USOO7722227B2
`
`(12) Unlted States Patent
`(10) Patent N0.:
`US 7,722,227 B2
`
`Zhang et al.
`(45) Date of Patent:
`May 25, 2010
`
`(54) LIGHTING FIXTURE WITH RECESSED
`BAFFLE TRIM UNIT
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`(75)
`
`ihVentorSI Kanghong Zhengs Torrance, CA (US);
`Daniel Dix, Irvme, CA (US)
`
`(73) Assignee: Cordelia Lighting, Inc., Rancho
`Dominguez, CA (US)
`
`( * ) Notice:
`
`Subject to any disclailnera the term ofthjs
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21) APP1~ N05 12/249-1683
`(22) F] d
`0 t 10 2008
`1 e I
`C .
`,
`
`*
`
`5,951,151 A
`6,217,189 B1
`6,719,438 B2
`7,186,008 B2
`7,220,029 B2
`7,255,461 B2
`2008/0112170 1A1)!<
`.
`.
`“ted by exammer
`Primary ExamineriSandra L O’Shea
`Assistant ExamineriMeghan K Dunwiddie
`(74)Attorney, Agent, orFirmiPaulY. Feng; Fulwider Patton
`LLP
`
`9/1999 Doubeck et 31.
`4/2001 Nassim
`4/2004 Sevack et al.
`3/2007 Patti
`5/2007 Bynum et 31.
`8/2007 Yang
`5/2008 Trott et 31.
`
`.................. 362/311
`
`(65)
`
`Prior Publication Data
`US 2009/0097262 A1
`Apr. 16, 2009
`
`Related US. Application Data
`.
`.
`.
`.
`(63) Cont1nuat1on of appl1catlon No. 29/295,943, filed on
`OCt’ 10’ 2007’ now Pat. NO’ Des. 5 95 5452‘
`(60) Provisional application No. 60/979,068, filed on Oct.
`103 2007.
`
`(51)
`
`Int. C1.
`(2006.01)
`F21 V17/00
`(52) us. Cl.
`....................... 362/364; 362/147; 362/294;
`362/362; 362/365; 362/373
`(58) Field of Classification Search ......... 362/1477148,
`362/294, 362, 3647366, 368, 3727373
`See application file for complete search history.
`
`(57)
`
`ABSTRACT
`~
`~
`~
`~
`~
`~
`~
`A recessed hghtmg fixture prov1d1ng 111um1nat1on from a
`light source comprising a plurality of light emitting diodes
`(LEDs) placed within a cavity of a planar surface, such as a
`ceiling, wall, or shower. The fixture comprises a baffle inte-
`grated with a low profile heat sink that is used to draw heat out
`ofthe fixture and communicate that heat to a trim ring 0f the
`fixture for dissipation of the heat in the room so that higher
`intensity light sources can be used. Improved grounding of
`the recessed trim unit to the recessed housing is provided with
`combination support and grounding springs. One embodi-
`ment of the light source is fixed in position while a second
`embodiment is gimbal mounted for aiming the light produced
`by the fixture
`
`26 Claims, 20 Drawing Sheets
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`50
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`32
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`/0’/
`/02.
`51
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`106
`NC:
`32.
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`80
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`104
`I02
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`73
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`80
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`

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`U.S. Patent
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`May 25, 2010
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`Sheet 1 of 20
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`US 7,722,227 B2
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`U.S. Patent
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`May 25, 2010
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`Sheet 2 of 20
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`US 7,722,227 B2
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`FIG.1A
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`47L
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`US. Patent
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`May 25, 2010
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`Sheet 3 of 20
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`FIG.2
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`U.S. Patent
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`May 25, 2010
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`Sheet 4 of 20
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`US 7,722,227 B2
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`US. Patent
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`May 25, 2010
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`Sheet 5 of 20
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`US 7,722,227 B2
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`FIG.4
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`

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`U.S. Patent
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`May 25, 2010
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`Sheet 6 of 20
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`US 7,722,227 B2
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`FIG. 5
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`US. Patent
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`May 25, 2010
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`Sheet 7 of 20
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`US 7,722,227 B2
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`52
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`107
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`FIG.6
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`U.S. Patent
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`May 25, 2010
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`Sheet 8 of 20
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`US 7,722,227 B2
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`____=_I=,|=“=|I=_,_=_L"nu-nun!
