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

`

`US 8,777,449 B2
`(10) Patent No.:
`a2) United States Patent
`Van De Venetal.
`(45) Date of Patent:
`Jul, 15, 2014
`
`
`US008777449B2
`
`(75)
`
`(54) LIGHTING DEVICES COMPRISING SOLID
`STATE LIGHT EMITTERS
`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 ofthis
`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
`
`aealan A
`’
`7
`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
`
`°Hono wer
`TO.
`4/1990 Coulter, Jr.
`8/1992 Kano
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`12/1992 Choi et al.
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`. rang
`(Continued)
`
`CN
`EP
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`FOREIGN PATENT DOCUMENTS
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`4/2008
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`1/2008
`
`.
`(Continued)
`OTHER PUBLICATIONS
`
`(65)
`
`Prior Publication Data
`
`USS. Appl No. 29/344,219, filed Sep. 25, 2009, Van de Ven.
`
`US 2011/0075422 Al
`
`Mar. 31, 2011
`
`(Continued)
`
`(51)
`
`(2006.01)
`
`Int. Cl.
`F21S 4/00
`(52) U.S. CL.
`USPC.
`...... 362/249.02; 362/401 ; 362/407; 362/640;
`362/646
`
`(58) Field of Classification Search
`USPC. oe 362/340, 646, 650, 249.02, 401, 407
`See application file for complete searchhistory.
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`446.142 A
`D188,916 S
`D207,867 S
`3,560,728 A
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`
`Primary Examiner — Anabel Ton
`(74) Attorney, Agent, or Firm — Burr & Brown, PLLC
`
`ABSTRACT
`(57)
`A lighting device comprising a trim element, an electrical
`connectorandat 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 willemit white light ofat 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 elementthat conducts heat away
`:
`:
`:
`.
`from at least onesolid state light emitter and dissipatesat least
`someofthe 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
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`Satco's Ex. 1011, Page 2
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`

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`Satco's Ex. 1011, Page 3
`
`Satco's Ex. 1011, Page 3
`
`

`

`U.S. Patent
`
`Jul. 15, 2014
`
`Sheet 1 of 5
`
`US 8,777,449 B2
`
`
`
`Satco's Ex. 1011, Page 4
`
`Satco's Ex. 1011, Page 4
`
`

`

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

`

`U.S. Patent
`
`Jul. 15, 2014
`
`Sheet 3 of 5
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`US 8,777,449 B2
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`
`
`Satco's Ex. 1011, Page 6
`
`Satco's Ex. 1011, Page 6
`
`

`

`U.S. Patent
`
`Jul. 15, 2014
`
`Sheet 4 of 5
`
`US 8,777,449 B2
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`
`
`Satco's Ex. 1011, Page 7
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`Satco's Ex. 1011, Page 7
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`

