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`US007993034B2
`
`c12) United States Patent
`Wegner
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 7 ,993,034 B2
`Aug. 9, 2011
`
`(54) REFLECTOR HAVING INFLECTION POINT
`AND LED FIXTURE INCLUDING SUCH
`REFLECTOR
`
`(75)
`
`Inventor: Scott David Wegner, Peachtree City,
`GA(US)
`
`(73) Assignee: Cooper Technologies Company,
`Houston, TX (US)
`
`( *) Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 62 days.
`
`(21) Appl. No.: 12/235,127
`
`(22) Filed:
`
`Sep.22,2008
`
`(65)
`
`Prior Publication Data
`
`US 2009/0086481 Al
`
`Apr. 2, 2009
`
`Related U.S. Application Data
`
`(60) Provisional application No. 60/994,792, filed on Sep.
`21, 2007, provisional application No. 61/010,549,
`filed on Jan. 9, 2008, provisional application No.
`61/065,914, filed on Feb. 15, 2008, provisional
`application No. 61/090,391, filed on Aug. 20, 2008.
`
`(51)
`
`Int. Cl.
`F21V 7109
`(2006.01)
`F21V 7120
`(2006.01)
`(52) U.S. Cl. ................... 362/296.05; 362/304; 362/347;
`362/350
`(58) Field of Classification Search ............. 362/296.01,
`362/304, 310, 296.05-296.09, 347, 348,
`362/350, 364-366
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
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`
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`OTHER PUBLICATIONS
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`
`(Continued)
`
`Ismael Negron
`Primary Examiner -
`(74) Attorney, Agent, or Firm - King & Spalding, LLP
`
`(57)
`
`ABSTRACT
`
`A recessed light fixture includes an LED light source and a
`reflector extending 360 degrees around a center line of light
`output from the light source. A cross-sectional geometry of
`the reflector includes a bell-shaped curve with two radii of
`curvature that join together at an inflection point. One of the
`radii defines a top portion of the curve, which is disposed
`above the inflection point and reflects light in a concentrated
`manner to achieve desired light at higher angles. The other
`radii defines a bottom portion of the curve, which is disposed
`below the inflection point and is more diverging than the top
`portion.
`
`16 Claims, 12 Drawing Sheets
`(1 of 12 Drawing Sheet(s) Filed in Color)
`
`345
`
`PETITIONERS, Ex. 1015
`
`

`

`US 7,993,034 B2
`Page 2
`
`.................. 362/147
`
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`
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`2003/0102810 Al*
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`
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`412010 Czech et al.
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`
`OTHER PUBLICATIONS
`
`U.S. Appl. No. 12/235,116, Tickner et al.
`U.S. Appl. No. 12/235,141, Wegner et al.
`U.S. Appl. No. 12/235,146, Thompson.
`Cree LED Lighting Product Description; 6 Recessed downlight;
`LR6; Jul. 2009.
`Cree Press Release, "LED Lighting Fixtures Announces Its First
`LED-Based Recessed Down Light," Feb. 7, 2007.
`Cree Press Release, "Award Winning Custom Home Builder Chooses
`LED Lighting Fixtures," Mar. 20, 2007.
`Cree Press Release, "LED Lighting Fixtures Announces New Com(cid:173)
`mercial Opportunity for LR6 Downlight," May 3, 2007.
`Cree Press Release, "University of Arkansas to Install LED Lighting
`Fixture's Downlights," Jun. 25, 2007.
`Cree Press Release, "LED Lighting Fixtures, Inc. achieves unprec(cid:173)
`edented gain in light output from new luminaire," Apr. 26, 2006.
`Cree Press Release, Cree LR6 LED Light Wins Silver International
`Design Excellence Award (IDEA), Jul. 18, 2008.
`Lighting for Tomorrow 2007 Winners Announced; Sep. 11, 2007.
`* cited by examiner
`
`PETITIONERS, Ex. 1015
`
`