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`U.S. Patent
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`May 25, 2010
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`Sheet 9 of 20
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`US 7,722,227 B2
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`US. Patent
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`May 25, 2010
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`Sheet 10 of 20
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`FIG.9
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`U.S. Patent
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`May 2
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`5, 2010
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`Sheet 11 of
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`20
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`US 7,722,227 B2
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`PETITIONERS, Ex. 1014
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`US. Patent
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`May 25, 2010
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`Sheet 12 of 20
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`US 7,722,227 B2
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`FIG.11
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`US. Patent
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`May 25, 2010
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`Sheet 13 of 20
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`US 7,722,227 B2
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`FIG.12
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`US. Patent
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`May 25, 2010
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`Sheet 14 of 20
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`U.S. Patent
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`May 25, 2010
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`Sheet 15 of 20
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`FIG.14
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`U.S. Patent
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`May 25, 2010
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`Sheet 16 of 20
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`US 7,722,227 B2
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`Qm
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`:____I_MIM_I__O
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`U.S. Patent
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`May 25, 2010
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`Sheet 17 of 20
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`US. Patent
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`May 25, 2010
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`Sheet 18 of 20
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`US 7,722,227 B2
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`FIG.17
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`US. Patent
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`May 25, 2010
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`Sheet 19 of 20
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`FIG.18
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`PETITIONERS, Ex. 1014
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`US. Patent
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`May 25, 2010
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`Sheet 20 of 20
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`US 7,722,227 B2
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`2 \\
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`2’77:
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`FIG.19
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`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`

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`US 7,722,227 B2
`
`1
`LIGHTING FIXTURE WITH RECESSED
`BAFFLE TRIM UNIT
`
`CROSS-REFERENCES TO RELATED
`APPLICATIONS
`
`This application claims priority from US. Provisional
`Application No. 60/979,068, filed Oct. 10, 2007, and from
`US. Design Application No. 29/295,943 filed Oct. 10, 2007,
`both of which are incorporated herein by reference in their
`entireties.
`
`BACKGROUND
`
`The present invention relates generally to lighting fixtures
`and, more particularly, to a recessed lighting fixture that pro-
`vides improved heat dissipation and grounding.
`Recessed lighting fixtures are well known in the art. Ide-
`ally, such fixtures are designed to be visually unobtrusive in
`that very little of the lighting fixture is visible from below the
`ceiling. However, some trim portions are visible as well as the
`light sources. An opening is cut into the ceiling into which
`most of the light fixture is mounted so that very little extends
`below the plane of the ceiling. A trim piece, which may take
`the form of a bezel, is generally located at the opening to
`enhance the appearance of the light fixture and conceal the
`hole cut into the ceiling. Typically, the trim piece is slightly
`below the planar surface of the ceiling.
`Such bezels or other types of trim pieces also include
`insulation located between the trim piece and the ceiling. In
`many cases, recessed lighting fixtures are installed in holes in
`ceilings where the temperature is much different from that of
`the room into which the light fixture provides illumination.
`The insulation tends to oppose changes of the room tempera-
`ture due to the hole cut in the ceiling for the light fixture.
`Although described in a ceiling embodiment, such light
`fixtures are also used in walls in both dwelling structures and
`in automobiles, in numerous commercial building applica-
`tions, and in many other applications. For the sake of refer-
`ence,
`such lighting fixtures are referred to herein as
`“recessed.”
`
`Different light sources are used for recessed lighting fix-
`tures. Some light sources generate substantial amounts of
`heat, so much so that the rating of the light fixture must be
`displayed and warnings given that light sources above a cer-
`tain wattage could pose an overheating danger and are not to
`be used. However, in some cases, the light fixture must be
`located a substantial distance away from the object to be
`illuminated and higher wattage light sources are necessary to
`develop the amount of illumination needed. Such wattage
`limits imposed by the lighting fixtures can undesirably limit
`the amount of light furnished by the fixture. For example,
`light fixtures located in higher ceilings, which are more com-
`mon today, or light fixtures that are meant to shine at an angle
`other than perpendicular to illuminate an object, may not
`provide enough light for the object if lower wattage light
`sources must be used. Consequently, light fixtures able to
`accommodate higher heat levels are desired in such situa-
`tions. Such light fixtures must be able to dissipate increased
`levels of heat to avoid a hazard.
