`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Ex. 1011
`
`EX. 1011
`
`
`
`

`

`US008777449B2
`
`(12) United States Patent
`US 8,777,449 B2
`Van De Ven et al.
`(45) Date of Patent:
`Jul. 15, 2014
`
`(10) Patent No.:
`
`(54) LIGHTING DEVICES COMPRISING SOLID
`STATE LIGHT EMITTERS
`
`(75)
`
`Inventors: Antony Paul Van De Ven, Hong Kong
`(CN); Wai Kwan Chan, Hong Kong
`(CN); Ho Chin Wah, Hong Kong (CN)
`
`(73) Assignee: Cree, Inc., Durham, NC (US)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 319 days.
`
`(21) Appl.No.: 12/566,861
`
`(22)
`
`Filed:
`
`Sep. 25, 2009
`
`4,839,535 A
`4,841,422 A
`4,918,487 A
`5,138,541 A
`5,151,679 A
`5,175,528 A
`5,345,167 A
`5,397,938 A
`5,528,467 A
`
`6/1989 Miller
`6/1989 Groh
`4/1990 Coulter, Jr.
`8/1992 Kano
`9/1992 Dimmick
`12/1992 Choiet a1.
`9/1994 Hasegawa et a1.
`3/1995 Wilheim et a1.
`6/1996 Jiang
`
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`CN
`EP
`
`101162745
`1 881 259
`
`4/2008
`1/2008
`
`(Continued)
`OTHER PUBLICATIONS
`
`(65)
`
`Prior Publication Data
`
`US 2011/0075422 A1
`
`Mar. 31, 2011
`
`U.S.App1N0. 29/344,219, filed Sep. 25, 2009, Van de Ven.
`
`(Continued)
`
`(51)
`
`Int. Cl.
`F21S 4/00
`(52) US. Cl.
`USPC ...... 362/249.02; 362/401; 362/407; 362/640;
`362/646
`
`(2006.01)
`
`(58) Field of Classification Search
`USPC ............. 362/340, 646, 650, 249.02, 401, 407
`See application file for complete search history.
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`446,142 A
`D188,916 S
`D207,867 S
`3,560,728 A
`3,755,697 A
`3,787,752 A
`4,090,189 A
`4,717,868 A
`4,798,983 A
`
`2/1891 Martin
`9/1960 Harling
`6/1967 Pettengill
`2/1971 Atkin
`8/1973 Miller
`1/1974 Delay
`5/1978 Fisler
`1/1988 Peterson
`1/1989 Mori
`
`Primary Examiner 7 Anabel Ton
`(74) Attorney, Agent, or Firm 7 Burr & Brown, PLLC
`
`(57)
`
`ABSTRACT
`
`A lighting device comprising a trim element, an electrical
`connector and at least one solid state light emitter, the lighting
`device weighing less than one kilogram. Ifcurrent of about 12
`watts (or in some cases about 15 watts, or in some cases not
`more than about 15 watts) is supplied to the electrical con-
`nector, the at least one solid state light emitter will illuminate
`so that the lighting device will emit white light of at least 500
`lumens. Also, a lighting device that weighs less than one
`kilogram and can generate white light of at least 500 lumens
`using a current of not more than about 15 watts. Also, a
`lighting device for mounting in a recessed housing, compris-
`ing a unitary structure trim element that conducts heat away
`from at least one solid state light emitter and dissipates at least
`some of the heat outside of the recessed housing.
`
`14 Claims, 5 Drawing Sheets
`
`
`
`
`
`Satco's Ex. 1011, Page 1
`
`Satco's Ex. 1011, Page 1
`
`

