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`Ex. 1009
`Ex. 1009
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`

`

`US007722227B2
`
`a2) United States Patent
`US 7,722,227 B2
`(10) Patent No.:
`
` Thangetal. (45) Date of Patent: May25, 2010
`
`
`(54) LIGHTING FIXTURE WITH RECESSED
`BAFFLE TRIM UNIT
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`9/1999 Doubecketal.
`4/2001 Nassim
`4/2004 Sevacket al.
`3/2007 Patti
`5/2007 Bynum etal.
`8/2007 Yang
`5/2008 Trottetal. we 362/311
`
`5,951,151 A
`6,217,189 BL
`6,719,438 B2
`7,186,008 B2
`7,220,029 B2
`7,255,461 B2
`2008/0112170 A1l*
`ot
`.
`cited by examiner
`Primary Examiner—Sandra L O’ Shea
`Assistant Examiner—Meghan K Dunwiddie
`(74) Attorney, Agent, or Firm—PaulY. Feng; Fulwider Patton
`LLP
`
`(57)
`
`ABSTRACT
`
`(75)
`
`Inventors: Kanghong Zhang, Torrance, CA (US);
`Daniel Dix, Irvine, CA (US)
`
`(73) Assignee: Cordelia Lighting, Inc., Rancho
`Dominguez, CA (US)
`
`( i ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21) Appl. No.: 12/249,683
`.
`Filed:
`
`Oct. 10, 2008
`
`(22)
`
`(65)
`
`Prior Publication Data
`US 2009/0097262 Al
`Apr. 16, 2009
`
`Related U.S. Application Data
`.
`.
`,
`(63) Continuation of application No. 29/295,943, filed on
`Oct. 10, 2007, now Pat. No. Des. 595,452.
`(60) Provisional application No. 60/979,068,filed on Oct.
`10, 2007.
`
`(51)
`
`A recessed lighting fixture providing illumination 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. Thefixture comprisesa baffle inte-
`grated with a low profile heat sink that is used to draw heat out
`of the fixture and communicate that heatto a trim ring of 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
`Int. Cl.
`combination support and grounding springs. One embodi-
`(2006.01)
`F21V 17/00
`mentof the light source is fixed in position while a second
`(52) U.S.C ceeeccccccccesseeee 362/364; 362/147; 362/294;
`embodimentis gimbal mountedfor aimingthe light produced
`362/362; 362/365; 362/373
`(58) Field of Classification Search ......... 362/147-148,_by the fixture.
`362/294, 362, 364-366, 368, 372-373
`See application file for complete search history.
`
`26 Claims, 20 Drawing Sheets
`
`Satco's Ex. 1009, Page 1
`
`Satco's Ex. 1009, Page 1
`
`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 1 of 20
`
`US 7,722,227 B2
`
`
`
`Satco's Ex. 1009, Page 2
`
`Satco's Ex. 1009, Page 2
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`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 2 of 20
`
`US 7,722,227 B2
`
`FIG.1A
`
`c
`
`Satco's Ex. 1009, Page 3
`
`Satco's Ex. 1009, Page 3
`
`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 3 of 20
`
`US 7,722,227 B2
`
`FIG.2
`
`Satco's Ex. 1009, Page 4
`
`Satco's Ex. 1009, Page 4
`
`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 4 of 20
`
`US 7,722,227 B2
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`
`
`Satco's Ex. 1009, Page 5
`
`Satco's Ex. 1009, Page 5
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`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 5 of 20
`
`US 7,722,227 B2
`
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`FIG.4
`
`Satco's Ex. 1009, Page 6
`
`Satco's Ex. 1009, Page 6
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`

`

`U.S. Patent
`
`May25, 2010
`
`Sheet 6 of 20
`
`US 7,722,227 B2
`
`UG
`
`V
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`Nac}WYy
`
`LL
`
`FIG. 5
`
`Satco's Ex. 1009, Page 7
`
`Satco's Ex. 1009, Page 7
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`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 7 of 20
`
`US 7,722,227 B2
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`52
`
`ue
`FIG.6
`>—— 14
`
`Satco's Ex. 1009, Page 8
`
`Satco's Ex. 1009, Page 8
`
`

