORY KIT
`FOR THE SAME
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`This application is a continuation-in-part of US. applica
`tion Ser. No. 12/775,310, ?led May 6, 2010, Which claims the
`bene?t ofU.S. Provisional Application Ser. No. 61/248,665,
`?led Oct. 5, 2009, both of Which are incorporated herein by
`reference in their entirety.
`
`BACKGROUND OF THE INVENTION
`
`The present disclosure relates generally to lighting, par
`ticularly to loW pro?le lighting, and more particularly to loW
`pro?le doWnlighting for retro?t applications.
`Light ?xtures come in many shapes and siZes, With some
`being con?gured for neW Work installations While others are
`con?gured 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
`?xture/enclosure or junction box existing behind a ceiling or
`Wall panel material. With recessed ceiling lighting, sheet
`metal can-type light ?xtures are typically used, While surface
`mounted ceiling and Wall lighting typically use metal or plas
`tic junction boxes of a variety of siZes and depths. With the
`advent of LED (light emitting diode) lighting, there is a great
`need to not only provide neW Work LED light ?xtures, but to
`also provide LED light ?xtures that are suitable for old Work
`applications, thereby enabling retro?t installations. One Way
`of providing old Work LED lighting is to con?gure an LED
`luminaire in such a manner as to utiliZe the volume of space
`available Within an existing ?xture (can-type ?xture or junc
`tion box). HoWever, such con?gurations typically result in
`unique designs for each type and siZe of ?xture. Accordingly,
`there is a need in the art for an LED lighting apparatus that
`overcomes these drawbacks.
`This background information is provided to reveal infor
`mation believed by the applicant to be of possible relevance to
`the present invention. No admission is necessarily intended,
`nor should be construed, that any of the preceding informa
`tion constitutes prior art against the present invention.
`
`20
`
`25
`
`30
`
`35
`
`40
`
`BRIEF DESCRIPTION OF THE INVENTION
`
`45
`
`2
`source having a plurality of light emitting diodes (LEDs). A
`poWer conditioner is disposed in electrical communication
`With the light source, the poWer conditioner being con?gured
`to receive AC voltage from an electrical supply line and to
`deliver DC voltage to the plurality of LEDs, the poWer con
`ditioner being so dimensioned as to ?t Within at least one of:
`a nominally siZed four-inch can light ?xture; and, a nominally
`siZed four-inch electrical junction box.
`An embodiment of the invention includes a luminaire hav
`ing a heat spreader, 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, a light source disposed in thermal
`communication 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 H/D is equal to or less than
`0.25. The de?ned combination is so dimensioned as to: cover
`an opening de?ned by a nominally siZed four-inch can light
`?xture; and, cover an opening de?ned by a nominally siZed
`four-inch electrical junction box.
`An embodiment of the 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 for mechanically sepa
`rating the trim unit from the light unit provides a thermal
`conduction path therebetWeen. The light unit has suf?cient
`thermal mass to spread heat generated by the light source to
`the means for mechanically separating, and the trim unit has
`suf?cient 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
`retro?t connection to an installed light ?xture 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 from
`the light unit. The trim unit de?nes a heat sinking thermal
`management element, con?gured to dissipate heat generated
`by the light source, that is completely 100% external of the
`concealed in-use housing of the installed light ?xture.
`An embodiment of the invention includes a luminaire and
`accessory kit combination. The luminaire includes a heat
`spreader; a heat sink; an LED light source; a poWer supply; an
`electrical supply line having a ?rst end connected to the poWer
`supply, and a second end connected to a plug-in connector;
`and, an optic securely retained relative to the heat spreader or
`heat sink. The accessory kit includes a ?rst pre-Wired jumper
`including a pair of insulated electrical Wires having a ?rst
`plug-in connector electrically connected at one end and an
`Edison base electrically connected at the other end; and/or, a
`second pre-Wired jumper including a pair of insulated elec
`trical Wires having a second plug-in connector electrically
`connected at one end and unconnected Wire ends at the other
`end. The plug-in connector of the ?rst pre-Wired jumper and
`the second pre-Wired jumper are each con?gured to electri
`cally engage With the plug-in connector of the electrical sup
`ply line.
`
`50
`
`55
`
`An embodiment of the 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 (LEDs). The
`heat spreader, the heat sink and the outer optic, in combina
`tion, have an overall height H and an overall outside dimen
`sion D such that the ratio of H/D is equal to or less than 0.25.