`
`There are two basic configurations of recessed lighting
`fixtures. One is know as a fixed position light source and the
`second is known as a movable or gimbaled light source. The
`first does not permit the light source to be aimed differently
`than when it was mounted while the second permits relatively
`easy movement ofthe light fixture for changing the aim ofthe
`light. In the second configuration, movement of the light
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`source to change its aim without disassembly of the fixture is
`provided. Both types are useful for many applications and in
`both, the dissipation of heat is a concern.
`Gimbaled lighting fixtures were created in which the light
`can be easily aimed. As is commonly used, a gimbaled mount-
`ing provides two mutually perpendicular and intersecting
`axes of rotation thus giving free angular movement in two
`directions. In the case of a recessed light source, a gimbaled
`mounting would provide for tilting the light source to achieve
`elevational control of its aim, and swiveling, or rotating, the
`light source to achieve azimuth control. This aiming proce-
`dure would typically be performed by a person who must
`touch the light source while it is in the “on” configuration; i.e.,
`while power is being applied to the light source, so that the
`direction oflight can be seen during adjustment. Touching the
`light source for aiming or other purposes while “on” exposes
`the person to any electrical potential or charge residing at the
`light source. Even if not aiming the light source, touching it
`for the purpose of repair or replacement can subject the per-
`son to any electrical potential residing on the light source.
`Dissipating heat and any electrical potential are two needs
`that have been identified for recessed lighting fixtures.
`As a brief overview of a recessed light source fixture, a
`recessed “can” or housing is fixedly mounted into the ceiling
`through the opening. Such housings are generally metallic
`and electrically conductive. They also are generally con-
`nected to earth ground. A “trim unit,” which includes one or
`more light sources, a trim ring, and other devices to provide
`the aesthetic design and lighting functions is mounted within
`the housing. Various “trim units” may be available for mount-
`ing within any one housing. The trim unit typically receives
`the light bulb or other light source or sources and provides the
`necessary electrical power to them for illumination.
`Various structures have been devised for holding a trim unit
`in a can. One desired structure is the use of devices that
`
`interlock or mate with other devices to positively hold the trim
`unit in place in the can. Other approaches involving only
`friction to maintain the trim unit in place are less desirable. It
`would also be desirable for such mounting devices to form an
`electrical pathway to the can so that any electrical charge that
`may build up on the trim unit can be dissipated.
`Hence, those skilled in the art have recognized the need for
`a light fixture in which brighter light sources can be used and
`any commensurate higher levels of heat can be dissipated.
`Those skilled in the art have also recognized a need for
`providing improved means for dissipation of heat from light
`sources and electrical supply devices used in recessed light
`fixtures, and for providing the dissipation of any electrical
`energy that may be developed at the light fixture, in particular
`at the part of the fixture more likely to be touched by a person
`attempting to repair or aim the light source. A need has also
`been recognized for a positive mounting arrangement of the
`trim unit in the recessed housing so that the trim unit is held in
`the housing through an interference or interlocking mounting
`system sufficient to prevent the trim unit from falling out of
`the recessed housing. The present invention fulfills these
`needs and others.
`
`SUMMARY OF THE INVENTION
`
`invention is
`the present
`Briefly and in general terms,
`directed to a recessed lighting fixture that allows aesthetically
`pleasing illumination when the fixture is placed within a
`cavity of a planar surface, such as a ceiling, wall, or shower.
`A low profile heat sink is integrated with a baffle to result in
`improved heat control. An improved grounding of the trim
`unit to the recessed housing is also provided.
`
`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`

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`US 7,722,227 B2
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`3
`In accordance with aspects of the invention, there is pro-
`vided a recessed lighting fixture located in an opening of a
`surface, the surface having an outer side and an inner side, the
`lighting fixture comprising a recessed housing located in a
`recessed configuration in the opening of the surface adjacent
`the inner side, a lighting trim unit comprising, a trim ring
`configured to be disposed at the opening the outer side of the
`surface, a light source that emits light, the light source located
`within the recessed housing and disposed so as to emit light at
`the opening, a baffle surrounding the light source and in
`contact with the trim ring to direct light from the light source
`at the opening, the baffle having a first end located adjacent
`the opening in the surface and a second end located within the
`recessed housing opposite the first end, and a low profile heat
`sink integrated with the baffle, wherein the integrated baffle
`heat sink draws heat out ofthe recessed housing and conducts
`it to the trim ring, whereby heat communicated to the trim
`ring may be dissipated at the outer side of the surface.
