Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 1 of 28 PageID 261
`
`
`
`Exhibit C
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 2 of 28 PageID 262
`
`US008967844B2
`
`(12) United States Patent
`Boomgaarden et a1.
`
`(10) Patent N0.:
`(45) Date of Patent:
`
`US 8,967,844 B2
`*Mar. 3, 2015
`
`(54)
`
`(71)
`
`(72)
`
`(73)
`
`(21)
`(22)
`(65)
`
`(63)
`
`(60)
`
`(51)
`
`(52)
`
`Inventors:
`
`LOW PROFILE LIGHT AND ACCESSORY KIT
`FOR THE SAME
`Applicant: Lightning Science Group Corporation,
`Satellite Beach, FL (US)
`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)
`Lighting Science Group Corporation,
`Satellite Beach, FL (US)
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`This patent is subject to a terminal dis
`claimer.
`Appl. N0.: 14/134,ss4
`Filed:
`Dec. 19, 2013
`Prior Publication Data
`
`Assignee:
`
`Notice:
`
`Apr. 17, 2014
`US 2014/0104847 A1
`Related US. Application Data
`
`Continuation of application No. 13/476,388, ?led on
`May 21, 2012, noW Pat. No. 8,672,518, Which is a
`continuation-in-part of application No. 12/775,310,
`?led on May 6, 2010, noW Pat. No. 8,672,518.
`
`Provisional application No. 61/248,665, ?led on Oct.
`5, 2009.
`Int. Cl.
`F21 V29/00
`F21 V23/00
`
`(2006.01)
`(2006.01)
`(Continued)
`
`US. Cl.
`CPC . F21K 9/10 (2013.01); F21V21/04 (2013.01);
`F21V29/004 (2013.01); F21V23/00
`(2013.01);
`
`(Continued)
`
`300 \
`
`(58) Field of Classi?cation Search
`USPC ............... .. 362/362, 364, 365, 368, 373, 294,
`362/249.01, 249.02
`See application ?le for complete search history.
`References Cited
`
`(56)
`
`U.S. PATENT DOCUMENTS
`
`6,168,299 B1
`6,431,728 B1
`
`1/2001 Yan
`8/2002 Fredericks et a1.
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`EP
`WO
`
`1950491 A1
`2008137732 A1
`
`7/2008
`11/2008
`
`OTHER PUBLICATIONS
`
`EP International Search Report for Application No. 101744498;
`Dated Dec. 14, 2010.
`
`(Continued)
`
`Primary Examiner * Ali Alavi
`(74) Attorney, Agent, or Firm * Cantor Colburn LLP
`(57)
`ABSTRACT
`A luminaire includes a heat spreader, a heat sink, a light
`source and an outer optic. The heat sink is substantially ring
`shaped and is disposed around and in thermal communication
`With an outer periphery of the heat spreader. The light source
`is disposed in thermal communication With the heat spreader,
`the light source having a plurality of light emitting diodes
`(LEDs) that are disposed in thermal communication With the
`heat spreader. The outer optic is disposed in optical commu
`nication With the plurality of LEDs. The heat spreader, the
`heat sink and the outer optic, in combination, have an overall
`height H and an overall outside dimension D such that the
`ratio of H/D 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.
`
`24 Claims, 17 DraWing Sheets
`
`450
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 3 of 28 PageID 263
`
`US 8,967,844 B2
`Page 2
`
`(2010.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`
`(51) 1111.0.
`F21K 99/00
`F21S 8/02
`F21S 8/04
`F21 V21/04
`F21Y101/02
`F21 V21/02
`(52) vs. C].