`

`U.S. Patent
`
`May25, 2010
`
`Sheet 8 of 20
`
`US 7,722,227 B2
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`
`
`Satco's Ex. 1009, Page 9
`
`Satco's Ex. 1009, Page 9
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`

`

`U.S. Patent
`
`May25, 2010
`
`Sheet 9 of 20
`
`US 7,722,227 B2
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`
`
`Satco's Ex. 1009, Page 10
`
`Satco's Ex. 1009, Page 10
`
`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 10 of 20
`
`US 7,722,227 B2
`
`FIG.9
`
`Satco's Ex. 1009, Page 11
`
`Satco's Ex. 1009, Page 11
`
`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 11 of 20
`
`US 7,722,227 B2
`
`FIG.10
`
`Satco's Ex. 1009, Page 12
`
`Satco's Ex. 1009, Page 12
`
`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 12 of 20
`
`US 7,722,227 B2
`
`FIG.11
`
`Satco's Ex. 1009, Page 13
`
`Satco's Ex. 1009, Page 13
`
`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 13 of 20
`
`US 7,722,227 B2
`
`FIG.12
`
`Satco's Ex. 1009, Page 14
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`Satco's Ex. 1009, Page 14
`
`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 14 of 20
`
`US 7,722,227 B2
`
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`Satco's Ex. 1009, Page 15
`
`Satco's Ex. 1009, Page 15
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`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 15 of 20
`
`US 7,722,227 B2
`
`FIG.14
`
`130.
`
`Satco's Ex. 1009, Page 16
`
`Satco's Ex. 1009, Page 16
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`

`

`U.S. Patent
`
`May25, 2010
`
`Sheet 16 of 20
`
`US 7,722,227 B2
`
`Of
`
`a
`
`Satco's Ex. 1009, Page 17
`
`Satco's Ex. 1009, Page 17
`
`
`

`

`U.S. Patent
`
`May25, 2010
`
`Sheet 17 of 20
`
`US 7,722,227 B2
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`Satco's Ex. 1009, Page 18
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`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 18 of 20
`
`US 7,722,227 B2
`
`FIG.17
`
`QQ
`
`Satco's Ex. 1009, Page 19
`
`Satco's Ex. 1009, Page 19
`
`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 19 of 20
`
`US 7,722,227 B2
`
`FIG.18
`
`Satco's Ex. 1009, Page 20
`
`Satco's Ex. 1009, Page 20
`
`

`

`U.S. Patent
`
`May 25, 2010
`
`Sheet 20 of 20
`
`US 7,722,227 B2
`
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`Satco's Ex. 1009, Page 21
`
`Satco's Ex. 1009, Page 21
`
`

`

`US 7,722,227 B2
`
`1
`LIGHTING FIXTURE WITH RECESSED
`BAFFLE TRIM UNIT
`
`CROSS-REFERENCES TO RELATED
`APPLICATIONS
`
`This application claims priority from U.S. Provisional
`Application No. 60/979,068, filed Oct. 10, 2007, and from
`USS. Design Application No. 29/295,943 filed Oct. 10, 2007,
`both of which are incorporated herein by reference in their
`entireties.
`
`BACKGROUND
`
`Thepresent invention relates generally to lighting fixtures
`and, moreparticularly, to a recessed lighting fixture that pro-
`vides improved heat dissipation and grounding.
`Recessed lighting fixtures are well knownin theart. 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, sometrim portions are visible as well as the
`light sources. An opening is cut into the ceiling into which
`mostofthe light fixture is mounted sothat 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 ofthe light fixture and conceal the
`hole cut into the ceiling. Typically, the trim piece is slightly
`below the planar surface ofthe ceiling.
`Such bezels or other types of trim pieces also include
`insulation located between the trim piece and the ceiling. In
`manycases, 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 manyother 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 sothat 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 andare 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 bythe 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-
`montoday,orlightfixtures 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 asa 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 movementofthe lightfixture for changing the aim ofthe
`light. In the second configuration, movement of the light
`
`35
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`40
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`45
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`50
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`55
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`60
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`2
`source to changeits 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.
`Gimbaledlighting 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 ofits 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
`touchthe light source whileit is in the “on” configuration;1.e.,
`while poweris 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, touchingit
`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 mountedintothe 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
`morelight 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 otherlight source or sources and provides the
`necessary electrical power to them for illumination.
`Various structures have been devisedfor 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 pathwayto the can sothat any electrical charge that
`maybuild up on the trim unit can be dissipated.
`Hence, thoseskilled in the art have recognizedthe 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 meansfor 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 atthe lightfixture, in particular
`at the part of the fixture morelikely to be touched by a person
`attempting to repair or aim the light source. A need has also
`been recognized for a positive mounting arrangementof the
`trim unitin the recessed housingsothat the trim unit is heldin
`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 andothers.
`
`SUMMARY OF THE INVENTION
`
`invention is
`the present
`Briefly and in general terms,
`directed to a recessed lighting fixture that allowsaesthetically
`pleasing illumination when the fixture is placed within a
`cavity of a planar surface, such as a ceiling, wall, or shower.
`A lowprofile 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.
`Satco's Ex. 1009, Page 22
`
`Satco's Ex. 1009, Page 22
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`