`

`US 8,777,449 B2
`
`Page 2
`
`(56)
`
`References Cited
`
`us. PATENT DOCUMENTS
`
`5,631,190 A
`5,661,645 A
`D384,430 S
`5,736,881 A
`5,803,579 A
`D400,280 s
`5,844,377 A
`5,912,477 A
`5,912,568 A
`13418520 s
`134255024 S
`6,079,852 A
`6,150,771 A
`6,161,910 A
`D437,439 s
`6,222,172 B1
`6,264,354 B1
`6,285,139 B1
`6,329,760 B1
`6,340,868 B1
`6350041 Bl
`6,362,578 Bl
`6,388,393 Bl
`6,400,101 B1
`6’528’954 B1
`6’577’072 B2
`6 586 890 B2
`
`5/1997 Negley
`8/1997 Hochstein
`9/1997 Lecluze
`4/1998 01112
`9/1998 Turnbull et a1.
`10/1998 Leen
`12/1998 Anderson et a1.
`6/1999 Negley
`6/1999 Kiley
`“2000 Gmssman
`5/2000 Klaus et 31.
`6/2000 Kamayaet 31.
`“/2000 Perry
`12/2000 Reisenaueretal.
`2/2001 Tang
`4/2001 Fossum et a1.
`7/2001 Motilal
`9/2001 Ghanem
`12/2001 Bebenroth
`1/2002 Lys et a1.
`2/2002 Tarsa etal~
`”002 SWanson “31
`”002 Illlngworth
`6/2002 B1eb1eta1.
`”003 Lys et 31'
`”003 SM" et 31'
`7/2003 Min et a1.
`
`9/2003 Hutchison et a1.
`6,614,358 B1
`10/2003 Rahm et 31.
`6,636,003 B2
`4/2004 Sakura et 31.
`6,724,376 132
`5/2004 Redfem
`D490,181 s
`6/2004 Barth etal.
`6,747,420 B2
`6/2004 Lackey ......................... 362/147
`6,755,550 B1*
`9/2004 Chun
`6,791,840 B2
`10/2004 Lebens et a1.
`6,808,287 B2
`12/2004 Swanson etal.
`6,836,081 B2
`1/2005 Berg-Johansen
`6,841,947 B2
`3/2005 Lémlfmafletfi
`6,873,203 Bl
`23882 $311M: 31.
`2’33}??? 3:
`.
`,
`,
`3/2006 King etlal~ ~~~~~~~~~~~~~~~ 362/29602
`7014341 132*
`5 2006 Lyseta'
`7’038’399 B2
`343882 £3}:th 31.
`3:83:33; 3%
`-
`$3882 ggfi‘imey etal'
`333%; 3%
`10/2006 Baldwin et a1.
`7,119,498 B2
`12/2006 Sun etal.
`7,144,140 B2
`2/2007 Kamikawa et a1.
`7,180,487 B2
`4/2007 Robinson et a1.
`7,202,608 B2
`5/2007 Van deVen
`7,213,940 B1
`6/2007 Hartmann et a1.
`D544,979 s
`6/2007 Lee etal.
`7,226,189 B2
`12/2007 Sandell
`D557,853 S
`12/2007 Sande“
`13558374 S
`8/2008 Sawadaetal.
`7,408,308 B2
`13/388: 33:12:21
`71323282 B1
`'
`“009 Wan
`7,513,639 B2
`7/2009 Gloisgten et a1.
`7,566,154 B2
`...... 362/296.01
`7,614,767 B2* 11/2009 Zulimetal.
`7:614:769 B2* 11/2009 Sell
`............................... 362/365
`7,628,513 B2
`”/2009 Chiu
`7,637,635 B2
`12/2009 Xiao et a1.
`D610,291 5
`2/201() Yoshinobu et 31.
`7,677,767 132
`3/2010 Chyn
`D618,376 s
`6/2010 Redfern et a1.
`7,758,223 B2
`7/2010 Osawa et a1.
`7,780,318 B2
`8/2010 Xiao
`D625,038 s
`10/2010 Yoo
`D627,502 s
`11/2010 Zheng etal.
`D627,911 s
`11/2010 Mo et a1.
`7,824,075 B2
`11/2010 Maxik
`7,862,201 B2
`1/2011 Ge etal.
`
`
`
`7,862,214 B2
`7,871,184 B2
`D633,099 S
`7,914,902 B2
`D636,921 S
`D636,922 S
`D638,160 S
`7,994,725 B2
`8,008,845 132