`CPC ....... .. F21Y2101/02 (2013.01); F21V29/2212
`(2013.01); F21V29/22 (2013.01); F21S 8/026
`(2013.01); F2] VZI/OZ (2013.01); F21S 8/04
`(2013.01)
`USPC ......... .. 362/547; 362/294; 362/235; 362/147;
`362/ 148
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`4/2004 Cao
`6,719,446 B2
`7,125,146 B2 * 10/2006 Willis et al. ................. .. 362/267
`7,413,321 B2
`8/2008 Kim
`7,547,112 B2
`6/2009 Kim
`7,607,812 B2 10/2009 Kim
`7,670,021 B2* 3/2010 Chou .......................... .. 362/148
`7,722,220 B2
`5/2010 Van De Ven
`7,722,227 B2 *
`5/2010 Zhang et a1. ................ .. 362/364
`7,810,960 B1* 10/2010 Soderman etal
`. 362/294
`7,828,465 B2* 11/2010 Roberge et al. ............. .. 362/294
`7,950,832 B2
`5/2011 Tanakaet a1.
`7,959,332 B2
`6/2011 Tickner et a1.
`7,980,736 B2
`7/2011 Soderman et a1.
`7,993,034 B2
`8/2011 Wegner
`8,201,968 B2* 6/2012 Maxik et a1. ................ .. 362/235
`8,348,477 B2
`1/2013 Tickner et a1.
`8,672,518 B2* 3/2014 Boomgaarden et al. .... .. 362/294
`2008/0037255 A1
`2/2008 Wang
`2008/0165535 A1
`7/2008 Mazzochette
`2008/0170398 A1
`7/2008 Kim
`2008/0232093 A1
`9/2008 Kim
`2008/0232116 A1
`9/2008 Kim
`2008/0285271 A1 11/2008 Roberge et a1.
`2009/0086474 A1* 4/2009 Chou .......................... .. 362/230
`
`2009/0086504 A1
`2009/0129086 A1
`2009/0141506 A1
`
`4/2009 Kim
`5/2009 Thompson, III
`6/2009 Lan et al.
`
`OTHER PUBLICATIONS
`
`European Of?ce Action for Application No. 10 174 449.8. Mailed on
`Apr. 8, 2013. 4 pages.
`Cree, Inc., LR6 Six-Inch LED Downlight product literature, Rev.
`Dec. 19, 2012, 4 pages.
`EP International Search Report for Application No. 101744498
`dated Dec. 14,2010.
`EP Of?ce Action for Application No. 10 174 449.8 mailed on Apr. 8,
`2013, 4 pages.
`Matsushita Electric Works, Ltd., MFORCE High-Output, High
`Color Rendering LED Unit for Lighting product literature, Annual
`Report 2007, 2 pages.
`Lighting Research Center, Lighting Research Program Project 2.3
`Low-Pro?le LED Luminaries, PIER Final Project Report, prepared
`for the California Energy Commission, Apr. 2007, CEC-500-2005
`141-A4, pp. 1-66.
`Inteltech Corporation, Silescent 100i LV Light literature, Rev. May
`2008, 4 pages.
`Cree, Inc., Defendant, “Preliminary Invalidity Contentions”, ?led in
`the United States District Court for the Middle District of Florida
`Orlando Division, Case No. 6:13-cv-00587-RBD-GJK, on Dec. 20,
`2013; 122 pages.
`European Of?ce Action for Application No. 101744498; Dated Sep.
`12, 2014.
`Exhibit 44iLighting Research Center, Lighting Research Program
`Project 2.3 Low-Pro?le LED Luminaries, PIER Final Project Report,
`prepared for the California Energy Commission, Apr. 2007, pp. 1-66,
`CEC-500-2005-141-A4.
`Exhibit 46iInteltech Corporation, Silescent 100i LV Light litera
`ture, Rev. May 2008, 4 pages.
`Exhibit 484Cree, Inc., LR6 Six-Inch LED Downlight product lit
`erature, Rev. Dec. 19, 2012, 4 pages.
`Exhibit SliMatsushita Electric Works, Ltd., MFORCE High-Out
`put, High-Color Rendering LED Unit for Lighting product literature,
`Annual Report 2007, 2 pages.
`Exhibit D4Cree, Inc., Defendant, “Preliminary Invalidity Conten
`tions”, ?led in the United States District Court for the Middle District
`ofFlorida Orlando Division, Case No. 6: 13-cv-00587-RBD-GJK, on
`Dec. 20, 2013; 500 pages.