`

`US 7,722,227 B2
`
`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 innerside, 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 openingthe outer side of the
`surface, a light source that emits light, the light source located
`within the recessed housing and disposedso 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 drawsheat 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
`formedinto the baffle heat sink having a plurality of heat sink
`fins protruding outwardly. In another aspect, the baffle heat
`sink fins protrude radially outwardly andare 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 baffle/heat sink being low profile.
`In yet more detailed aspects, the recessed lighting fixture
`further comprises a second heatsink 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
`secondheat 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 powerto the light source with the second
`heat sink being mountedto the driver andto thelight source,
`the second heat sink configured to draw heat from the light
`source anddriver, the second heat sink connectedto the baffle.
`In other aspects, the recessed lighting fixture comprises a
`light sourcethatis fixed in position in relation to the trim ring
`and integrated baffie/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
`oneofthe trim ring,the housing, and the integrated baffle/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 interferencefit to thereby hold the trim unitin
`place in relation to the recessed housing and providean elec-
`trical pathway between the trim unit and the recessed hous-
`ing. The recessed housing comprises spring mounting open-
`ings for receiving the bent endsof the spring to thereby hold
`the trim unitin placein 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 eventthat the trim unit were
`to fall slightly from the recessed housing due to shock or
`vibration.
`
`10
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`25
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`30
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`35
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`40
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`45
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`50
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`60
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`65
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`4
`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 ofthe 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 endsof 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 adjustmentof elevational aim of the light source with-
`out having to removethe 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 adjacentthe innerside, a lighting trim unit comprising
`a trim ring havinga 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 formedofan 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 comprisesa plu-
`rality of light emitting diodes. The light source is fixed in
`position and cannot be movedto changethe direction oflight
`emitted, and in anotheraspect, the light source is configured
`to be movablesothatthe direction oflight 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 madeto receive a recessedlight fixture at the inner
`side of the surface, showing the recessed housing of the
`fixture and, in partial cutaway, a schematic view ofa trim unit
`mounted within the housing with associated wiring;
`FIG. 1A is across-sectionalside 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 shownis a coiled
`torsion spring used to hold the trim unit in the housing;
`FIG.2 is a bottom perspective view ofa trim unit in accor-
`dance with aspects of the invention having a fixed position
`light source, showing the frusto-conically-shaped baffle with
`Satco's Ex. 1009, Page 23
`
`Satco's Ex. 1009, Page 23
`
`