`The combination de?ned by the heat spreader, the heat sink
`and the outer optic, is so dimensioned as to: cover an opening
`de?ned by a nominally siZed four-inch can light ?xture; and,
`cover an opening de?ned 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 thermally 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
`
`60
`
`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 luminaire in
`accordance With an embodiment of the invention;
`FIG. 2 depicts a top vieW of the luminaire of FIG. 1;
`
`65
`
`

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`
`3
`FIG. 3 depicts a bottom View of the luminaire of FIG. 1;
`FIG. 4 depicts a side View of the luminaire of FIG. 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 of the heat sink of
`FIG. 5;
`FIG. 8 depicts a top View of an alternatiVe heat spreader
`assembly in accordance with an embodiment ofthe inVention;
`FIG. 9 depicts a top View of another altematiVe heat
`spreader assembly in accordance with an embodiment of the
`inVention;
`FIG. 10 depicts a top View of yet another alternatiVe heat
`spreader assembly in accordance with an embodiment of the
`inVention;
`FIG. 11 depicts a bottom View of a heat spreader haVing a
`power conditioner in accordance with an embodiment of the
`inVention;
`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 of existing electrical
`can-type light fixtures and electrical junction boxes for use in
`accordance with an embodiment of the inVention;
`FIGS. 19-21 depict a side View, top View and bottom View,
`respectiVely, of a 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 in isometric, top and side Views, respec-
`tiVely, an altematiVe reflector to that depicted in FIGS. 10 and
`12;
`FIG. 27 depicts an exploded assembly View of an alterna-
`tiVe luminaire in accordance with an embodiment of the
`inVention;
`FIG. 28 depicts a side View of the luminaire of FIG. 27;
`FIG. 29 depicts a back View of the luminaire of FIG. 27;
`FIG. 30 depicts a cross section View of the luminaire of
`FIG. 27, and more particularly depicts a cross section View of
`the outer optic used in accordance with an embodiment of the
`inVention;
`FIG. 31 depicts an accessory kit in accordance with an
`embodiment of the inVention;
`FIG. 32 depicts a formed spring included in the accessory
`kit of FIG. 31;
`FIG. 33 depicts a top-down View of a luminaire similar to
`that depicted in FIG. 27, and illustratiVe of an assembly of a
`formed spring of FIG. 32 onto the luminaire;
`FIG. 34 depicts a side View of the luminaire of FIG. 33;
`FIG. 35 depicts an exploded assembly View of the lumi-
`naire of FIGS. 33 and 34;
`FIGS. 36A and 36B are side View depictions of a first
`position (not engaged) and a second position (engaged),
`respectiVely, of an engagement tab of an optic snap-fitting
`into an engagement opening of a base, where both the optic
`and the base are part of the luminaire of FIG. 35; and
`FIGS. 37A and 37B are plan View depictions of an alter-
`natiVe arrangement to that depicted in FIGS. 36A and 36B,
`respectiVely, and more specifically are depictions of a first
`position (not engaged) and a second position (engaged),
`respectiVely, of an engagement tab of an optic rotationally-
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`4
`
`fitting into an engagement opening of a base, where both the
`optic and the base are part of the luminaire of FIG. 35.
`
`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 luminaire,
`haVing an LED light source disposed on a heat spreader,
`which in mm is thermally coupled to a heat sink that also
`serVes as the trim plate of the luminaire. The luminaire 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. Retrofit installation of the
`
`luminaire is accomplished utilizing an accessory kit that
`includes a pre-wired electrical jumper and mounting hard-
`ware. For installations inVolVing a can-type fixture, the pre-
`wired jumper includes a plug-in connector electrically con-
`nected to an Edison base Via flexible insulated wires For
`
`installations inVolVing a J-box, the pre-wiredjumper includes
`a plug-in connector electrically connected to flexible insu-
`lated wires that may or may not be pre-stripped, or partially
`pre-stripped, on the opposing end.