`In accordance with more detailed aspects, the integrated
`baffle heat sink surrounds the light source. The integrated
`baffle heat sink is in contact with the light source to draw heat
`from the light source. The trim ring and the baffle are formed
`together as a single part. In another aspect, the trim ring, the
`baffle, and the integrated baffle heat sink are formed together
`as a single part.
`Further more detailed aspects include the baffle being
`formed into the baffle heat sink having a plurality of heat sink
`fins protruding outwardly. In another aspect, the baffle heat
`sink fins protrude radially outwardly and are oriented in par-
`allel with a longitudinal axis of the baffle. The sizes and
`number of baffle heat sink fins are selected to result in the
`
`integrated baflIe/heat sink being low profile.
`In yet more detailed aspects, the recessed lighting fixture
`further comprises a second heat sink located at the second end
`of the baffle to which the light source is mounted, the second
`heat sink configured to draw heat from the light source, the
`second heat sink connected to the baffle. The second heat sink
`
`comprises a plurality of heat sink fins protruding outwardly.
`The recessed lighting fixture further comprises a driver con-
`figured to provide power to the light source with the second
`heat sink being mounted to the driver and to the light source,
`the second heat sink configured to draw heat from the light
`source and driver, the second heat sink connected to the baffle.
`In other aspects, the recessed lighting fixture comprises a
`light source that is fixed in position in relation to the trim ring
`and integrated baffle/heat sink so that light provided by the
`light source cannot be selectively aimed. In another aspect,
`the light source is movable in position in relation to at least
`one ofthe trim ring, the housing, and the integrated baflIe/heat
`sink so that light provided by the light source can be selec-
`tively aimed. The movable light source is gimbal mounted.
`Other aspects include the trim unit further comprising an
`electrically conductive spring in electrical contact with the
`trim unit, the spring having two elongated legs for contact
`with the recessed housing, each leg having a bent portion at an
`end that is shaped so as to engage a portion of the recessed
`housing in an interference fit to thereby hold the trim unit in
`place in relation to the recessed housing and provide an elec-
`trical pathway between the trim unit and the recessed hous-
`ing. The recessed housing comprises spring mounting open-
`ings for receiving the bent ends of the spring to thereby hold
`the trim unit in place in the recessed housing. Further, the ends
`of the springs are spaced from a mounting point of the spring
`to the trim unit to provide a fail-safe distance of engagement
`with the recessed housing in the event that the trim unit were
`to fall slightly from the recessed housing due to shock or
`vibration.
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`In other more detailed aspects, a first portion of the trim
`ring is located on the outer side of the opening and a second
`portion of the trim ring extends into the opening, and the
`spring has a central coil which is attached to the second
`portion of the trim ring to thereby hold the first portion of the
`trim ring against the opening and hold the remaining portion
`of the trim unit in the recessed housing when the ends of the
`springs are engaged with the recessed housing.
`Yet other aspects include the trim unit further comprising a
`tilting mechanism to which the light source is mounted to
`permit adjustment of elevational aim of the light source with-
`out having to remove the trim unit from the recessed housing.
`The trim unit further comprises a gimbal mounting mecha-
`nism disposed so that the light source is gimbal mounted in
`relation to one or both of the trim ring and the housing.
`Other aspects include the light source comprising at least
`one light emitting diode.
`In accordance with still further aspects of the invention,
`there is provided a recessed lighting fixture located in an
`opening of a surface, the surface having an outer side and an
`inner side, the lighting fixture comprising a recessed housing
`located in a recessed configuration in the opening of the
`surface adjacent the inner side, a lighting trim unit comprising
`a trim ring having a first portion located on the outer side of
`the opening and a second portion of the trim ring extending
`into the opening, the trim ring formed of an electrically and
`thermally conductive material, a light source that emits light,
`the light source located within the recessed housing and dis-
`posed so as to emit light at the opening, a baffle having an
`integrated low profile heat sink formed as a single piece
`disposed about the light source and connected with the trim
`ring, the baffle located within the recessed housing, wherein
`the integrated heat sink comprises a plurality of heat sink
`elements protruding outwardly, the baffle formed of an elec-
`trically and thermally conductive material, and a metallic
`spring in electrical contact with the baffle, the spring config-
`ured to engage the recessed housing to thereby establish an
`electrical pathway between the baffle and the housing and to
`hold the trim unit in place in relation to the recessed housing.
