`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Ex. 1001
`Ex. 1001
`
`
`
`
`
`(12) United States Patent
`Boomgaarden et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 8,672,518 B2
`Mar. 18, 2014
`
`US008672518B2
`
`(54)
`
`(75)
`
`(73)
`
`(*)
`
`(21)
`(22)
`(65)
`
`(63)
`
`(60)
`
`(51)
`
`(52)
`
`(58)
`
`LOW PROFILE LIGHT AND ACCESSORY KIT
`FOR THE SAME
`
`(56)
`
`References Cited
`
`|U.S. PATENT DOCUMENTS
`
`Inventors: Mark Penley Boomgaarden, Satellite
`Beach, FL (US); Michael Balestracci,
`Satellite Beach, FL (US); Rick LeClair,
`Melbourne, FL (US); Wei Sun,
`Indialantic, FL (US); David Henderson,
`Indialantic, FL (US); Shane Sullivan,
`Indialantic, FL (US)
`Assignee: 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 44 days.
`Appl. No.: 13/476,388
`Filed:
`May 21, 2012
`
`Notice:
`
`Prior Publication Data
`|US 2012/0262921 A1
`Oct. 18, 2012
`
`Related U.S. Application Data
`Continuation-in-part of application No. 12/775,310,
`filed on May 6, 2010, now Pat. No. 8,201,968.
`Provisional application No. 61/248,665, filed on Oct.
`5, 2009.
`
`Int. Cl.
`F2IV 29/00
`U.S. CI.
`USPC ........... 362/294; 362/147; 362/148; 362/365;
`362/235; 362/249.02
`
`(2006.01)
`
`Field of Classification Search
`USPC .......... 362/147, 148, 150, 404, 294, 373, 365
`See application file for complete search history.
`
`6,431,728 B1* 8/2002 Fredericks et al. ........... 362/244
`6,719,446 B2 * 4/2004 Cao ....................
`... 362/547
`2008/0037255 A1* 2/2008 Wang ............................ 362/294
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`EP
`WO
`
`7/2008
`1950.491 A1
`2008 137732 A1 1 1/2008
`
`OTHER PUBLICATIONS
`
`EP International Search Report for Application No. 10174449.8;
`Mail Date: Dec. 14, 2010; 8 pgs.
`(Continued)
`Primary Examiner – Ali Alavi
`(74) Attorney, Agent, or Firm – Cantor Colburn LLP
`(57)
`ABSTRACT
`A 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. An acces
`sory 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 electri
`cally connected at the other end; and/or, a second pre-wired
`jumper including a pair of insulated electrical wires having a
`second plug-in connector electrically connected at one end
`and unconnected wire ends at the other end. The plug-in
`connector of the first pre-wired jumper and the second pre
`wired jumper are each configured to electrically engage with
`the plug-in connector of the electrical supply line.
`15 Claims, 17 Drawing Sheets
`
`
`
`145
`
`Satco's Ex. 1001, Page 1
`
`
`
`US 8,672,518 B2
`Page 2
`
`(56)
`
`References Cited
`
`OTHER PUBLICATIONS
`
`|U.S. PATENT DOCUMENTS
`-
`7/2008 Kim
`9/2008 Kim
`4/2009 Chou
`6/2009 Lan et al.
`
`2008/0170398 A1
`2008/0232116 A1
`2009/0086474 A1
`2009/014 1506 A1
`
`European Office Action for Application No. 10 174449.8. Mailed on
`Apr. 8, 2013. 4 pages.