`13646011 S
`8,157,422 132
`8,235,555 B2
`8,246,202 B2
`2002/0097095 A1
`2005/0007164 A1
`2005/0111222 A1
`2005/0128752 A1
`2005/0169015 A1
`2005/0174065 A1
`2005/0242742 A1
`2005/0276053 A1
`2006/0244396 A1
`2006/0255753 A1
`2007/0108843 A1
`2007/0137074 A1
`2007/0139920 A1
`2007/0139923 A1
`2007/0170447 A1
`2007/0171145 A1
`2007/0215027 A1
`
`2007/0236920 A1
`2007/0247414 A1
`2007/0263393 A1
`2007/0267983 A1
`2007/0274063 A1
`2007/0274080 A1
`2007/0278503 A1
`2007/0278934 A1
`2007/0278974 A1
`2007/0279440 A1
`2007/0279903 A1
`2007/0280624 A1
`2008/0030993 A1
`2008/0054281 A1
`2008/0084685 A1
`2008/0084700 A1
`2008 0084701 A1
`2008/0088248 A1
`2008/0089053 A1
`2008/0089071 A1
`2008/0094000 A1
`2008/0094829 A1
`2008/0105887 A1
`2008/0106895 A1
`2008/0106907 A1
`2008/0112168 A1
`2008/0112170 A1
`2008/0112183 A1
`2008/0117500 A1
`2008/0128718 A1
`2008/0130285 A1
`2008/0136313 A1
`2008/0137347 A1
`2008/0186704 A1
`2008/0211415 A1
`2008/0259589 A1
`2008/0278928 A1
`2008/0278940 A1
`2008/0278950 A1
`2008/0278952 A1
`2008/0278957 A1
`2008/0304260 A1
`2008/0304261 A1
`2008/0304269 A1
`2008/0309255 A1
`
`1/2011 Trott et a1.
`1/2011 Peng
`2/2011 Van deVen et a1.
`3/2011 Kao et a1.
`4/2011 Van C16Ven etal.
`4/2011 Yoshldaet a1.
`5/2011 Van deVen et a1.
`8/2011 Bouchard
`80011 Van deVen
`9/2011 Rashldl
`40012 Palk etal~
`8/2012 Thomasetal.
`8/2012 Maltetal.
`7/2002 Jeon etal.
`1/2005 Callahan
`5/2005 OIS-SOH et a1.
`6/2005 EW1ngt0n et a1.
`8/2005 Luk et a1.
`8/2005 Janning
`11/2005 Cheang et a1.
`12/2005 Nonrup et a1.
`11/2006 Bucur
`11/2006 Sawadaetal.
`5/2007 Preston et al.
`6/2007 Van deVen
`6/2007 Van deVen
`6/2007 Negley
`7/2007 Ne 1e
`7/2007 C 1g y
`9/2007 Moafgljnlald etal
`
`~
`
`'
`
`
`
`10/2007 Snyder
`10/2007 Roberts
`11/2007 Van deVen
`11/2007 Van deVen
`11/2007 \Iegley
`11/2007 \Iegley
`12/2007 Van deVen
`12/2007 Van deVen
`12/2007 Van deVen
`12/2007 \Iegley
`12/2007 \Iegley
`12/2007 \Iegley
`2/2008 \Iarendran et a1.
`3/2008 Varendmn et 31
`4/2008 Van deVen
`4/2008 Van geVen
`42008 Van eVen
`4/2008 VIyers
`4/2008 \Tegley
`4/2008 Wang
`4/2008 Yamamoto et a1.
`4/2008 \Iarendran et a1.
`5/2008 \Iarendran et a1.
`5/2008 Van deVen
`5/2008 Trott
`5/2008 Pickard
`5/2008 Trott
`5/2008 Negley
`5/2008 Narendran et a1.
`6/2008 Sumitani
`“008 Negley
`“008 Van deVen
`“008 Tm“
`8/2008 Chou etal.
`9/2008 Altamura
`10/2008 Van deVen
`11/2008 Van deVen
`11/2008 Van deVen
`11/2008 Pickard et a1.
`11/2008 Trott
`11/2008 Pickard et a1.
`12/2008 Van deVen
`12/2008 Van deVen
`12/2008 Pickard
`12/2008 Myers
`
`Satco's Ex. 1011, Page 2
`
`Satco's Ex. 1011, Page 2
`
`