`

`U.S. Patent
`
`Aug. 9, 2011
`
`Sheet 1of12
`
`US 7,993,034 B2
`
`115
`
`FIG. 1
`
`, ,
`
`I
`
`'I
`
`120
`
`105
`
`I
`I
`I
`I
`I
`I
`I
`....... ··\_ ........ .,"
`~ ........... \- ....
`
`I
`
`,_ , , ,
`
`105
`
`110c
`
`FIG. 2
`
`PETITIONERS, Ex. 1015
`
`

`

`U.S. Patent
`
`Aug. 9, 2011
`
`Sheet 2of12
`
`US 7,993,034 B2
`
`345
`
`335c
`
`310
`
`320
`
`FIG. 3
`
`335c
`
`FIG. 4
`
`PETITIONERS, Ex. 1015
`
`

`

`U.S. Patent
`
`Aug. 9, 2011
`
`Sheet 3of12
`
`US 7,993,034 B2
`
`315
`
`345
`
`FIG. 5
`
`PETITIONERS, Ex. 1015
`
`

`

`U.S. Patent
`
`Aug. 9, 2011
`
`Sheet 4of12
`
`US 7,993,034 B2
`
`300
`
`340a
`
`340a
`
`325d 340
`
`FIG. 6
`
`320cb
`
`320cb
`
`320cb
`
`FIG. 7
`
`PETITIONERS, Ex. 1015
`
`

`

`345
`
`,.---"'
`
`300
`
`315
`
`,.-----/~
`
`~-'·
`
`330a
`
`-~~=~=~:~=~·1•
`f!i?·'·'
`
`~-
`
`340a
`
`FIG. 8
`
`~
`00
`•
`~
`~
`~
`
`~ = ~
`
`~
`~
`~v::i
`N
`
`0 ....
`....
`
`('D
`('D
`
`1J1 =(cid:173)
`.....
`Ul
`0 .....
`....
`N
`
`d
`rJl
`-....l
`\c
`
`\C w = w
`~ = N
`
`PETITIONERS, Ex. 1015
`
`

`

`U.S. Patent
`
`Aug. 9, 2011
`
`Sheet 6of12
`
`US 7,993,034 B2
`
`311b
`
`311b
`
`311b
`
`311
`
`311
`
`311
`
`311b
`
`311b
`
`311
`
`311
`
`311
`
`FIG. 9
`
`311
`
`311
`
`311
`
`311
`
`FIG. 10
`
`PETITIONERS, Ex. 1015
`
`

`

`U.S. Patent
`
`Aug. 9, 2011
`
`Sheet 7of12
`
`320b
`
`32Dbb ~
`
`US 7 ,993,034 B2
`
`FIG. 11
`
`320C
`
`1205C
`
`FIG. 12
`
`PETITIONERS, Ex. 1015
`
`

`

`U.S. Patent
`
`Aug. 9, 2011
`
`Sheet 8 of 12
`
`US 7,993,034 B2
`
`320ca
`
`FIG. 13
`
`PETITIONERS, Ex. 1015
`
`