`
`* cited by examiner
`
`Satco's Ex. 1001, Page 2
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 1 of 17
`
`US 8,672,518 B2
`
`
`
`Satco's Ex. 1001, Page 3
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 2 of 17
`
`US 8,672,518 B2
`
`
`
`Satco's Ex. 1001, Page 4
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 3 of 17
`
`US 8,672,518 B2
`
`
`
`Satco's Ex. 1001, Page 5
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 4 of 17
`
`US 8,672,518 B2
`
`
`
`-
`
`Satco's Ex. 1001, Page 6
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 5 of 17
`
`US 8,672,518 B2
`
`
`
`145
`
`FIG. I. I
`
`Satco's Ex. 1001, Page 7
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 6 of 17
`
`US 8,672,518 B2
`
`
`
`Satco's Ex. 1001, Page 8
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 7 of 17
`
`US 8,672,518 B2
`
`
`
`Satco's Ex. 1001, Page 9
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 8 of 17
`
`US 8,672,518 B2
`
`
`
`Satco's Ex. 1001, Page 10
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 9 of 17
`
`US 8,672,518 B2
`
`140'
`
`105
`
`FIG. 22
`
`
`
`FIG. 23
`
`Satco's Ex. 1001, Page 11
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 10 of 17
`
`US 8,672,518 B2
`
`
`
`Satco's Ex. 1001, Page 12
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 11 of 17
`
`US 8,672,518 B2
`
`
`
`ZZ (5) I HI
`
`Satco's Ex. 1001, Page 13
`
`
`
`
`
`
`
`
`
`Satco's Ex. 1001, Page 14
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`US 8,672,518 B2
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`s § s N
`
`09 (ADIAH
`
`Satco's Ex. 1001, Page 15
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 14 of 17
`
`US 8,672,518 B2
`
`
`
`FIG, 31
`
`505 TN
`
`560
`
`550
`
`551
`
`555
`
`FIG. 32
`
`Satco's Ex. 1001, Page 16
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 15 of 17
`
`US 8,672,518 B2
`
`
`
`Satco's Ex. 1001, Page 17
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 16 of 17
`
`US 8,672,518 B2
`
`
`
`300'
`
`Satco's Ex. 1001, Page 18
`
`
`
`U.S. Patent
`
`Mar. 18, 2014
`
`Sheet 17 of 17
`
`US 8,672,518 B2
`
`§
`
`2-
`§
`
`SS
`\c º
`S
`s
`R.
`
`*s-
`
`—sº-
`
`
`
`S
`ce,
`Q5
`s
`
`SS
`Fº
`&
`S
`s
`
`S.
`er,
`S
`§
`
`Satco's Ex. 1001, Page 19
`
`
`
`US 8,672,518 B2
`
`1
`LOW PROFILE LIGHT AND ACCESSORY KIT
`FOR THE SAME
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`This application is a continuation-in-part of U.S. applica
`tion Ser. No. 12/775,310, filed May 6, 2010, which claims the
`benefit of U.S. Provisional Application Ser. No. 61/248,665,
`filed Oct. 5, 2009, both of which are incorporated herein by
`reference in their entirety.
`
`BACKGROUND OF THE INVENTION
`
`2
`source having a plurality of light emitting diodes (LEDs). A
`power conditioner is disposed in electrical communication
`with the light source, the power conditioner being configured
`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 fit within at least one of:
`a nominally sized four-inch can light fixture; and, a nominally
`sized four-inch electrical junction box.
`An embodiment of the invention includes a luminaire hav
`ing a heat spreader, a heat sink thermally coupled to and
`disposed diametrically outboard of the heat spreader, an outer
`optic securely retained relative to at least one of the heat
`spreader and the heat sink, a light source disposed in thermal
`communication with the heat spreader, and an electrical sup
`ply line disposed in electrical communication with the light
`source. The heat spreader, heat sink and outer optic, in com
`bination, have an overall height H and an overall outside
`dimension D such that the ratio of H/D is equal to or less than
`0.25. The 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 linehaving 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;
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`The present disclosure relates generally to lighting, par
`ticularly to low profile lighting, and more particularly to low
`profile downlighting for retrofit applications.
`Light fixtures come in many shapes and sizes, with some
`being configured for new work installations while others are
`configured for old work installations. New work installations
`are not limited to as many constraints as old work installa
`tions, which must take into account the type of electrical
`fixture/enclosure or junction box existing behind a ceiling or
`wall panel material. With recessed ceiling lighting, sheet
`metalcan-type light fixtures 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 fixtures, but to
`also provide LED light fixtures that are suitable for old work
`applications, thereby enabling retrofit installations. One way
`of providing old work LED lighting is to configure an LED
`luminaire in such a manner as to utilize the volume of space
`available within an existing fixture (can-type fixture or junc
`tion box). However, such configurations typically result in
`unique designs for each type and size offixture. 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.
`
`BRIEF DESCRIPTION OF THE INVENTION
`
`45
`
`50
`
`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 defined by the heat spreader, the heat sink
`and the outer optic, is so dimensioned as to: cover an opening
`defined by a nominally sized four-inch can light fixture; and,
`cover an opening defined by a nominally sized four-inch
`electrical junction box.