`

`US 8,777,449 B2
`
`Page 3
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`WO
`WO
`WC
`
`2008/051957
`2008/061082
`2008/ 129504
`
`5/2008
`5/2008
`10/2008
`
`2009/0034283 A1
`ggggéggggggg :1
`2009/0086474 A1
`2009/0101930 A1
`2009/0108269 A1
`2009/0147517 A1
`2009/0160363 A1
`2009/0161356 A1
`2009/0184616 A1
`2009/0184662 A1
`2009/0184666 A1
`2009/0196037 A1
`2009/0296384 A1
`2010/0014289 A1
`2010/0027258 A1
`2010/0060130 A1
`2010/0060175 A1
`2010/0067227 A1
`2010/0079059 A1
`2010/0079262 A1
`2010/0102199 A1
`2010/0102697 A1
`2010/0103678 A1
`2010/0109570 A1
`2010/0135016 A1
`igigfigéggggg :1
`3818;832:213; :1
`2010/0308739 A1
`2010/0327746 A1
`201 1/0031894 A1
`2011/0068696 A1
`2011/0068702 A1
`2011/0074265 A1
`2011/0074289 A1
`2011/0075411 A1
`2011/0075414 A1
`2011/0075422 A1
`201 1/0075423 A1
`2011/0169417 A1
`2011/0180818 A1
`2011/0181194 A1
`2011/0198984 A1
`2011/0211351 A1
`
`2/2009 Albright et al.
`$883 Eilffii'
`4/2009 Chou
`4/2009 Li
`4/2009 Negley
`6/2009 Li Ct 211.
`6/2009 Negley
`6/2009 Negley
`7/2009 Van de Ven
`7/2009 Given et a1.
`7/2009 Myers
`8/2009 Xiao et 31.
`12/2009 Van de Ven
`1/2010 Thomas et al.
`2/2010 Maxik et al.
`3/2010 Li
`3/2010 Lethellier
`3/2010 Budike
`4/2010 Roberts et al.
`4/2010 Van Laanen
`4/2010 Negley et 3L
`4/2010 Van De Ven et 3L
`4/2010 Van De Ven et 3L
`5/2010 Weaver .
`6/2010 IshlbaShl
`55818 Thcnlfairaiet al
`'
`gggig ¥mZ¥fiILt al
`12/2010 Shteynberg et a1
`12/2010 Hisayasu
`2/201 1 Van de Ven
`3/2011 Van de Ven
`3/2011 Van de Ven
`3/2011 Van de Ven et a1.
`3/2011 Van de Ven
`3/2011 Van de Ven et 31.
`3/2011 Van de Ven et 31.
`3/2011 Van de Ven et a1.
`3/201 1 Van de Ven
`7/2011 Hum et 31.
`7/2011 Lerman et 31.
`7/2011 Hum et a1.
`8/2011 Van de Ven
`9/2011 Van de Ven
`
`'
`
`FOREIGN PATENT DOCUMENTS
`
`WO
`WO
`
`2006/007388
`2008/036873
`
`1/2006
`3/2008
`
`OTHER PUBLICATIONS
`U.S.App1No. 29/353,900, filed Jan. 15, 2010, Van de Ven.
`U.S. Appl. No. 12/535,319, filed Aug. 4, 2009.
`U.S. Appl. No. 12/441,905, filed Mar. 26, 2009.
`U.S. Appl. No. 12/566,936, filed Sep. 25, 2009.
`US. Appl. N0. 12/566,850, filed Sep. 25, 2009.
`U.S.App1. No. 12/566,857, filed Sep. 25, 2009.
`U.S.App1. N0. l2/621,970, filed NOV. 19, 2009.
`U~S~App1~ No. 12/704,995, filed Feb. 12, 2010.
`U~S~App1~ No. 12/566,142, filed $61124, 2009
`U.S.App1. No. 12/566,195, filed Sep. 24, 2009.
`“Assist Recommends .
`.
`. LED Life for General Lighting: Definition
`OfLife”, V01. 1, Issue 1, Feb. 2005.
`“Bright TomorrowLighting Competition (LprizeTM)”, May28, 2008,
`Document No. 08NT006643.
`“Energy StarTM Program Requirements for Solid State Lighting
`Luminaires, Eligibily CriteriaiVersion 1.1 ”, Final: Dec. 19, 2008.
`Application Note: CLD-AP06.006, entitled Cree® XLamp® XR
`Family & 4550 LED Reliability, published at cree.com/Xlamp, Sep.
`2008.
`Bulborama, Lighting Terms Reference and Glossary, http://www.
`bulborama.com/storelightingreferenceglossary-13.htrnl, 6 pages.
`DuPont, “DuPontTM Difluse Light Reflector”, Publication K-20044,
`May 2008, 2 pages.
`Furukawa Electric Co., Ltd., Data Sheet, “New Materialfor Illumi—
`nated Panels Microcellular Reflective Sheet MCPET”, updated Apr.
`8, 2008, 2 pages.
`Illuminating Engineering Society Siandard LM-80-08, entitled “IES
`ApprovedMethodfor Measuring Lumen Maintenance ofLED Light
`Sources”, Sep. 22, 2008, ISBN No. 978-0-87995,227-3.
`Kim et al., “Strongly Enhanced Phosphor Efficiency in GaInN White
`Light-Emitting Diodes Us1ng Remote Phosphor Configuration and
`Diffuse Reflector Cup” Japanese Journal of Applied Physics
`44(21)1L649'_L651 (2005)
`_
`LEDs Magazme, Press Release May 23, 2007, “Furukawa America
`Debuts MCPET Reflective Sheets to Improve Clarity, Eficiency of
`Lighting Fixtures”, downloaded Jun. 25, 2009 from http://www.
`ledsmagazineconvpress/ 15 145, 2 pages.
`Philips Lumileds, Technology White Paper: “Understanding power
`LED lifetime
`analysis”,
`downloaded
`from http://www.
`philipslumileds.com/pdfs/WP12.pdf, Document No. WP12, Last
`Modified May 22,2007.
`MCPETiMicrocellular Reflective Sheet Properties, http://www.
`trocellen.com, downloaded Jun. 25, 2009, 2 pages.
`Chinese Office Action (and translation provided by foreign counsel)
`from a corresponding Chinese patent application bearing a mailing
`date of Dec. 19,2013, 14 pages.
`
`* cited by examiner
`
`Satco's Ex. 1011, Page 3
`
`Satco's Ex. 1011, Page 3
`
`