`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 105, a heat sink 110 thermally
`coupled to and disposed diametrically outboard of the heat
`spreader, an outer optic 115 securely retained relatiVe to at
`least one ofthe heat spreader 105 and the heat sink 110, a light
`source 120 disposed in thermal communication with the heat
`spreader 105, and an electrical supply line 125 disposed in
`electrical communication 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 of H/D is equal to or less than 0.25. In an example
`embodiment, height H is 1 .5-inches, and outside dimension D
`is a diameter of 7-inches. Other dimensions for H and D are
`
`contemplated such that the combination of the heat spreader
`105, 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, such as a four-inch can or a six-
`inch can for example (see FIGS. 14 and 15 for example); and,
`(ii) coVer an opening defined by an industry standard electri-
`cal junction box haVing nominal sizes from three-inches to
`six-inches, such as a four-inch J-box or a six-inch J-box for
`
`

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`US 8,672,518 B2
`
`5
`example (see FIGS. 16 and 17 for example). Since can-type
`light fixtures and ceiling/wall mount junction 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 ofthe heat sink
`110, thereby permitting the luminaire 100 to sit substantially
`flush on the surface ofthe ceiling/wall material. Alternatively,
`small standoffs 200 (see FIG. 12 for example) may be used to
`promote air movement around the luminaire 100 for
`improved heat transfer to ambient air, which will be discussed
`further below. Securement of the luminaire 100 to a junction
`box may be accomplished by using suitable fasteners 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 embodiment, the light source 120 includes a plurality
`of light 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. In application, the LED chip
`package generates heat at the junction of each LED die. To
`dissipate this heat, the LED chip package is disposed in
`suitable thermal communication with the heat spreader 105,
`which in an embodiment is made using aluminum, and the
`heat spreader is disposed in suitable thermal communication
`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. In a DC-powered embodiment, the electrical supply
`lines 125, which receive DC voltage from a DC supply, are
`directly connected to the plurality of LEDs 120. Holes 210
`(see FIG. 9 for example) in the heat spreader 105 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 ofthe heat spreader as the plurality of LEDs 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 on either the front side or the
`back side ofthe heat spreader 105, with holes through the heat
`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. 11, 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-type light fixture or an
`industry-standard nominally sized wall/ceiling junction box.
`
`6
`Electrical connections between the power conditioner 165
`and the 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 145 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 100, showing a
`stepped configuration of the reflector 145, 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. 10 includes a reflector 145, it will be appreci-
`ated that not all embodiments of the invention disclosed
`
`herein may employ a reflector 145, and that when a reflector
`145 is employed it may be used for certain optical preferences
`or to mask the electronics of the power conditioner 140, 160.
`The reflective surface of the reflector 145 may be white,
`reflective polished metal, or metal film over plastic, for
`example, and may have surface detail for certain optical
`effects, such as color mixing or controlling light distribution
`and/or 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
`LEDs 120 during installation of the luminaire 100 to a can
`fixture or junction box, but also offers another means of
`color-mixing and/or diffusing and/or color-temperature-ad-
`justing the light output from the LEDs 120. In alternative
`embodiments, the inner optic 180 may be a standalone ele-
`ment, or integrally formed with the reflector 145. In an
`embodiment, the LEDs 120 are encapsulated in a phosphor of
`a type suitable to produce a color temperature output of 2700
`deg-Kelvin. Other LEDs with or without phosphor encapsu-
`lation may be used to produce other color temperatures as
`desired.
`
`Referring to FIG. 13, a back surface 185 of an embodiment
`of the heat sink 110 includes a first plurality of recesses 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 localized air movement within the respective recess
`due at least in part to localized air temperature gradients and
`resulting localized air pressure gradients. Without being held
`to any particular 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
`in the narrow end that are higher than localized air tempera-
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
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`55
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`60
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`65
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`

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`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 24 of 27 PageID 257
`Case 6:16-cv-00680-RBD-GJK Document 13-2 Filed 06/20/16 Page 24 of 27 Page|D 257
`
`US 8,672,518 B2
`
`7
`tures in the associated broad end, due to the difference of
`proximity ofthe surrounding “heated” walls ofthe associated
`recess. It is contemplated that the presence of such air tem-
`perature gradients, with resulting air pressure gradients,
`within a given recess 190, 195 will cause localized air move-
`ment 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 alternating
`the orientation of the recesses 190, 195, such that the first
`plurality of recesses 190 and the second plurality of recesses
`195 are disposed in an alternating fashion around the circum-
`ference ofthe back 185 ofthe heat sink 110, it is contemplated
`that further enhancements in heat transfer will be achieved,
`either by the packing density of recesses achievable by nest-
`ing one recess 190 adjacent the other 195, or by alternating the
`direction vectors of the localized air temperature/pressure
`gradients to enhance overall air movement. In an embodi-
`ment, 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). Embodiments of the inven-
`tion are configured and sized for use with such fixtures of
`FIGS. 14-18.
`
`FIGS. 19-21 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 140', 165' having a different 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 conically-shaped with a centrally dis-
`posed aperture 215' for receiving the LED package 120. The
`cone of reflector 145' has a shallow form factor so as to fit in
`
`the low profile luminaire 100, 100'. Similar to reflector 145,
`the reflective surface of the reflector 145' may be white,
`reflective polished metal, or metal film over plastic, for
`example, and may have surface detail for certain optical
`effects, such as color mixing or controlling light distribution
`and/or focusing for 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.
`From the foregoing, it will be appreciated that embodi-
`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 110, the light
`unit including a light source