`An embodiment of the invention includes a luminaire hav
`ing a heat spreader and a heat sink thermally coupled to and
`disposed diametrically outboard of the heat spreader. An
`outer optic is securely retained relative to at least one of the
`65
`heat spreader and the heat sink. A light source is disposed in
`thermal communication with the heat spreader, the light
`
`55
`
`60
`
`Satco's Ex. 1001, Page 20
`
`
`
`US 8,672,518 B2
`
`5
`
`Althoughthe following detailed description contains many
`specifics for the purposesof illustration, anyone of ordinary
`skill in the art will appreciate that many variations and alter-
`ations to the following details are within the scope of the
`invention. Accordingly,the following preferred embodiments
`ofthe invention are set forth without any loss of generality to,
`and without imposing limitations upon, the claimed inven-
`tion.
`An embodimentof the invention, as shown and described
`bythe variousfigures and accompanyingtext, 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 dimensionedforretrofit installation on stan-
`dard can-typelight fixtures used for recessedceiling lighting,
`and on standardceiling or wall junction boxes (J-boxes) used
`for ceiling or wall mounted lighting. The luminaire is also
`suitable for new workinstallation. Retrofit installation of the
`
`3
`4
`fitting into an engagement opening of a base, where both the
`FIG. 3 depicts a bottom view of the luminaire of FIG.1;
`FIG.4 depicts a side view of the luminaire of FIG.1;
`optic and the baseare part of the luminaire of FIG. 35.
`FIG.5depicts atop view ofa heat spreader assembly, a heat
`DETAILED DESCRIPTION OF THE INVENTION
`sink, and an outer optic in accordance with an embodimentof
`the invention;
`FIG. 6 depicts an isometric view of the heat spreader of
`FIG.5;
`FIG.7 depicts a partial isometric view of the heat sink of
`FIG.5;
`FIG. 8 depicts a top view of an alternative heat spreader
`assembly in accordance with an embodimentofthe invention;
`FIG. 9 depicts a top view of another alternative heat
`spreader assembly in accordance with an embodimentof the
`invention;
`FIG. 10 depicts a top view of yet another alternative heat
`spreader assembly in accordance with an embodimentof the
`invention;
`FIG. 11 depicts a bottom view of a heat spreader having a
`powerconditioner in accordance with an embodimentof the
`invention;
`FIG. 12 depicts a section view ofa luminaire in accordance
`with an embodimentofthe invention;
`FIG. 13 depicts a bottom view of a heat sink having
`recesses in accordance with an embodimentofthe invention;
`luminaire is accomplished utilizing an accessory kit that
`includes a pre-wired electrical jumper and mounting hard-
`FIGS. 14-18 depict isometric views of existing electrical
`ware. For installations involving a can-typefixture, the pre-
`can-typelight fixtures and electrical junction boxes for use in
`accordance with an embodimentof the invention;
`wired jumper includes a plug-in connectorelectrically con-
`nected to an Edison base via flexible insulated wires For
`FIGS. 19-21 depict a side view, top view and bottom view,
`installations involving a J-box, the pre-wiredjumperincludes
`respectively, of a luminaire similar but alternative to that of
`FIGS. 2-4, in accordance with an embodiment of the inven-
`a plug-in connectorelectrically connected to flexible insu-
`tion;
`lated wires that may or may notbe pre-stripped, or partially
`pre-stripped, on the opposing end.
`FIGS. 22-23 depict top and bottom views, respectively, of
`While embodiments of the invention described andillus-
`a heat spreader having an alternative power conditioner in
`accordance with an embodimentof the invention;
`trated herein depict an example luminaire for use as a down-
`FIG. 24-26 depictin isometric, top and side views, respec- light when disposed uponaceiling, it will be appreciatedthat
`
`tively, an alternative reflector to that depicted in FIGS. 10 and
`embodiments of the invention also encompassother lighting
`12;
`applications, such as a wall sconce for example.
`While embodiments of the invention described andillus-
`FIG. 27 depicts an exploded assembly view ofan alterna-
`tive luminaire in accordance with an embodiment of the
`trated herein depict example powerconditioners having visu-
`invention;
`ally defined sizes, it will be appreciated that embodiments of
`FIG. 28 depicts a side view of the luminaire of FIG. 27;
`the invention also encompass other power conditioners hav-
`FIG. 29 depicts a back view of the luminaire of FIG. 27;
`ing other sizes as long as the powerconditioners fall within
`the ambit of the invention disclosed herein.