`

`U.S. Patent
`
`Aug. 9, 2011
`
`Sheet 9of12
`
`US 7,993,034 B2
`
`1400
`
`METHOD FOR INSTALLING
`AN LED MODULE IN AN EXISTING,
`NON-LED FIXTURE
`
`RELEASE THE SOCKET FROM
`THE EXISTING FIXTURE
`
`1410
`NO
`- - - - - - - - - -<
`
`1415
`
`1420
`
`SCREW AN EDISON BASE
`ADAPTER INTO THE SOCKET
`
`1425
`
`PLUG WIRING FROM THE
`LED MODULE INTO THE
`EDISON BASE ADAPTER
`
`~1---------''-----~
`
`1430
`MOUNT THE EDISON BASE ADAPTER
`AND SOCKET TO A BRACKET ON
`THE LED MODULE
`
`1435
`SQUEEZE TORSION SPRINGS ON THE
`LED MODULE TOGETHER
`
`1450
`
`CUT WIRES IN THE EXISTING FIXTURE,
`REMOVING AN EDISON BASE FROM
`THE FIXTURE
`
`1455
`
`CUT WIRES ON AN EDISON BASE
`ADAPTER TO REMOVE AN EDISON
`SCREW-IN PLUG
`
`1460
`
`CONNECT THE WIRES FROM THE
`EDISON BASE ADAPTER TO THE
`EXISTING FIXTURE, AND PLUG WIRING
`FROM THE LED MODULE INTO THE
`EDISON BASE ADAPTER
`
`1440
`
`1445
`
`INSTALL BRACKET ENDS OF THE
`TORSION SPRINGS IN THE
`RECESSED HOUSING
`
`1465
`
`MOUNT THE EDISON BASE
`ADAPTER TO A BRACKET ON
`THE LED MODULE
`
`ROUTE WIRES INTO FIXTURE AND
`PUSH LED MODULE FLUSH
`TO CEILING SURFACE
`
`END
`
`FIG. 14
`
`PETITIONERS, Ex. 1015
`
`

`

`U.S. Patent
`
`Aug. 9, 2011
`
`Sheet 10 of 12
`
`US 7,993,034 B2
`
`1530 350
`
`1520c
`
`300
`
`FIG. 15
`
`1520b
`
`1520
`
`1520a
`
`FIG. 16
`
`PETITIONERS, Ex. 1015
`
`

`

`U.S. Patent
`
`Aug. 9, 2011
`
`Sheet 11 of 12
`
`US 7,993,034 B2
`
`330f
`330ba
`
`FIG. 17
`
`330bb
`
`330
`
`330d
`330bc~30cb
`
`330f
`
`FIG. 18
`
`PETITIONERS, Ex. 1015
`
`

`

`U.S. Patent
`
`Aug. 9, 2011
`
`Sheet 12 of 12
`
`US 7,993,034 B2
`
`1900f
`
`I
`
`7
`1 1900d
`~
`
`FIG. 19
`
`2010
`
`2010
`
`FIG. 20
`
`PETITIONERS, Ex. 1015
`
`