`

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

`

`US 8,777,449 B2
`
`1
`LIGHTING DEVICES COMPRISING SOLID
`STATE LIGHT EMITTERS
`
`FIELD OF THE INVENTIVE SUBJECT MATTER
`
`Thepresent inventive subject matter is directed to lighting
`devices. In someaspects, the present inventive subject matter
`is directedto 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 systemsthat 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
`whichis 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 muchattention due to their energy efficiency. It is
`well knownthat incandescent light bulbs are very energy-
`inefficient light sources—aboutninety percentoftheelectric-
`ity they consumeis released as heat rather than light. Fluo-
`rescentlight bulbs are moreefficient than incandescentlight
`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 normallifetimes of solid
`state light emitters, e.g., light emitting diodes, incandescent
`light bulbs haverelatively 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 fixturesis
`about 20 years, corresponding to a light-producing device
`usage of at least about 44,000 hours (based on usage of 6
`hoursper 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 accessis 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 addedto 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 solidstate 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 incandescentlight sources and/or one or
`more fluorescent light sources). The ability for the lighting
`device to be lightweight and/orto fit in a space that is similar
`to (or identical to) a space into which conventional devices
`can fit is important whenretro-fitting a lighting device, as well
`when installing a lighting device in new construction (let
`alone when shippingit).
`Onesuch 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 CRI). Asa 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 employlight sources(e.g.,
`one or moresolid 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
`reasonsthat one or moresolidstate 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 challengeis 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 moresolid 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). Sometypesofsolid state light emitters (e.g., solid state
`light emitters that emit light of different colors) experience
`differencesin intensity of light emission (if supplied with the
`samecurrent) at different temperatures, and frequently such
`changesin intensity occur to differing extents for emitters that
`emit light of different colors as temperature changes. For
`example, somelight emitting diodes that emit red light have a
`very strong temperature dependencein 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 InGaN+YAG:Celight emitting diodes can reduce in
`optical output by about -0.15%/degree C.).
`Another example of a reason that one or moresolid state
`light emitters might vary in their intensity of light emission is
`aging. Somesolid 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 occurat differing rates.
`Another example of a reason that one or moresolid 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
`manysolid state light emitters may be reduced whenthey are
`subjected to elevated temperatures. For example, manylight
`emitting diode light sources have average operating lifetimes
`of decades as opposed to just months or 1-2 years for many
`incandescent bulbs, but somelight 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
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`Satco's Ex. 1011, Page 9
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`US 8,777,449 B2
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`4
`In accordance with an aspect of the present inventive sub-
`ject matter, there is provided a lighting device that comprises
`a trim element.
`
`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 (orstructures) to
`In accordance with another aspectof the present inventive
`provide a desired degree of heat dissipation.
`subject matter, there is provided a lighting device that com-
`Another challenge presented in making a lighting device
`prises a trim elementandatleast one solidstate light emitter,
`with light emitting diodes, that often necessitates the inclu-
`and in which the lighting device weighs not greater than one
`sion of additional components, arises from therelatively high
`kilogram (and in some cases not greater than about 2.4
`light output from a relatively small area provided by solid
`pounds, in somecasesless, e.g., not greater than about 750
`state emitters. Such a concentration of light output may
`gramsornot greater than about 500 grams, ornot greater than
`present challenges in providing solid state lighting systems
`about 14, 12, 10 or 9 ounces).
`for general illuminationin that, in general, a large difference
`In some embodiments according to the present inventive
`in brightness in a small area may be perceived as glare and
`subject matter, including some embodiments that include or
`maybedistracting to occupants. In many instances, therefore,
`do not include any of the features as discussed herein,if a
`there is a desire to provide additional structure to assist in
`current (e.g., AC or DC current) of about 12 watts (in some
`mixing the emitted light and/or creating the perception that
`cases, 13 watts, 14 watts, 15 watts or less than 15 watts, e.g.,
`the emitted light is output through a largerarea.
`in some cases about 11 watts, 10 watts, 9 watts 8 watts (or
`Another challenge presented in making a lighting device
`less) is supplied to the lighting device, light having a bright-
`with light emitting diodes, that often necessitates the inclu-
`ness of at least about 500 lumens will be emitted by the
`sion of additional components, is that light emitting diodes
`lighting device (in somecases, at least about 400 lumens, 425
`are typically run most effectively on low voltage DC current,
`lumens, 450 lumens, 475 lumens, 525 lumens, 550 lumens,
`while line voltage typically is much higher voltage AC cur-
`575 lumens, 600 lumens, 700 lumens, 800 lumens, 900
`rent. Asa result, there is often a desire to provide circuitry that
`lumens, 1000 lumensor more, can be generated by supplying
`converts line voltage, e.g., from AC to DC and/orthat reduces
`current of 12 watts, or any of such lumen outputs can be
`voltage.
`achieved by supplying current of 8 watts, 9 watts, 10 watts, 11
`In addition, in somecircumstances, there is a desire either
`watts, 13 watts, 14 watts, or 15 watts). In some embodiments,
`to retrofit or install a lighting device in a circuit that has a
`the lighting device has an aperture diameter of about 4.5
`conventional dimmer. Some dimmers operate based on sig-