`
`* cited by examiner
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 4 of 28 PageID 264
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`US. Patent
`
`Mar. 3, 2015
`
`Sheet 1 0f 17
`
`US 8,967,844 B2
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 5 of 28 PageID 265
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`US. Patent
`
`Mar. 3, 2015
`
`Sheet 2 0f 17
`
`US 8,967,844 B2
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 6 of 28 PageID 266
`
`US. Patent
`
`Mar. 3, 2015
`
`Sheet 3 0f 17
`
`US 8,967,844 B2
`
`115
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 7 of 28 PageID 267
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`US. Patent
`
`Mar. 3, 2015
`
`Sheet 4 0f 17
`
`US 8,967,844 B2
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`

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`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 8 of 28 PageID 268
`
`US. Patent
`
`Mar. 3, 2015
`
`Sheet 5 0f17
`
`US 8,967,844 B2
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`145
`
`FIG. 10
`
`FIG. 11
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 9 of 28 PageID 269
`
`US. Patent
`
`Mar. 3, 2015
`
`Sheet 6 0f 17
`
`US 8,967,844 B2
`
`FIG. 13
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 10 of 28 PageID 270
`
`US. Patent
`
`h4ar.3,2015
`
`Sheet70f17
`
`US 8,967,844 B2
`
`

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`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 11 of 28 PageID 271
`
`US. Patent
`
`Mar. 3, 2015
`
`Sheet 8 0f 17
`
`US 8,967,844 B2
`
`FIG. 21
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 12 of 28 PageID 272
`
`US. Patent
`
`Mar. 3, 2015
`
`Sheet 9 0f 17
`
`US 8,967,844 B2
`
`140' A
`Q
`
`105
`
`FIG. 22
`
`FIG. 23
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 13 of 28 PageID 273
`Case 6:16—cv—OO680—RBD—GJK Document 13-3 Filed 06/20/16 Page 13 of 28 Page|D 273
`
`U.S. Patent
`
`Mar. 3, 2015
`
`Sheet 10 of 17
`
`US 8,967,844 B2
`
`145"\
`
`
`
`145'
`
`FIG. 25
`
`215'
`
`FIG. 26
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 14 of 28 PageID 274
`
`US. Patent
`
`h4ar.3,2015
`
`Sheet110f17
`
`US 8,967,844 B2
`
`omw
`
`RN @NE
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 15 of 28 PageID 275
`
`U.S. Patent
`
`Mar. 3, 2015
`
`Sheet 12 of 17
`
`US 8,967,844 B2
`
`L‘,
`
`FIG. 28
`
`=..._z
`
`47W
`m.»\’/
`
`II
`
`FIG. 29
`
`
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 16 of 28 PageID 276
`
`US. Patent
`
`Mar. 3, 2015
`
`Sheet 13 0f 17
`
`US 8,967,844 B2
`
`FIG. 30
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 17 of 28 PageID 277
`
`US. Patent
`
`Mar. 3, 2015
`
`Sheet 14 0f 17
`
`US 8,967,844 B2
`
`505
`\ 560
`
`FIG. 32
`
`J 555
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 18 of 28 PageID 278
`
`US. Patent
`
`Mar. 3, 2015
`
`Sheet 15 0f 17
`
`US 8,967,844 B2
`
`505 J K
`A
`
`505
`A W
`
`FIG. 34 V
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 19 of 28 PageID 279
`
`US. Patent
`
`Mar. 3, 2015
`
`Sheet 16 0f 17
`
`US 8,967,844 B2
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`128’“- 1——\125
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`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 20 of 28 PageID 280
`Case 6:16—cv—OO680—RBD—GJK Document 13-3 Filed 06/20/16 Page 20 of 28 Page|D 280
`
`U.S. Patent
`
`Mar. 3, 2015
`
`Sheet 17 of 17
`
`US 8,967,844 B2
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`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 21 of 28 PageID 281
`
`US 8,967,844 B2
`
`1
`LOW PROFILE LIGHT AND ACCESSORY KIT
`FOR THE SAME
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`This application is a continuation of US. application Ser.