`

`US 7,993,034 B2
`
`1
`REFLECTOR HAVING INFLECTION POINT
`AND LED FIXTURE INCLUDING SUCH
`REFLECTOR
`
`RELATED APPLICATIONS
`
`2
`not fit in existing incandescent lamp sockets and generally
`require complex electrical and thermal management systems.
`Therefore, traditional recessed light fixtures have not used
`LED light sources. Accordingly, a need currently exists in the
`5 art for a recessed light fixture that uses an LED light source.
`
`This application claims priority under 35 U.S.C. §119 to
`U.S. Provisional Patent Application No. 60/994,792, titled
`"Light Emitting Diode Downlight Can Fixture," filed Sep. 21,
`2007, U.S. Provisional Patent Application No. 61/010,549,
`titled "Diverging Reflector for Light Emitting Diode or Small
`Light Source," filed Jan. 9, 2008, U.S. Provisional Patent
`Application No. 61/065,914, titled "Dimmable LED Driver,"
`filed Feb. 15, 2008, and U.S. Provisional Patent Application
`No. 61/090,391, titled "Light Emitting Diode Downlight Can 15
`Fixture," filed Aug. 20, 2008. In addition, this application is
`related to co-pending U.S. patent application Ser. No. 12/235,
`116, titled "Light Emitting Diode Recessed Light Fixture,"
`filed Sep. 22, 2008, U.S. patent application Ser. No. 12/235,
`146, titled "Thermal Management for Light Emitting Diode 20
`Fixture," filed Sep. 22, 2008, U.S. patent application Ser. No.
`12/235,141, titled "Optic Coupler for Light Emitting Diode
`Fixture," filed Sep. 22, 2008, and U.S. Design Patent Appli(cid:173)
`cation No. 29/305,946, titled "LED Light Fixture," filed Mar.
`31, 2008. The complete disclosure of each of the foregoing 25
`priority and related applications is hereby fully incorporated
`herein by reference.
`
`TECHNICAL FIELD
`
`The invention relates generally to recessed luminaires, and
`more particularly, to a light emitting diode downlight can
`fixture for a recessed luminaire.
`
`BACKGROUND
`
`A luminaire is a system for producing, controlling, and/or
`distributing light for illumination. For example, a luminaire
`can include a system that outputs or distributes light into an
`environment, thereby allowing certain items in that environ(cid:173)
`ment to be visible. Luminaires are often referred to as "light
`fixtures".
`A recessed light fixture is a light fixture that is installed in
`a hollow opening in a ceiling or other surface. A typical
`recessed light fixture includes hanger bars fastened to spaced(cid:173)
`apart ceiling supports or joists. A plaster frame extends
`between the hanger bars and includes an aperture configured
`to receive a lamp housing or "can" fixture.
`Traditional recessed light fixtures include a lamp socket
`coupled to the plaster frame and/or the can fixture. The lamp
`socket receives an incandescent lamp or compact fluorescent
`lamp ("CFL") discussed above. As is well known in the art,
`the traditional lamp screws into the lamp socket to complete
`an electrical connection between a power source and the
`lamp.
`Increasingly, lighting manufacturers are being driven to
`produce energy efficient alternatives to incandescent lamps.
`One such alternative was the CFL discussed above. CFLs fit
`in existing incandescent lamp sockets and generally use less
`power to emit the same amount of visible light as incandes(cid:173)
`cent lamps. However, CFLs include mercury, which compli(cid:173)
`cates disposal of the CFLs and raises environmental con(cid:173)
`cerns.
`Another mercury-free alternative to incandescent lamps is
`the light emitting diode ("LED"). LEDs are solid state light(cid:173)
`ing devices that have higher energy efficiency and longevity
`than both incandescent lamps and CFLs. However, LEDs do
`
`SUMMARY
`
`The invention provides a recessed light fixture with an LED
`10 light source. The light fixture includes a housing or "can"
`within which an LED module is mounted. The LED module
`includes a single LED package that generates all or substan(cid:173)
`tially all the light emitted by the recessed light fixture. For
`example, the LED package can include one or more LEDs
`mounted to a common substrate. Each LED is an LED die or
`LED element that is configured to be coupled to the substrate.
`The LEDs can be arranged in any of a number of different
`configurations. For example, the LEDs can be arranged in a
`round-shaped area having a diameter ofless than two inches
`or a rectangular-shaped area having a length ofless than two
`inches and a width ofless than two inches.
`The LED package can be thermally coupled to a heat sink
`configured to transfer heat from the LEDs. The heat sink can
`have any of a number of different configurations. For
`example, the heat sink can include a core member extending
`away from the LED package and fins extending from the core
`member. Each fin can include a curved, radial portion and/or
`a straight portion. For example, each fin can include a radial
`portion that extends from the core member, and a straight
`30 portion that further extends out from the radial portion. In this
`configuration, heat from the LEDs can be transferred along a
`path from the LEDs to the core member, from the core mem(cid:173)
`ber to the radial portions of the fins, from the radial portions
`of the fins to their corresponding straight portions, and from
`35 the corresponding straight portions to a surrounding environ(cid:173)
`ment. Heat also can be transferred by convection directly
`from the core member and/or the fins to one or more gaps
`between the fins. The LED package can be coupled directly to
`the core member or to another member disposed between the
`40 LED package and the core member.
`A reflector housing can be mounted substantially around
`the LED package. For example, the reflector housing can be
`coupled to the heat sink and/or the can. The reflector housing
`can be configured to receive a reflector and to serve as a
`45 secondary heat sink for the LED module. For example, the
`reflector housing can be at least partially composed of a
`conductive material for transmitting heat away from the LED
`package. The reflector can be composed of any material for
`reflecting, refracting, transmitting, or diffusing light from the
`50 LED package. For example, the reflector can comprise a
`specular, semi-specular, semi-diffuse, or diffuse finish, such
`as gloss white paint or diffuse white paint. The reflector can
`have any of a number of different configurations. For
`example, a cross-sectional profile of the reflector can have a
`55 substantially bell-shaped geometry that includes a smooth
`curve comprising an inflection point. Top and bottom portions
`of the curve are disposed on opposite sides of the inflection
`point. To meet a requirement of a top-down flash while also
`creating a smooth, blended light pattern, the bottom portion
`60 of the curve can be more diverging than the top portion of the
`curve.
`An optic coupler can be mounted to the reflector housing,
`for covering electrical connections at the substrate of the LED
`package and/or for guiding or reflecting light emitted by the
`65 LED package. For example, the optic coupler can include a
`member with a central channel that is aligned with one or
`more of the LEDs of the LED package such that the channel
`
`PETITIONERS, Ex. 1015
`
`