`inchesor greater and delivers at least 575 lumensoflight.
`nals contained in the current supplied to the lighting device
`In some embodiments according to the present inventive
`(for example, duty cycle of an AC signal, e.g., from a triac),
`subject matter, including some embodiments that include or
`for which additional circuitry is generally needed. An
`do not include any of the features as discussed herein, the
`example ofalighting device that includes someorall ofthese
`lighting device emits white light.
`various additional components, retrofits into many conven-
`In some embodiments according to the present inventive
`tional recessed lighting housings and works with many con-
`subject matter, including some embodiments that include or
`ventional dimmersis the LR6 from Cree LED Lighting Solu-
`do not include any of the features as discussed herein, the
`tions of Morrisville, N.C. The LR6 is a 6 inch recessed
`lighting device emits light at a shield angle of at least 15
`downlight that provides 650 delivered lumensoflight, con-
`degrees.
`sumes only 12 watts of electrical power and has a CRI of 92.
`In some embodiments according to the present inventive
`The LR6 weighsslightly less than 1 kg.
`subject matter, including some embodiments that include or
`Tt would be desirable to be able to make lighting devices
`do not include any of the features as discussed herein,if a
`that include solid state light emitters in order to achieve high
`current is supplied to the lighting device to cause thelighting
`wall plug efficiency, while providing consistently good color
`device to emit light having a brightness of at least 500 lumens
`quality, suitable brightness and goodsolid state light emitter
`(or at least about 400 lumens, 425 lumens, 450 lumens, 475
`lifetimes, in a lighting device that is of light weight (e.g., in
`lumens, 525 lumens, 550 lumens, 575 lumens, 600 lumens,
`comparisonto other lighting devices that comprisesolid state
`700 lumens, 800 lumens, 900 lumens, 1000 lumensor more),
`light emitters, for example, devices that comprise one or more
`the temperature ofthe at least onesolid state light emitter will
`solid state light emitters and that provide someorall of the
`be maintainedat or below a 25,000 hourrated lifetime junc-
`features described herein).
`tion temperature (and in some embodiments, at least a 35,000
`hourrated lifetime junction temperature or at least a 50,000
`hourrated 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 somecasesat least 35 lumensper watt, in some
`cases at least 50 lumensper watt, in some cases at least 60
`lumensper watt, in some cases at least 70 lumensper watt,
`and in somecasesat least 80 lumensper watt.
`In some embodiments according to the present inventive
`subject matter, including some embodiments that include or
`do not include any ofthe features as discussedherein,at least
`one ofthe at least one solid state light emitter is mounted on
`the trim element.
`
`In someaspects, 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 weightare all provided.
`In some embodiments according to the present inventive
`subject matter, including some embodimentsthat 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 byplural 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).
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`BRIEF SUMMARY OF THE INVENTIVE
`SUBJECT MATTER
`
`Satco's Ex. 1011, Page 10
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`Satco's Ex. 1011, Page 10
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`US 8,777,449 B2
`
`5
`In some embodiments according to the present inventive
`subject matter, including some embodimentsthat 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.
`Theinventive subject matter may be morefully understood
`with reference to the accompanying drawingsandthe follow-
`ing detailed description of the inventive subject matter.
`
`BRIEF DESCRIPTION OF THE DRAWING
`FIGURES
`
`FIG.1 is an explodedperspective view ofa lighting device
`100.
`
`FIG.2 is a perspective view ofthe lighting device 100.
`FIG. 3 is an exploded perspective view of a driver sub-
`assembly 101 of the lighting device 100.
`FIG.41s 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
`
`Thepresent 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 construedas 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 conveythe scopeofthe inventive subject matter to those
`skilled in the art. Like numbersrefer to like elements through-
`out. As used herein the term “and/or” includes any andall
`combinations of one or more of the associated listed items.
`
`The terminology used herein is for the purposeof 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 intendedto include the
`plural formsas 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 mayalso be present. In contrast, when an elementis
`referred to herein as being “directly on” or extending
`“directly onto” another element, there are no intervening
`elements present. Also, when an elementis 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
`elementis referred to herein as being “directly connected” or
`“directly coupled” to another element, there are no interven-
`
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`6
`ing elements present. In addition, a statement that a first
`element is “on” a second element is synonymous with a
`statementthat the second elementis “on”the first element.
`
`The expression “in contact with”, as used herein, means
`that the first structure that is in contact with a secondstructure
`is in direct contact with the second structureor is in indirect
`contact with the secondstructure. The expression “in indirect
`contact with” means that the first structure is not in direct
`contact with the secondstructure, butthat there are a plurality
`of structures (including the first and second structures), and
`each ofthe 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, meansthat the first structure
`which is “in direct contact” with a secondstructure is touch-
`
`ing the secondstructure and there are no intervening struc-
`tures between thefirst and secondstructures at least at some
`location.
`
`A statement herein that two components in a device are
`“electrically connected,’ meansthat there are no components
`electrically between the componentsthat 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 thoughtof as a small resistor); likewise, two
`components can be referred to as being electrically con-
`nected, even though they may have an additional electrical
`component between them whichallowsthe device to perform
`an additional function, while not materially affecting the
`function or functions provided by a device whichis identical
`except for not including the additional component; similarly,