`FIG. 30 depicts a cross section view of the luminaire of
`FIG.27, and moreparticularly depicts a cross section view of
`Referring to FIGS. 1-26 collectively, a luminaire 100
`the outer optic used in accordance with an embodimentof the
`includes a heat spreader 105, a heat sink 110 thermally
`invention;
`coupled to and disposed diametrically outboard of the heat
`FIG. 31 depicts an accessory kit in accordance with an
`spreader, an outer optic 115 securely retained relative to at
`embodimentof the invention;
`least one ofthe heat spreader 105 andthe heat sink 110, a light
`FIG. 32 depicts a formed spring included in the accessory
`source 120 disposed in thermal communication with the heat
`kit of FIG. 31;
`spreader 105, and an electrical supply line 125 disposed in
`FIG. 33 depicts a top-down view of a luminaire similar to
`electrical communication with the light source 120. To pro-
`that depicted in FIG. 27, andillustrative of an assembly of a
`vide for a low profile luminaire 100, the combination of the
`formed spring of FIG. 32 onto the luminaire;
`heat spreader 105, heat sink 110 and outer optic 115, have an
`FIG. 34 depicts a side view of the luminaire of FIG. 33;
`overall height H and an overall outside dimension D suchthat
`FIG. 35 depicts an exploded assembly view of the lumi-
`the ratio of H/D is equal to or less than 0.25. In an example
`naire of FIGS. 33 and 34;
`embodiment, height H is 1.5-inches, and outside dimension D
`is a diameter of 7-inches. Other dimensions for H and D are
`FIGS. 36A and 36B are side view depictions ofa first
`position (not engaged) and a second position (engaged),
`contemplated such that the combination of the heat spreader
`respectively, of an engagement tab of an optic snap-fitting
`105, heat sink 110 and outer optic 115, are configured and
`into an engagement opening of a base, where both the optic
`sized so as to; (i) cover an opening defined by an industry
`and the base are part of the luminaire of FIG. 35; and
`standard can-type light fixture having nominal sizes from
`three-inches to six-inches, such as a four-inch can or a six-
`FIGS. 37A and 37Bare plan view depictions of an alter-
`native arrangement to that depicted in FIGS. 36A and 36B,
`inch can for example (see FIGS. 14 and 15 for example); and,
`respectively, and more specifically are depictions of a first
`(11) cover an opening defined by an industry standardelectri-
`position (not engaged) and a second position (engaged),
`cal junction box having nominalsizes from three-inches to
`six-inches, such as a four-inch J-box or a six-inch J-box for
`respectively, of an engagementtab of an optic rotationally-
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`Satco's Ex. 1001, Page 21
`
`Satco's Ex. 1001, Page 21
`
`
`
`5
`example (see FIGS. 16 and 17 for example). Since can-type
`light fixtures and ceiling/wall mount junction boxes are
`designed for placement behind a ceiling or wall material, an
`example luminaire has the back surface of the heat spreader
`105 substantially planar with the back surface of the heat sink
`110, thereby permitting the luminaire 100 to sit substantially
`flush on the surface of the ceiling/wall material. Alternatively,
`small standoffs 200 (see FIG. 12 for example) may be used to
`promote air movement around the luminaire 100 for
`improved heat transfer to ambient air, which will be discussed
`further below. Securement of the luminaire 100 to a junction
`box may be accomplished by using suitable fasteners through
`appropriately spaced holes 150 (see FIG.8 for example), and
`securement of the luminaire 100 to a can-type fixture may be
`accomplished by using extension springs 205 fastened at one
`end to the heat spreader 105 (see FIG. 12 for example) and
`then hooked at the other end onto an interior detail of the
`can-type fixture.
`In an embodiment, the light source 120 includes a plurality
`of light emitting diodes (LEDs) (also herein referred to as an
`LED chip package), which is represented by the “checkered
`box” in FIGS. 5, 6 and 8-10. In application, the LED chip
`package generates heat at the junction of each LED die. To
`dissipate this heat, the LED chip package is disposed in
`suitable thermal communication with the heat spreader 105,
`which in an embodiment is made using aluminum, and the
`heat spreader is disposed in suitable thermal communication
`with the heat sink 110, which in an embodiment is also made
`using aluminum. To provide for suitable heat transfer from
`the heat spreader 105 to the heat sink 110, an embodiment
`employs a plurality of interconnecting threads 130, 135,
`which when tightened provide suitable surface area for heat
`transfer thereacross.