`

`US 7,993,034 B2
`
`3
`guides light emitted by the LEDs while portions of the mem(cid:173)
`ber around the channel cover the electrical connections at the
`substrate of the LED package. The optic coupler can have any
`of a number of different geometries that may or may not
`correspond to a configuration of the LED package. For
`example, depending on the sizes and locations of the electri(cid:173)
`cal connections at the substrate, the portion of the optic cou(cid:173)
`pler around the channel can have a substantially square, rect(cid:173)
`angular, rounded, conical, or frusto-conical shape.
`The LED module can be used in both new construction and 1 o
`retrofit applications. The retrofit applications can include
`placing the LED module in an existing LED or non-LED
`fixture. To accommodate installation in a non-LED fixture,
`the LED module can further include a member comprising a
`profile that substantially corresponds to an interior profile of
`a can of the non-LED fixture such that the member creates a
`junction box between the member and a top of the can when
`the LED module is mounted in the can. To install the LED
`module, a person can electrically couple an Edison base
`adapter to both the existing, non-LED fixture and the LED
`module. For example, a person can cut at least one wire to
`remove an Edison base from the existing fixture, cut at least
`one other wire to remove an Edison screw-in plug from the
`Edison base adapter, and connect together the cut wires to
`electrically couple the Edison base adapter and the existing
`fixture. Alternatively, a person can release a socket from the
`existing fixture and screw the Edison base adapter into the
`socket to electrically couple the Edison base adapter and the
`existing fixture. The junction box can house the Edison base
`adapter and at least a portion of the wires coupled thereto.
`These and other aspects, features and embodiments of the
`invention will become apparent to a person of ordinary skill in
`the art upon consideration of the following detailed descrip(cid:173)
`tion of illustrated embodiments exemplifying the best mode
`for carrying out the invention as presently perceived.
`
`4
`FIG. 9 is an elevational cross-sectional top view of a heat
`sink of the LED module of FIG. 3, in accordance with certain
`exemplary embodiments.
`FIG. 10 illustrates a thermal scan of the heat sink of the
`LED module of FIG. 3, in accordance with certain exemplary
`embodiments.
`FIG. 11 is a perspective side view of a reflector housing of
`the LED module of FIG. 3, in accordance with certain exem(cid:173)
`plary embodiments.
`FIG. 12 is a perspective side view of a reflector being
`inserted in the reflector housing of FIG. 11, in accordance
`with certain exemplary embodiments.
`FIG. 13 is a perspective side view of a trim ring aligned for
`installation with the reflector housing of FIG. 11, in accor-
`15 dance with certain exemplary embodiments.
`FIG. 14 is a flow chart diagram illustrating a method for
`installing the LED module of FIG. 3 in an existing, non-LED
`fixture, in accordance with certain exemplary embodiments.
`FIG. 15 is a perspective side view of the LED module of
`20 FIG. 3 connected to a socket of an existing, non-LED fixture
`via an Edison base adapter, in accordance with certain exem(cid:173)
`plary embodiments.
`FIG. 16 is an elevational side view of the Edison base
`adapter of FIG. 15, in accordance with certain exemplary
`25 embodiments.
`FIG. 17 is a perspective top view of an optic coupler of the
`LED module of FIG. 3, in accordance with certain exemplary
`embodiments.
`FIG.18 is a perspective bottom view of the optic coupler of