`

`US 7,722,227 B2
`
`6
`5
`LEDlights, a driver to provide powerto the lights, a ground
`integrated heat sink, a plurality of LED lights forming a light
`strap, a light socket adapter, and electrically conductive
`source, a driver to provide appropriate power to the LED
`mounting springs;
`lights, a grounding strap connectedto the trim unit for attach-
`FIG.11 is a top perspective view of the gimbaled trim unit
`ment to the housing, a light socket adapter, and electrically
`shownin FIG. 10 showing moredetail of a gimbals mecha-
`conductive mounting springs usable to provide an electrical
`nism permitting the tilting of the trim unit to control the
`pathway betweenthe trim unit and the housing;
`elevational aim of the light source and rotation of the inte-
`FIG.3 is a top perspective view of the trim unit shown in
`grated baffle/heat sink device to control the azimuthal aim of
`FIG. 2 showing more detail of the heat sink integrated with
`the light source, also showing the electrically conductive
`the baffle which are also made formed with the trim ring as a
`mounting springs, the driver, and a second heatsink disposed
`single piece, the electrically conductive mounting springs, the
`between the driver and the LED lights to further draw heat
`driver, and a secondheatsink disposed betweenthe driver and
`away, the view also showingthe integrated baffle/heat sink in
`the LED lights to further draw heat away from the light
`contact with a trim ring to assist in drawing heat away from
`fixture, the view also showing how the integrated baffle/heat
`the light source;
`sink and trim ring formed as a single piece will assist in
`FIG. 12 is a further embodiment of a gimbaled trim unit
`drawing heat away from the light source to dissipate the heat
`that may both betilted for elevational aim control and swiv-
`on the outer side of the planar surface in which the recessed
`eled for azimuthal aim control, also demonstrating the
`fixture is mounted;
`optionaluse ofadriver in that the light emitting diodesofthis
`FIG.41s a further embodimentofatrim unit having a fixed
`embodiment do not require a driver, hence non has been
`position light source similar to FIGS. 2 and 3 in which the trim
`installed at the trim unit resulting in the figure more clearly
`ring and baffle with integrated heat sink are formedas a single
`showing the second heat sink at the end ofthe baffle;
`piece for conducting heat out through the trim ring, also
`FIG. 13 is an exploded view of the gimbaled trim unit of
`demonstrating the optional use of a driver in that the light
`FIGS. 10 and 11 showing in detail the gimbals mechanism
`emitting diodes of this embodimentdo not require a driver,
`that provides the ability to aim the light source throughtilting
`hence non has beeninstalled at the trim unit resulting in the
`and rotating, the LED light sources andlenses, the integrated
`figure more clearly showing the secondheatsink at the end of
`baffle/heat sink, the trim unit end cup with integrated heat
`the baffle, the second heat sink being formed asa single piece
`sink,the driver unit, and the electrically conductive mounting
`with the end cap ofthe baffle, the circuit board of the LED
`springs;
`lights being attachedto the inner surface of the end cap;
`FIG. 14 is a side view of the trim unit of FIGS. 10 and 11
`FIG. 5 is an exploded view ofthe trim unit of FIGS. 2 and
`showing a grounding strap for connection to a grounded
`3 showing in somedetail the lenses that are positioned over
`recessed housing, and a light socket adapter for engaging
`the LED lights,the single piece baffle/heat sink and trim ring
`mains powerfor use in powering the light source;
`combination, the second heat sink formedas part of the trim
`FIG.15 is a side view ofthe gimbaled trim unit ofFIGS. 10,
`unit end cap as a single piece, the drive unit, andthe electri-
`11, and 14 rotated ninety degrees from FIG. 14 showing more
`cally conductive mounting springs;
`clearly the attachmentof the electrically conductive mount-
`FIG. 6 is a side view of the trim unit of FIGS. 2 and 3
`ing springs;
`FIG. 16 isa 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 ofthetilted gimbaled trim
`unit of FIG. 16, the view being rotated at an angle from that
`shown in FIG. 16 to show the gimbaledtilt axis and the stop
`device for limiting the azimuthal aimingofthe 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, andthe 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.
`
`showing a grounding strap for connection to a grounded
`recessed housing or “can”such as that shown in FIG. 1, andan
`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 showingthe attachmentof
`the electrically conductive mounting springs to the trim unit,
`and also showingthe heat radiating fins formedas an integral
`part of the baffle;
`FIG.8 is a bottom view ofthe 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
`innerportion 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 attachmentofthe
`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 groundstrap, and the heatradiating fins located on
`the integrated baffle/heat sink;
`FIG. 10 is a bottom perspective view of a gimbaled trim
`unit that can betilted 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
`
`40
`
`45
`
`DETAILED DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`Referring now to the drawings in more detail in whichlike
`reference numerals refer to like or corresponding devices
`among the views, there is shown in FIGS. 1 and 1A a top
`perspective view anda side view, respectively, of a planar
`surface 30 having an opening 32 madeto receive a recessed
`lightfixture 34. Both figures show the recessed housing 36 or
`“can”ofthe light fixture and in cutawayviews,a trim unit 38
`Satco's Ex. 1009, Page 24
`
`Satco's Ex. 1009, Page 24
`
`