`

`US. Patent
`
`Jul. 15, 2014
`
`Sheet 1 of5
`
`US 8,777,449 B2
`
`
`
`Satco's Ex. 1011, Page 4
`
`Satco's Ex. 1011, Page 4
`
`

`

`US. Patent
`
`Jul. 15, 2014
`
`Sheet 2 of5
`
`US 8,777,449 B2
`
`
`
`Satco's Ex. 1011, Page 5
`
`Satco's Ex. 1011, Page 5
`
`

`

`US. Patent
`
`Jul. 15, 2014
`
`Sheet 3 of5
`
`US 8,777,449 B2
`
`
`
`Satco's Ex. 1011, Page 6
`
`Satco's Ex. 1011, Page 6
`
`

`

`US. Patent
`
`Jul. 15, 2014
`
`Sheet 4 of5
`
`US 8,777,449 B2
`
`
`
`Satco's Ex. 1011, Page 7
`
`Satco's Ex. 1011, Page 7
`
`

`

`U.S. Patent
`
`Jul. 15, 2014
`
`Sheet 5 of 5
`
`US 8,777,449 B2
`
`
`
`IIIl“
`
`“"— a
`.7 1'
`‘V-mv
`nu :.
`==== «II V
`
`. y
`
`A
`
`Satco's Ex. 1011, Page 8
`
`Satco's Ex. 1011, Page 8
`
`

`

`US 8,777,449 B2
`
`1
`LIGHTING DEVICES COMPRISING SOLID
`STATE LIGHT EMITTERS
`
`FIELD OF THE INVENTIVE SUBJECT MATTER
`
`The present inventive subject matter is directed to lighting
`devices. In some aspects, the present inventive subject matter
`is directed to lighting devices that comprise one or more solid
`state light emitters, e.g., one or more light emitting diodes.
`
`BACKGROUND
`
`There is an ongoing effort to develop systems that are more
`energy-efficient. A large proportion (some estimates are as
`high as twenty-five percent) ofthe electricity generated in the
`United States each year goes to lighting, a large portion of
`which is general illumination (e.g., downlights, flood lights,
`spotlights and other general residential or commercial illumi-
`nation products). Accordingly, there is an ongoing need to
`provide lighting that is more energy-efficient.
`Solid state light emitters (e.g., light emitting diodes) are
`receiving much attention due to their energy efficiency. It is
`well known that incandescent light bulbs are very energy-
`inefficient light sourcesiabout ninety percent ofthe electric-
`ity they consume is released as heat rather than light. Fluo-
`rescent light bulbs are more efficient than incandescent light
`bulbs (by a factor of about 10) but are still less efficient than
`solid state light emitters, such as light emitting diodes.
`In addition, as compared to the normal lifetimes of solid
`state light emitters, e.g., light emitting diodes, incandescent
`light bulbs have relatively short lifetimes, i.e., typically about
`750-1000 hours. In comparison, light emitting diodes, for
`example, have typical lifetimes between 50,000 and 70,000
`hours. Fluorescent bulbs generally have lifetimes (e.g.,
`10,000-20,000 hours) that are longer than those of incandes-
`cent lights, but they typically provide less favorable color
`reproduction. The typical lifetime of conventional fixtures is
`about 20 years, corresponding to a light-producing device
`usage of at least about 44,000 hours (based on usage of 6
`hours per day for 20 years). Where the light-producing device
`lifetime of the light emitter is less than the lifetime of the
`fixture, the need for periodic change-outs is presented. The
`impact of the need to replace light emitters is particularly
`pronounced where access is difficult (e.g., vaulted ceilings,
`bridges, high buildings, highway tunnels) and/or where
`change-out costs are extremely high.
`There are a number of challenges presented with using
`light emitting diodes in lighting devices. In many cases, addi-
`tional components are added to the lighting devices in order to
`address these challenges. Additional components tend to
`increase the weight of lighting devices, as well as the size of
`lighting devices. It would be desirable to provide a lighting
`device that comprises one or more solid state light emitters, in
`which such challenges are addressed and yet the lighting
`device is lightweight and/or can fit within the same or sub-
`stantially the same space that is provided for comparable
`conventional
`lighting devices (e.g.,
`lighting devices that
`include one or more incandescent light sources and/or one or
`more fluorescent light sources). The ability for the lighting
`device to be lightweight and/or to fit in a space that is similar
`to (or identical to) a space into which conventional devices
`can fit is important when retro -fitting a lighting device, as well
`when installing a lighting device in new construction (let
`alone when shipping it).
`One such challenge results from the fact that the emission