`30 FIG. 17, in accordance with certain exemplary embodiments.
`FIG. 19 is a perspective top view of an optic coupler of the
`LED module of FIG. 3, in accordance with certain alternative
`exemplary embodiments.
`FIG. 20 is an exaggerated depiction of a profile of the
`35 reflector, in accordance with certain exemplary embodi(cid:173)
`ments.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`DETAILED DESCRIPTION OF EXEMPLARY
`EMBODIMENTS
`
`For a more complete understanding of the present inven(cid:173)
`tion and the advantages thereof, reference is now made to the 40
`following description, in conjunction with the accompanying
`figures briefly described as follows. The patent or application
`file contains at least one drawing executed in color. Copies of
`this patent or patent application publication with color draw(cid:173)
`ing(s) will be provided by the Office upon request and pay- 45
`ment of the necessary fee.
`FIG. 1 is an elevational top view of hanger bars, a plaster
`frame, a can, and a junction box of a recessed lighting fixture,
`in accordance with certain exemplary embodiments.
`FIG. 2 is an elevational cross-sectional side view of the 50
`recessed lighting fixture of FIG. 1, in accordance with certain
`exemplary embodiments.
`FIG. 3 is an elevational side view of an LED module of a
`recessed lighting fixture, in accordance with certain exem(cid:173)
`plary embodiments.
`FIG. 4 is an elevational top view of the LED module ofFIG.
`3, in accordance with certain exemplary embodiments.
`FIG. 5 is an elevational cross-sectional side view of the
`LED module of FIG. 3, in accordance with certain exemplary
`embodiments.
`FIG. 6 is a perspective side view of the LED module of
`FIG. 3, in accordance with certain exemplary embodiments.
`FIG. 7 is an elevational bottom view of the LED module of
`FIG. 3, in accordance with certain exemplary embodiments.
`FIG. 8 is a perspective exploded side view of the LED 65
`module of FIG. 3, in accordance with certain exemplary
`embodiments.
`
`The following description of exemplary embodiments
`refers to the attached drawings, in which like numerals indi(cid:173)
`cate like elements throughout the several figures. FIG. 1 is an
`elevational top view of hanger bars 105, a plaster frame 110,
`a can-shaped receptacle for housing a light source (a "can")
`115, and a junction box 120 ofa recessed lighting fixture 100,
`according to certain exemplary embodiments. FIG. 2 is an
`elevational cross-sectional side view of the hanger bars 105,
`plaster frame 110, can 115, and junction box 120 of the
`recessed lighting fixture 100 of FIG. 1, in accordance with
`certain exemplary embodiments. With reference to FIGS. 1
`and 2, the hanger bars 105 are configured to be mounted
`between spaced supports or joists (not shown) within a ceiling
`(not shown). For example, ends of the hanger bars 105 can be
`55 fastened to vertical faces of the supports or joists by nailing or
`other means. In certain exemplary embodiments, the hanger
`bars 105 can include integral fasteners for attaching the
`hanger bars 105 to the supports or joists, substantially as
`described in co-pending U.S. patent application Ser. No.
`60 10/090,654, titled "Hanger Bar for Recessed Luminaires with
`Integral Nail," and U.S. patent application Ser. No. 12/122,
`945, titled "Hanger Bar for Recessed Luminaires with Inte(cid:173)
`gral Nail," the complete disclosures of which are hereby fully
`incorporated herein by reference.
`The distance between the supports or joists can vary to a
`considerable degree. Therefore,
`in certain exemplary
`embodiments, the hanger bars 105 can have adjustable
`
`PETITIONERS, Ex. 1015
`
`