`In more detailed aspects, the light source comprises a plu-
`rality of light emitting diodes. The light source is fixed in
`position and cannot be moved to change the direction of light
`emitted, and in another aspect, the light source is configured
`to be movable so that the direction of light emitted by the light
`source can be selectively aimed.
`These and other aspects, features, and advantages of the
`present invention will become apparent from the following
`detailed description of the preferred embodiments which,
`taken in conjunction with the accompanying drawings, illus-
`trate by way of example the principles of the invention.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a top perspective view of a planar surface having
`an opening made to receive a recessed light fixture at the inner
`side of the surface, showing the recessed housing of the
`fixture and, in partial cutaway, a schematic view of a trim unit
`mounted within the housing with associated wiring;
`FIG. 1A is a cross-sectional side view diagram showing the
`recessed housing of FIG. 1 mounted in the opening of the
`planar surface with the trim ring being located on the outer
`side ofthe planar surface through which an opening was made
`to receive the recessed light fixture, also shown is a coiled
`torsion spring used to hold the trim unit in the housing;
`FIG. 2 is a bottom perspective view of a trim unit in accor-
`dance with aspects of the invention having a fixed position
`light source, showing the frusto-conically-shaped baffle with
`
`PETITIONERS, Ex. 1014
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`PETITIONERS, Ex. 1014
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`

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`US 7,722,227 B2
`
`5
`integrated heat sink, a plurality of LED lights forming a light
`source, a driver to provide appropriate power to the LED
`lights, a grounding strap connected to the trim unit for attach-
`ment to the housing, a light socket adapter, and electrically
`conductive mounting springs usable to provide an electrical
`pathway between the trim unit and the housing;
`FIG. 3 is a top perspective view of the trim unit shown in
`FIG. 2 showing more detail of the heat sink integrated with
`the baffle which are also made formed with the trim ring as a
`single piece, the electrically conductive mounting springs, the
`driver, and a second heat sink disposed between the driver and
`the LED lights to further draw heat away from the light
`fixture, the view also showing how the integrated baflie/heat
`sink and trim ring formed as a single piece will assist in
`drawing heat away from the light source to dissipate the heat
`on the outer side of the planar surface in which the recessed
`fixture is mounted;
`FIG. 4 is a further embodiment of a trim unit having a fixed
`position light source similar to FIGS. 2 and 3 in which the trim
`ring and baffle with integrated heat sink are formed as a single
`piece for conducting heat out through the trim ring, also
`demonstrating the optional use of a driver in that the light
`emitting diodes of this embodiment do not require a driver,
`hence non has been installed at the trim unit resulting in the
`figure more clearly showing the second heat sink at the end of
`the baffle, the second heat sink being formed as a single piece
`with the end cap of the baffle, the circuit board of the LED
`lights being attached to the inner surface of the end cap;
`FIG. 5 is an exploded view of the trim unit of FIGS. 2 and
`3 showing in some detail the lenses that are positioned over
`the LED lights, the single piece baflie/heat sink and trim ring
`combination, the second heat sink formed as part of the trim
`unit end cap as a single piece, the drive unit, and the electri-
`cally conductive mounting springs;
`FIG. 6 is a side view of the trim unit of FIGS. 2 and 3
`
`showing a grounding strap for connection to a grounded
`recessed housing or “can” such as that shown in FIG. 1, and an
`AC light socket adapter for engaging a mains power con-
`necter;
`FIG. 7 is a side view ofthe trim unit of FIGS. 2, 3, and 6
`rotated ninety degrees from FIG. 6 showing the attachment of
`the electrically conductive mounting springs to the trim unit,
`and also showing the heat radiating fins formed as an integral
`part of the baffle;
`FIG. 8 is a bottom view of the trim unit of FIGS. 6 and 7
`