`spectrum of any particular light emitting diode is typically
`concentrated around a single wavelength (as dictated by the
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`
`light emitting diode’s composition and structure), which is
`desirable for some applications, but not desirable for others,
`(e.g., for providing general illumination, such an emission
`spectrum generally does not provide light that appears white,
`and/or provides a very low CR1). As a result, in many cases
`(e.g., to make devices that emit light perceived as white or
`near-white, or to make devices that emit light that is not
`highly saturated) it is necessary to employ light sources (e. g.,
`one or more solid state light emitters and optionally also one
`or more other types of light sources, e.g., additional light
`emitting diodes, luminescent materials, incandescent lights,
`etc.) that emit light of different colors. There are a variety of
`reasons that one or more solid state light emitters might cease
`emitting light and/or vary in their intensity of light emission,
`which can throw offthe balance of color output and cause the
`lighting device to emit light that is perceived as being of a
`color that differs from the desired color of light output. As a
`result, in many of such devices, one challenge that necessi-
`tates the inclusion ofadditional components, is that there may
`be a desire to provide additional circuitry that can adjust the
`current supplied to respective solid state light emitters (and/or
`other light emitters) in order to maintain the balance of color
`output among the light emitters that emit light of different
`colors in order to achieve the desired color output. Another
`such challenge is that there may be a desire to mix the light of
`different colors emitted from the different solid state light
`emitters by providing additional structure to assist in such
`mixing.
`One example of a reason that one or more solid state light
`emitters might vary in their intensity of light emission is
`temperature change (resulting, e.g., from change in ambient
`temperature and/or heating up of the solid state light emit-
`ters). Some types of solid state light emitters (e. g., solid state
`light emitters that emit light of different colors) experience
`differences in intensity of light emission (if supplied with the
`same current) at different temperatures, and frequently such
`changes in intensity occur to differing extents for emitters that
`emit light of different colors as temperature changes. For
`example, some light emitting diodes that emit red light have a
`very strong temperature dependence in at least some tempera-
`ture ranges (e.g., AllnGaP light emitting diodes can reduce in
`optical output by ~20% when heated up by ~40 degrees C.,
`that is, approximately —0.5% per degree C.; some blue light
`emitting lnGaN+YAGzCe light emitting diodes can reduce in
`optical output by about —0.15%/degree C.).
`Another example of a reason that one or more solid state
`light emitters might vary in their intensity of light emission is
`aging. Some solid state light emitters (e.g., solid state light
`emitters that emit
`light of different colors) experience
`decreases in intensity of light emission (if supplied with the
`same current) as they age, and frequently such decreases in
`intensity occur at differing rates.
`Another example of a reason that one or more solid state
`light emitters might vary in their intensity of light emission is
`damage to the solid state light emitter(s) and/or damage to
`circuitry that supplies current
`to the solid state light
`emitter(s).
`Another challenge presented in making a lighting device
`with light emitting diodes, that often necessitates the inclu-
`sion of additional components, is that the performance of
`many solid state light emitters may be reduced when they are
`subjected to elevated temperatures. For example, many light
`emitting diode light sources have average operating lifetimes
`of decades as opposed to just months or 1-2 years for many
`incandescent bulbs, but some light emitting diodes’ lifetimes
`can be significantly shortened if they are operated at elevated
`temperatures. A common manufacturer recommendation is
`
`Satco's Ex. 1011, Page 9
`
`Satco's Ex. 1011, Page 9
`
`