`

`US 7,993,034 B2
`
`5
`6
`"white," incandescent light to a human observer. In certain
`lengths. Each hanger bar 105 includes two inter-fitting mem(cid:173)
`bers 105a and 105b that are configured to slide in a telescop(cid:173)
`exemplary embodiments, the emitted light includes substan(cid:173)
`ing manner to provide a desired length of the hanger bar 105.
`tially white light that seems slightly blue, green, red, yellow,
`A person of ordinary skill in the art having the benefit of the
`orange, or some other color or tint. In certain exemplary
`present disclosure will recognize that many other suitable 5
`embodiments, the light emitted from the LEDs in the LED
`means exist for providing adjustable length hanger bars 105.
`package 305 has a color temperature between 2500 and 5000
`For example, in certain alternative exemplary embodiments,
`degrees Kelvin.
`one or more of the hanger bars described in U.S. Pat. No.
`In certain exemplary embodiments, an optically transmis(cid:173)
`6,105,918, titled "Single Piece Adjustable Hanger Bar for
`sive or clear material (not shown) encapsulates at least a
`Lighting Fixtures," the complete disclosure of which is 10
`portion of the LED package 305 and/or each LED therein.
`hereby fully incorporated herein, may be utilized in the light(cid:173)
`This encapsulating material provides environmental protec(cid:173)
`ing fixture 100 of FIG. 1.
`tion while transmitting light from the LEDs. For example, the
`The plaster frame 110 extends between the hanger bars 105
`encapsulating material can include a conformal coating, a
`and includes a generally rectangular, flat plate llOa with
`silicone gel, a cured/curable polymer, an adhesive, or some
`upturned edges 11 Ob. For example, the flat plate 11 Oa can rest 15
`other material known to a person of ordinary skill in the art
`on a top surface of the ceiling. The junction box 120 is
`having the benefit of the present disclosure. In certain exem(cid:173)
`mounted to a top surface llOaa of the flat plate llOa. The
`plary embodiments, phosphors are coated onto or dispersed in
`junction box 120 is a box-shaped metallic container that
`the encapsulating material for creating white light. In certain
`typically includes insulated wiring terminals and knock-outs
`exemplary embodiments, the white light has a color tempera(cid:173)
`for connecting external wiring (not shown) to an LED driver 20
`ture between 2500 and 5000 degrees Kelvin.
`(not shown) disposed within the can 115 of the light fixture
`100 or elsewhere within the light fixture 100.
`In certain exemplary embodiments, the LED package 305
`In certain exemplary embodiments, the plaster frame 110
`includes one or more arrays of LEDs that are collectively
`includes a generally circular-shaped aperture llOc sized for
`configured to produce a lumen output from 1 lumen to 5000
`receiving at least a portion of the can 115 therethrough. The 25
`lumens in an area having less than two inches in diameter or
`can 115 typically includes a substantially dome-shaped mem(cid:173)
`in an area having less than two inches in length and less than
`ber configured to receive an LED module (not shown) that
`two inches in width. In certain exemplary embodiments, the
`LED package 305 is a CL-L220 package, CL-L230 package,
`includes at least one LED light source (not shown). The
`aperture 11 Oc provides an illumination pathway for the LED
`CL-L240 package, CL-L102 package, or CL-L190 package
`light source. A person of ordinary skill in the art having the 30
`manufactured by Citizen Electronics Co., Ltd. By using a
`benefit of the present disclosure will recognize that, in certain
`single, relatively compact LED package 305, the LED mod-
`alternative exemplary embodiments, the aperture llOc can
`ule 300 has one light source that produces a lumen output that
`have another, non-circular shape that corresponds to an outer