`Embodiments of luminaire 100 may be powered by DC
`voltage, while other embodiments may be powered by AC
`35
`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 of the heat spreader as the plurality of LEDs 120. In
`an embodiment, the power conditioner 140 is an electronic
`circuit board having electronic components configured to
`receive AC voltage from the electrical supply line 125 and to
`deliver DC voltage to the plurality of LEDs through appro
`priate electrical connections on either the front side or the
`back side of the heat spreader 105, with holes through the heat
`spreader or insulated electrical traces across the surface of the
`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 oran
`industry-standard nominally sized wall/ceiling junction box.
`
`55
`
`40
`
`45
`
`50
`
`60
`
`65
`
`US 8,672,518 B2
`
`10
`
`15
`
`20
`
`25
`
`30
`
`6
`Electrical connections between the power conditioner 165
`and the LEDs 120 are made via wires 170, which may be
`contained within the can fixture or junction box, or may be
`self-contained within the power conditioner housing. Electri
`cal wires 175 receive AC voltage via electrical connections
`within the can fixture or junction box.
`Referring now to FIGS. 8-10 and 12, an embodiment
`includes a reflector 145 disposed on the heat spreader 105 so
`as to cover the power conditioner 140, 160, while permitting
`the plurality of LEDs 120 to be visible (i.e., uncovered)
`through an aperture 215 of the reflector 145. Mounting holes
`155 in the reflector 145 align with mounting holes 150 in the
`heat spreader 105 for the purpose discussed above. The
`reflector 145 provides a reflective covering that hides power
`conditioner 140, 160 from view when viewed from the outer
`optic side of luminaire 100, while efficiently reflecting light
`from the LEDs 120 toward the outer optic 115. FIG. 12
`illustrates a section view through luminaire 100, showing a
`stepped configuration of the reflector 145, with the power
`conditioner 140,160 hidden inside a pocket (i.e., between the
`reflector 145 and the heat spreader 105), and with the LEDs
`120 visible through the aperture 215. In an embodiment, the
`outer optic is made using a glass-bead-impregnated-plastic
`material. In an embodiment the outer optic 115 is made of a
`suitable material to mask the presence of a pixilated light
`source 120 disposed at the center of the luminaire. In an
`embodiment, the half angle power of the luminaire, where the
`light intensity of the light source when viewed at the outer
`optic drops to 50% of its maximum intensity, is evident within
`a central diameter of the outer optic that is equal to or greater
`than 50% of the outer diameter of the outer optic.
`While FIG. 10 includes a reflector 145, it will be appreci
`ated that not all embodiments of the invention disclosed
`herein may employ a reflector 145, and that when a reflector
`145 is employed it may be used for certain optical preferences
`or to mask the electronics of the power conditioner 140,160.
`The reflective surface of the reflector 145 may be white,
`reflective polished metal, or metal film over plastic, for
`example, and may have surface detail for certain optical
`effects, such as color mixing or controlling light distribution
`and/or focusing for example.
`Referring to FIG. 12, an embodiment includes an inner
`optic 180 disposed over the plurality of LEDs 120. Employ
`ing an inner optic 180 not only provides protection to the
`LEDs 120 during installation of the luminaire 100 to a can
`fixture or junction box, but also offers another means of
`color-mixing and/or diffusing and/or color-temperature-ad
`justing the light output from the LEDs 120. In alternative
`embodiments, the inner optic 180 may be a standalone ele
`ment, or integrally formed with the reflector 145. In an
`embodiment, the LEDs 120 are encapsulated in a phosphor of
`a type suitable to produce a color temperature output of 2700
`deg-Kelvin. Other LEDs with or without phosphor encapsu
`lation may be used to produce other color temperatures as
`desired.
`Referring to FIG. 13, a back surface 185 of an embodiment
`of the heat sink 110 includes a first plurality of recesses 190
`oriented in a first direction, and a second plurality of recesses
`195 oriented in a second opposing direction, each recess of
`the first plurality and the second plurality having a shape that
`promotes localized air movement within the respective recess
`due at least in part to localized air temperature gradients and
`resulting localized air pressure gradients. Without being held
`to any particular theory, it is contemplated that a teardrop
`shaped recess 190, 195 each having a narrow end and an
`opposing broad end will generate localized air temperatures
`in the narrow end that are higher than localized air tempera
`
`Satco's Ex. 1001, Page 22
`
`
`
`US 8,672,518 B2
`
`7
`tures in the associated broad end, due to the difference of
`proximity ofthe surrounding “heated”walls ofthe associated
`recess. It is contemplated that the presence of such air tem-
`perature gradients, with resulting air pressure gradients,
`within a given recess 190, 195 will cause localized air move-
`ment within the associated recess, which in turn will enhance
`the overall heat transfer of the thermal system (the thermal
`system being the luminaire 100 as a whole). By alternating
`the orientation of the recesses 190, 195, such that the first
`plurality of recesses 190 and the second plurality of recesses
`195 are disposedin an alternating fashion aroundthe circum-
`ference ofthe back 185 ofthe heat sink 110, itis contemplated
`that further enhancements in heat transfer will be achieved,
`either by the packing density of recesses achievable by nest-
`ing one recess 190 adjacent the other 195, or by alternating the
`direction vectors of the localized air temperature/pressure
`gradients to enhance overall air movement. In an embodi-
`ment, the first plurality of recesses 190 have a first depth into
`the back surface of the heat sink, and the secondplurality of
`recesses 195 have a second depthinto the back surface of the
`heat sink, the first depth being different from the second
`depth, which is contemplated to further enhanceheattransfer.