`

`US 8,777,449 B2
`
`3
`that the junction temperature of a light emitting diode should
`not exceed 85 degrees C. if a long lifetime is desired. There
`may be a desire to counteract such problems,
`in many
`instances, by providing additional structure (or structures) to
`provide a desired degree of heat dissipation.
`Another challenge presented in making a lighting device
`with light emitting diodes, that often necessitates the inclu-
`sion of additional components, arises from the relatively high
`light output from a relatively small area provided by solid
`state emitters. Such a concentration of light output may
`present challenges in providing solid state lighting systems
`for general illumination in that, in general, a large difference
`in brightness in a small area may be perceived as glare and
`may be distracting to occupants. In many instances, therefore,
`there is a desire to provide additional structure to assist in
`mixing the emitted light and/or creating the perception that
`the emitted light is output through a larger area.
`Another challenge presented in making a lighting device
`with light emitting diodes, that often necessitates the inclu-
`sion of additional components, is that light emitting diodes
`are typically run most effectively on low voltage DC current,
`while line voltage typically is much higher voltage AC cur-
`rent. As a result, there is often a desire to provide circuitry that
`converts line voltage, e. g., fromAC to DC and/or that reduces
`voltage.
`In addition, in some circumstances, there is a desire either
`to retrofit or install a lighting device in a circuit that has a
`conventional dimmer. Some dimmers operate based on sig-
`nals contained in the current supplied to the lighting device
`(for example, duty cycle of an AC signal, e.g., from a triac),
`for which additional circuitry is generally needed. An
`example of a lighting device that includes some or all ofthese
`various additional components, retrofits into many conven-
`tional recessed lighting housings and works with many con-
`ventional dimmers is the LR6 from Cree LED Lighting Solu-
`tions of Morrisville, NC. The LR6 is a 6 inch recessed
`downlight that provides 650 delivered lumens of light, con-
`sumes only 12 watts of electrical power and has a CRI of 92.
`The LR6 weighs slightly less than 1 kg.
`It would be desirable to be able to make lighting devices
`that include solid state light emitters in order to achieve high
`wall plug efficiency, while providing consistently good color
`quality, suitable brightness and good solid state light emitter
`lifetimes, in a lighting device that is of light weight (e.g., in
`comparison to other lighting devices that comprise solid state
`light emitters, for example, devices that comprise one or more
`solid state light emitters and that provide some or all of the
`features described herein).
`
`BRIEF SUMMARY OF THE INVENTIVE
`SUBJECT MATTER
`
`In some aspects, the present inventive subject matter pro-
`vides lighting devices (and lighting devices that can provide
`such features, e. g., in which high efficiency, consistently good
`output light color quality, good solid state light emitter life-
`time, suitable brightness and light weight are all provided.
`In some embodiments according to the present inventive
`subject matter, including some embodiments that include or
`do not include any of the features as discussed herein, (1) a
`single element performs two or more functions that are per-
`formed by plural elements in other lighting devices, (2) heat
`dissipation is provided to some degree by the trim element,
`and/or (3) fewer interfaces have to be crossed by heat on its
`way to being dissipated (e.g., in some embodiments, one or
`more solid state light emitters can be mounted on the trim
`element).
`
`4
`
`In accordance with an aspect of the present inventive sub-
`ject matter, there is provided a lighting device that comprises
`a trim element.
`
`In accordance with another aspect of the present inventive
`subject matter, there is provided a lighting device that com-
`prises a trim element and at least one solid state light emitter,
`and in which the lighting device weighs not greater than one
`kilogram (and in some cases not greater than about 2.4
`pounds, in some cases less, e.g., not greater than about 750
`grams or not greater than about 500 grams, or not greater than
`about 14, 12, 10 or 9 ounces).
`In some embodiments according to the present inventive
`subject matter, including some embodiments that include or
`do not include any of the features as discussed herein, if a
`current (e.g., AC or DC current) of about 12 watts (in some
`cases, 13 watts, 14 watts, 15 watts or less than 15 watts, e.g.,
`in some cases about 11 watts, 10 watts, 9 watts 8 watts (or
`less) is supplied to the lighting device, light having a bright-
`ness of at least about 500 lumens will be emitted by the
`lighting device (in some cases, at least about 400 lumens, 425
`lumens, 450 lumens, 475 lumens, 525 lumens, 550 lumens,
`575 lumens, 600 lumens, 700 lumens, 800 lumens, 900
`lumens, 1000 lumens or more, can be generated by supplying
`current of 12 watts, or any of such lumen outputs can be
`achieved by supplying current of 8 watts, 9 watts, 10 watts, 1 1
`watts, 13 watts, 14 watts, or 15 watts). In some embodiments,
`the lighting device has an aperture diameter of about 4.5
`inches or greater and delivers at least 575 lumens of light.
`In some embodiments according to the present inventive
`subject matter, including some embodiments that include or
`do not include any of the features as discussed herein, the
`lighting device emits white light.
`In some embodiments according to the present inventive
`subject matter, including some embodiments that include or
`do not include any of the features as discussed herein, the
`lighting device emits light at a shield angle of at least 15
`degrees.
`In some embodiments according to the present inventive
`subject matter, including some embodiments that include or
`do not include any of the features as discussed herein, if a
`current is supplied to the lighting device to cause the lighting
`device to emit light having a brightness of at least 5001umens
`(or at least about 400 lumens, 425 lumens, 450 lumens, 475
`lumens, 525 lumens, 550 lumens, 575 lumens, 600 lumens,
`7001umens, 8001umens, 9001umens, 10001umens or more),
`the temperature ofthe at least one solid state light emitter will
`be maintained at or below a 25,000 hour rated lifetime junc-
`tion temperature (and in some embodiments, at least a 35,000
`hour rated lifetime junction temperature or at least a 50,000
`hour rated lifetime junction temperature) for the solid state
`light emitter in a 25° C. surrounding environment (and, in
`some embodiments, in a 30° C. surrounding environment, or
`a 35° C. or higher surrounding environment).
`In some embodiments according to the present inventive
`subject matter, including some embodiments that include or
`do not include any of the features as discussed herein, the
`lighting device has a wall plug efficiency of at least 25 lumens
`per watt, in some cases at least 35 lumens per watt, in some
`cases at least 50 lumens per watt, in some cases at least 60
`lumens per watt, in some cases at least 70 lumens per watt,
`and in some cases at least 80 lumens per watt.
`In some embodiments according to the present inventive
`subject matter, including some embodiments that include or
`do not include any of the features as discussed herein, at least
`one of the at least one solid state light emitter is mounted on
`the trim element.
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`Satco's Ex. 1011, Page 10
`
`Satco's Ex. 1011, Page 10
`
`