`mounted in a housing or “can” showing five LED light
`sources that are fixed in position, the trim ring that would be
`located on the outer side of the planar surface within which
`the recessed light fixture is mounted as shown in FIG. 1, the
`inner portion ofthe baffle that is integrated with the heat sink,
`and the mechanical and electrical interconnection of the trim
`
`unit with the recessed housing effected by the physical inter-
`ference or interlocking fit of the springs with openings or
`brackets positioned on the internal surface of the recessed
`housing;
`FIG. 9 is a top view ofthe trim unit of FIG. 5 in which the
`light source is fixed in position, showing the attachment ofthe
`electrically conductive mounting springs to the trim unit, the
`driver unit, the light socket adapter that may be screwed into
`a standard electrical
`light socket for receiving electrical
`power, the ground strap, and the heat radiating fins located on
`the integrated baflie/heat sink;
`FIG. 10 is a bottom perspective view of a gimbaled trim
`unit that can be tilted in elevation and swiveled in azimuth to
`
`enable selection of the aim of the light source, showing the
`trim ring, the baffle with integrated heat sink, a plurality of
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`LED lights, a driver to provide power to the lights, a ground
`strap, a light socket adapter, and electrically conductive
`mounting springs;
`FIG. 11 is a top perspective view of the gimbaled trim unit
`shown in FIG. 10 showing more detail of a gimbals mecha-
`nism permitting the tilting of the trim unit to control the
`elevational aim of the light source and rotation of the inte-
`grated baflie/heat sink device to control the azimuthal aim of
`the light source, also showing the electrically conductive
`mounting springs, the driver, and a second heat sink disposed
`between the driver and the LED lights to further draw heat
`away, the view also showing the integrated baffle/heat sink in
`contact with a trim ring to assist in drawing heat away from
`the light source;
`FIG. 12 is a further embodiment of a gimbaled trim unit
`that may both be tilted for elevational aim control and swiv-
`eled for azimuthal aim control, also demonstrating the
`optional use of a driver in that the light emitting diodes ofthis
`embodiment do not require a driver, hence non has been
`installed at the trim unit resulting in the figure more clearly
`showing the second heat sink at the end of the baffle;
`FIG. 13 is an exploded view of the gimbaled trim unit of
`FIGS. 10 and 11 showing in detail the gimbals mechanism
`that provides the ability to aim the light source through tilting
`and rotating, the LED light sources and lenses, the integrated
`baffle/heat sink, the trim unit end cup with integrated heat
`sink, the driver unit, and the electrically conductive mounting
`springs;
`FIG. 14 is a side view of the trim unit of FIGS. 10 and 11
`
`showing a grounding strap for connection to a grounded
`recessed housing, and a light socket adapter for engaging
`mains power for use in powering the light source;
`FIG. 15 is a side view ofthe gimbaled trim unit ofFIGS. 10,
`11, and 14 rotated ninety degrees from FIG. 14 showing more
`clearly the attachment of the electrically conductive mount-
`ing springs;
`FIG. 16 is a side view ofFIG. 15 in which the gimbaled trim
`unit has been selectively tilted by approximately fifteen
`degrees to aim the light from the light sources at a selected
`location;
`FIG. 17 is a top perspective view ofthe tilted gimbaled trim
`unit of FIG. 16, the view being rotated at an angle from that
`shown in FIG. 16 to show the gimbaled tilt axis and the stop
`device for limiting the azimuthal aiming of the light source;
`FIG. 18 is a bottom view of the gimbaled trim unit of FIG.
`16 showing five LED light sources, the trim ring that is
`located on the outer side of the planar surface within which
`the recessed light fixture is mounted, the baffle, and the elec-
`trically-conductive mounting springs for securing the gim-
`baled trim unit in a housing; and
`FIG. 19 is a top view of the gimbaled trim unit of FIG. 18
`showing the electrically conductive mounting springs, the
`driver unit, the integrated baffle/heat sink, the light socket
`adapter that may be screwed into a standard electrical light
`socket, and the heat radiating fins located on the integrated
`baffle/heat sink.