`FIGS. 14-18 illustrate typical industry standard can-type
`light fixtures for recessed lighting (FIGS. 14-15), and typical
`industry standardelectrical junction boxes for ceiling or wall
`mounted lighting (FIGS. 16-18). Embodiments of the inven-
`tion are configured and sized for use with such fixtures of
`FIGS. 14-18.
`
`FIGS. 19-21 illustrate an alternative luminaire 100' having
`a different form factor (flat top, flat outer optic, smaller
`appearance) as compared to luminaire 100 of FIGS. 1-4.
`FIGS. 22-23 illustrate alternative electronic power condi-
`tioners 140', 165' having a different form factor as compared
`to power conditioners 140, 165 of FIGS. 8 and 11, respec-
`tively. All alternative embodiments disclosed herein, either
`explicitly, implicitly or equivalently, are considered within
`the scope of the invention.
`FIGS. 24-26 illustrate an alternative reflector 145' to that
`
`illustrated in FIGS. 10 and 12, with FIG. 24 depicting an
`isometric view, FIG. 25 depicting a top view, and FIG. 26
`depicting a side view ofalternative reflector 145’. As illus-
`trated, reflector 145' is conically-shaped with a centrally dis-
`posed aperture 215' for receiving the LED package 120. The
`cone of reflector 145' has a shallow form factor soasto fit in
`the low profile luminaire 100, 100'. Similar to reflector 145,
`the reflective surface of the reflector 145' may be white,
`reflective polished metal, or metal film over plastic, for
`example, and may have surface detail for certain optical
`effects, such as color mixing or controlling light distribution
`and/or focusing for example. As discussed herein with respect
`to reflector 145, alternative reflector 145' may or may not be
`employed as required to obtain the desired opticaleffects.
`From the foregoing, it will be appreciated that embodi-
`ments of the invention also include a luminaire 100 with a
`
`housing (collectively referred to by reference numerals 105,
`110 and 115) having a light unit (collectively referred to by
`reference numerals 105 and 115) and a trim unit 110, the light
`unit including a light source 120, the trim unit being mechani-
`cally separable from the light unit, a means for mechanically
`separating 130, 135 the trim unitfrom the light unit providing
`athermal conduction path therebetween, the light unit having
`sufficient thermal mass to spread heat generated by the light
`source to the means for mechanically separating,the trim unit
`having sufficient thermal mass to serve as a heat sink to
`dissipate heat generated by the light source.
`From the foregoing,it will also be appreciated that embodi-
`ments of the invention further include a luminaire 100 for
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`8
`retrofit connection to an installed lightfixture having a con-
`cealed in-use housing (see FIGS. 14-18 for example), the
`luminaire including a housing 105, 110, 115 having a light
`unit 105, 115 and a trim unit 110, the light unit comprising a
`light source 120, the trim unit being mechanically separable
`from the light unit, the trim unit defining a heat sinking
`thermal management element configured to dissipate heat
`generated bythe light source that is completely 100% exter-
`nal of the concealed in-use housing of the installed light
`fixture. As used herein, the term “concealed in-use housing”
`refers to a housing that is hidden behind a ceiling or a wall
`panel once the luminaire of the invention has been installed
`thereon.
`Reference is now made to FIG. 27, which depicts an
`exploded assembly view of an alternative luminaire 300 to
`that depicted in FIGS. 1-12. Similar to luminaire 100 (where
`like elements are numbered alike, and similar elements are
`named alike but numbered differently),
`luminaire 300
`includes a heat spreader 305 integrally formed with a heat
`sink 310 disposed diametrically outboard ofthe heat s