`

`US 7,722,227 B2
`
`7
`mounted within the housing. Power wires 40 provide power
`to a drive unit 42 that provides powerto 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 surfacefor the trim unit 38 so that
`it cannot be recessed entirely into the opening. In the case
`where the planar surface 30 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 47for dissipation which will result in cooling ofthe trim
`unit.
`Although shownas free standing in FIG. 1, the recessed
`housing 36 mayalso 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
`
`8
`sources 57 mounted within the baffle. The heat drawn from
`the light sources may betransferred from the trim unit 50 by
`thermaltransfer, 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 numeral58 is only pointingto a singlefin, itis 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 and3, andin otherfigures,
`aplurality 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-sectional shape, although other shapes can be used.
`Also, the heat sink fins are oriented radially about the longi-
`tudinal axis 59 of the integrated baffle/heat sink 54/56 and
`known mounting techniques for recessed housings have been
`extend in parallel with that longitudinal axis. The heat sink
`excluded for the sake of clarity in the drawings. Various
`fins 58 provide a muchlarger surface area for the dissipation
`additional mounting techniques are well knownto those of
`of heat conducted to the fins from the enclosedlight sources.
`skill in the art and no further details are provided herein. The
`
`provision ofelectrical energy in FIG. 1 is shownas two wires FIGS. 2 and3also show the use ofalight socket adapter 60
`from a conduit 48; however, as will be shown in otherfigures,
`to provide power for light source operation, although other
`electricity may be provided by other means, such as a light
`means mayalso be used. In this embodiment, a driver unit 62
`socket adapter.
`is wired 64 to the adapter and processesthereceivedelectrical
`The light source, such as light emitting diodes (“LEDs”),
`energy for use by the light sources 57. A groundstrap 66 is
`and/or the driver 42 that provides the necessary electrical
`also provided in this embodiment to provide an electrical
`energy to cause the LEDsto emitlight typically create heat.
`connection between the driver unit 62 and the housing 36
`Because they are located within the housing 36, the internal
`(FIG. 1), which is typically grounded to earth ground. A
`space 49 in the housing will typically increase in temperature.
`connector 68 is provided for easy connection and disconnec-
`In accordancewith an aspect ofthe invention,the trim unit 38
`tion of the drive unit to the light source 57. Additionally, a
`is configured to conduct heat from the heat-producing ele-
`second heat sink 70 (FIG. 3) is provided to draw heat away
`ments to the trim ring 44 that is located within a much larger
`from the drive unit and heat from the light source that exits at
`space; 1.e., the room 47. It can be seen in FIG. 1A thatthe trim
`the trim cup 72 located at the second end 73 of the baffle. In
`ring 44 located within the room 47is in contact with the other
`this embodiment, the trim ring 52 and integrated baffleand
`components of the trim unit 38 located within the recessed
`heat sink 54 are formed as a single piece of cast aluminum.
`housing 36. Those other componentsofthe trim unitare also
`The trim cup 72 and secondheat sink 70 are also formed as a
`in contact with heat that may exist in the internal space 49 of
`single piece of cast aluminum in this embodiment
`the housing 36, and are therefore equally capable of also
`Also forming a part of the trim unit 50 is a pair of torsion
`conducting thatheatto the trim ring for dissipation within the
`springs 80. Each spring includes a central coil 82, two elon-
`room.In this way, heat developed within the housing can be
`gated legs 84 and a bent end 86. In this case, the end is bentat
`better controlled. This enables the use of higher wattage light
`a