`
`DETAILED DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`Referring now to the drawings in more detail in which like
`reference numerals refer to like or corresponding devices
`among the views, there is shown in FIGS. 1 and 1A a top
`perspective view and a side view, respectively, of a planar
`surface 30 having an opening 32 made to receive a recessed
`light fixture 34. Both figures show the recessed housing 36 or
`“can” of the light fixture and in cutaway views, a trim unit 38
`
`PETITIONERS, Ex. 1014
`
`PETITIONERS, Ex. 1014
`
`

`

`US 7,722,227 B2
`
`7
`mounted within the housing. Power wires 40 provide power
`to a drive unit 42 that provides power to the light sources (not
`shown). The trim unit includes a trim ring 44 located on the
`outer side 46 of the planar surface 30 that is larger than the
`opening 32 (shown in FIG. 1A). The trim ring covers the
`opening and provides a stop surface for the trim unit 38 so that
`it cannot be recessed entirely into the opening. In the case
`where the planar surface 3 0 is a ceiling, the trim ring is located
`within the room 47 of which the ceiling forms a part. As
`described below in more detail, the trim ring is configured to
`draw heat away from the trim unit 38 and conduct it to the
`room 47 for dissipation which will result in cooling ofthe trim
`unit.
`
`Although shown as free standing in FIG. 1, the recessed
`housing 36 may also be braced by connection to studs or other
`construction features in the ceiling or wall or other structure
`in which it is located. Details of such common and well
`
`known mounting techniques for recessed housings have been
`excluded for the sake of clarity in the drawings. Various
`additional mounting techniques are well known to those of
`skill in the art and no further details are provided herein. The
`provision of electrical energy in FIG. 1 is shown as two wires
`from a conduit 48; however, as will be shown in other figures,
`electricity may be provided by other means, such as a light
`socket adapter.
`The light source, such as light emitting diodes (“LEDs”),
`and/or the driver 42 that provides the necessary electrical
`energy to cause the LEDs to emit light typically create heat.
`Because they are located within the housing 36, the internal
`space 49 in the housing will typically increase in temperature.
`In accordance with an aspect ofthe invention, the trim unit 38
`is configured to conduct heat from the heat-producing ele-
`ments to the trim ring 44 that is located within a much larger
`space; i.e., the room 47. It can be seen in FIG. 1A that the trim
`ring 44 located within the room 47 is in contact with the other
`components of the trim unit 38 located within the recessed
`housing 36. Those other components of the trim unit are also
`in contact with heat that may exist in the internal space 49 of
`the housing 36, and are therefore equally capable of also
`conducting that heat to the trim ring for dissipation within the
`room. In this way, heat developed within the housing can be
`better controlled. This enables the use of higher wattage light
`sources in the trim unit.
`
`Also shown partially in FIG. 1A is the use of springs 80 to
`hold the trim unit 38 within the recessed housing 36.
`Although not shown clearly, the torsion springs 80 are fit into
`openings in the housing in an interlocking manner resulting in
`the force of the springs pulling and holding the trim unit up in
`the housing with the trim ring 44 held against the outer side 46
`of the surface 30. Although not shown, insulation may be
`positioned between the trim ring 44 and the opening 32 of the
`outer side 46 of the surface 30 to prevent the temperature of
`the air in the area 51 surrounding the recessed housing 36
`from affecting the temperature in the room 47.
`Referring now to FIGS. 2 and 3, bottom and top perspective
`views are provided of a first trim unit 50. This particular trim
`unit is a fixed position trim unit, meaning that once mounted,
`the aim of the light source within it cannot be changed. This
`is in contrast to a gimbaled light source in which the light
`source aim can be relatively easily moved, as is discussed in
`more detail below. The trim unit of FIGS. 2 and 3 comprises
`a trim ring 52, similar to that shown in FIGS. 1 and 1A, which
`is part of a baffle 54. In this case, the baffle and trim ring are
`a single piece; however in other embodiments, they may be
`separate pieces, as discussed and shown below. In accordance
`with an aspect of the invention, the baffle is integrated with a
`low profile heat sink 56 used to draw heat from the light
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`sources 57 mounted within the baffle. The heat drawn from
`
`the light sources may be transferred from the trim unit 50 by
`thermal transfer, such as convection, conduction, or radiation.
`The integrated baffle/low profile heat sink includes, in this
`embodiment, a plurality of heat sink fins 58. Although the
`drawing numeral 58 is only pointing to a single fin, it is meant
`to include all fins in the figures. A single fin is indicated with
`the reference numeral to maintain the clarity of the drawing.
`The same reason applies for the reference numeral 57 to
`indicate a light source. In FIGS. 2 and 3, and in other figures,
`a plurality of light emitting diodes (LEDs) 57 are used for the
`light source. For the sake of clarity of the drawings, the
`numeral 57 is only pointing to one, although it is meant to
`include all.
`
`In this embodiment, the heat sink fins have a rectangular
`cross-sec