`

`US 8,777,449 B2
`
`5
`In some embodiments according to the present inventive
`subject matter, including some embodiments that include or
`do not include any ofthe features as discussed herein, the trim
`element comprises at least a portion of a mixing chamber
`sub-assembly.
`The inventive subject matter may be more fully understood
`with reference to the accompanying drawings and the follow-
`ing detailed description of the inventive subject matter.
`
`BRIEF DESCRIPTION OF THE DRAWING
`FIGURES
`
`FIG. 1 is an exploded perspective view of a lighting device
`100.
`
`FIG. 2 is a perspective view of the lighting device 100.
`FIG. 3 is an exploded perspective view of a driver sub-
`assembly 101 of the lighting device 100.
`FIG. 4 is a perspective view ofthe driver sub-assembly 101.
`FIG. 5 is an exploded perspective view of a trim sub-
`assembly 102 of the lighting device 100.
`FIG. 6 is a perspective view of the trim sub-assembly 102.
`FIG. 7 is an exploded perspective view of a mixing cham-
`ber sub-assembly 103 of the lighting device 100.
`FIG. 8 is a perspective view of the mixing chamber sub-
`assembly 103.
`FIG. 9 depicts a light fixture 90 in accordance with the
`present inventive subject matter.
`
`DETAILED DESCRIPTION OF THE INVENTIVE
`SUBJECT MATTER
`
`The present inventive subject matter now will be described
`more fully hereinafter with reference to the accompanying
`drawings, in which embodiments of the inventive subject
`matter are shown. However, this inventive subject matter
`should not be construed as being limited to the embodiments
`set forth herein. Rather, these embodiments are provided so
`that this disclosure will be thorough and complete, and will
`fully convey the scope of the inventive subject matter to those
`skilled in the art. Like numbers refer to like elements through-
`out. As used herein the term “and/or” includes any and all
`combinations of one or more of the associated listed items.
`
`The terminology used herein is for the purpose of describ-
`ing particular embodiments only and is not intended to be
`limiting of the inventive subject matter. As used herein, the
`singular forms “a”, “an” and “the” are intended to include the
`plural forms as well, unless the context clearly indicates oth-
`erwise. It will be further understood that the terms “com-
`
`prises” and/or “comprising,” when used in this specification,
`specify the presence of stated features, integers, steps, opera-
`tions, elements, and/or components, but do not preclude the
`presence or addition of one or more other features, integers,
`steps, operations, elements, components, and/or groups
`thereof.
`
`When an element such as a layer, region or substrate is
`referred to herein as being “on”, being mounted “on” or
`extending “onto” another element, it can be directly on or
`extend directly onto the other element or intervening ele-
`ments may also be present. In contrast, when an element is
`referred to herein as being “directly on” or extending
`“directly onto” another element, there are no intervening
`elements present. Also, when an element is referred to herein
`as being “connected” or “coupled” to another element, it can
`be directly connected or coupled to the other element or
`intervening elements may be present. In contrast, when an
`element is referred to herein as being “directly connected” or
`“directly coupled” to another element, there are no interven-
`
`6
`ing elements present. In addition, a statement that a first
`element is “on” a second element is synonymous with a
`statement that the second element is “on” the first element.
`
`5
`
`The expression “in contact wit ”, as used herein, means
`that the first structure that is in contact with a second structure
`is in direct contact with the second structure or is in indirect
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`contact with the second structure. The expression “in indirect
`contact wit ” means that the first structure is not in direct
`
`contact with the second structure, but that there are a plurality
`of structures (including the first and second structures), and
`each of the plurality of structures is in direct contact with at
`least one other of the plurality of structures (e. g., the first and
`second structures are in a stack and are separated by one or
`more intervening layers). The expression “direct contact”, as
`used in the present specification, means that the first structure
`which is “in direct contact” with a second structure is touch-
`
`ing the second structure and there are no intervening struc-
`tures between the first and second structures at least at some
`location.
`
`A statement herein that two components in a device are
`“electrically connected,” means that there are no components
`electrically between the components that affect the function
`or functions provided by the device. For example, two com-
`ponents can be referred to as being electrically connected,
`even though they may have a small resistor between them
`which does not materially affect the function or functions
`provided by the device (indeed, a wire connecting two com-
`ponents can be thought of as a small resistor); likewi