`No. 13/476,388, ?led May 21, 2012, which is a continuation
`in-part of US. application Ser. No. 12/775,310, ?led May 6,
`2010, now US. Pat. No. 8,201,968, which claims the bene?t
`of US. Provisional Application Ser. No. 61/248,665, ?led
`Oct. 5, 2009, all 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
`
`45
`
`BRIEF DESCRIPTION OF THE INVENTION
`
`2
`and a power conditioner. The heat sink is substantially ring
`shaped and is disposed around and in thermal communication
`with an outer periphery of the heat spreader. The light source
`is disposed in thermal communication with the heat spreader,
`the light source having a plurality of light emitting diodes
`(LEDs) that are disposed in thermal communication with the
`heat spreader such that the heat spreader facilitates transfer of
`heat from the LEDs to the heat sink. The outer optic is dis
`posed in optical communication with the plurality of LEDs.
`The power conditioner is disposed and con?gured to receive
`AC voltage from an electrical supply and to provide DC
`voltage for the plurality of LEDs.
`An embodiment of the invention includes a luminaire hav
`ing a heat spreader, a heat sink a light source, an outer optic,
`and a power conditioner. The heat sink is substantially ring
`shaped and is disposed around and in thermal communication
`with an outer periphery of the heat spreader. The light source
`is disposed in thermal communication with the heat spreader,
`the light source having a plurality of light emitting diodes
`(LEDs) that are disposed in thermal communication with the
`heat spreader such that the heat spreader facilitates transfer of
`heat from the LEDs to the heat sink. The outer optic is dis
`posed in optical communication with the plurality of LEDs.
`The power conditioner is disposed and con?gured to receive
`AC voltage from an electrical supply and to provide DC
`voltage for the plurality of LEDs. The LEDs are disposed on
`one side of the heat spreader and the power conditioner is
`disposed on another opposing side of the heat spreader. The
`power conditioner is con?gured and sized to ?t at least par
`tially within an interior space of: a nominally sized can light
`?xture; and, a nominally sized electrical junction box. 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 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 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
`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, a light source and an outer
`optic. The heat sink is substantially ring-shaped and is dis
`posed around and in thermal communication with an outer
`periphery of the heat spreader. The light source is disposed in
`thermal communication with the heat spreader, the light
`source having a plurality of light emitting diodes (LEDs) that
`are disposed in thermal communication with the heat
`spreader such that the heat spreader facilitates transfer of heat
`from the LEDs to the heat sink. The outer optic is disposed in
`optical communication with the plurality of LEDs. The heat
`spreader, the heat sink and the outer optic, in combination,
`have an overall height H and an overall outside dimension D
`such that the ratio of H/D 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, a heat sink, a light source, an outer optic,
`
`50
`
`55
`
`60
`
`65
`
`

`
`Case 6:16-cv-00680-RBD-GJK Document 13-3 Filed 06/20/16 Page 22 of 28 PageID 282
`Case 6:16-cv-OO680-RBD-GJK Document 13-3 Filed 06/20/16 Page 22 of 28 Page|D 282
`
`US 8,967,844 B2
`
`3
`An embodiment of the invention includes a luminaire hav-
`
`ing a heat spreader, a heat sink thermally coupled to and
`disposed 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 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 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 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 sufficient
`thermal mass to spread heat generated by the light source to
`the means for mechanically separating, and the trim unit has
`sufficient 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 from
`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 of the
`concealed in-use housing of the installed light fixture.
`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 first 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 first pre-wired jumper
`including a pair of insulated electrical wires having a first
`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 first pre-wired jumper and
`the second pre-wired jumper are each configured to electri-
`cally engage with the plug-in connector of the electrical sup-
`ply line.
`
`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;
`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;
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`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 alternative 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 of a 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 alternative reflector to that depicted in FIGS. 10 and
`12;
`FIG. 27 depicts an exploded assembly view of an altema-
`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 ofthe
`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-
`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-
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`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 turn 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
`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
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`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 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 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.
`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
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`as to cover the power conditioner 140, 160, while permitting
`the p