`is equivalent to a variety oflamp types, such as incandescent
`profile of the can 115.
`lamps, in a source that takes up a smaller volume within the
`fixture. Although illustrated in FIGS. 7 and 8 as including
`FIGS. 3-8 illustrate an exemplary LED module 300 of the 35
`LEDs arranged in a substantially square geometry, a person of
`recessed lighting fixture 100 of FIG. 1. The exemplary LED
`module 300 can be configured for installation within the can
`ordinary skill in the art having the benefit of the present
`disclosure will recognize that the LEDs can be arranged in
`115 of the lighting fixture 100 ofFIG.1. The LED module 300
`any geometry. For example, the LEDs can be arranged in
`includes an LED package 3 05 mounted to a heat sink 310. The
`LED package 305 may be mounted directly to the heat sink 40
`circular or rectangular geometries in certain alternative exem(cid:173)
`310 or with one or more other components mounted in-be(cid:173)
`plary embodiments.
`tween the LED package 305 and the heat sink 310.
`The LEDs in the LED package 305 are attached to the
`The LED package 305 includes one or more LEDs
`substrate 306 by one or more solder joints, plugs, epoxy or
`mounted to a common substrate 306. The substrate 306
`bonding lines, and/or other means for mounting an electrical/
`includes one or more sheets of ceramic, metal, laminate,
`45 optical device on a surface. Similarly, the substrate 306 is
`circuit board, mylar, or another material. Each LED includes
`mounted to a bottom surface 310a of the heat sink 310 by one
`a chip of semi-conductive material that is treated to create a
`or more solder joints, plugs, epoxy or bonding lines, and/or
`positive-negative ("p-n") junction. When the LED package
`other means for mounting an electrical/optical device on a
`305 is electrically coupled to a power source, such as a driver
`surface. For example, the substrate 306 can be mounted to the
`315, current flows from the positive side to the negative side
`50 heat sink 310 by a two-part arctic silver epoxy.
`of each junction, causing charge carriers to release energy in
`The substrate 306 is electrically connected to support cir(cid:173)
`the form of incoherent light.
`cuitry (not shown) and/or the driver 315 for supplying elec(cid:173)
`The wavelength or color of the emitted light depends on the
`trical power and control to the LED package 305. For
`materials used to make the LED package 305. For example, a
`example, one or more wires (not shown) can couple opposite
`blue or ultraviolet LED can include gallium nitride ("GaN") 55 ends of the substrate 306 to the driver 315, thereby complet(cid:173)
`or indium gallium nitride ("InGaN"), a red LED can include
`ing a circuit between the driver 315, substrate 306, and LEDs.
`aluminum gallium arsenide ("AlGaAs"), and a green LED
`In certain exemplary embodiments, the driver 315 is config(cid:173)
`ured to separately control one or more portions of the LEDs to
`can include aluminum gallium phosphide ("AlGaP"). Each of
`adjust light color or intensity.
`the LEDs in the LED package 305 can produce the same or a
`distinct color oflight. For example, the LED package 305 can 60
`As a byproduct of converting electricity into light, LEDs
`include one or more white LED's and one or more non-white
`generate a substantial amount of heat that raises the operating
`LEDs, such as red, yellow, amber, or blue LEDs, for adjusting
`temperature of the LEDs if allowed to accumulate. This can
`the color temperature output of the light emitted from the
`result in efficiency degradation and premature failure of the
`fixture 100. A yellow or multi-chromatic phosphor may coat
`LEDs. The heat sink 310 is configured to manage heat output
`orotherwise be used in a blue or ultraviolet LED to create blue
`65 by the LEDs in the LED package 305. In particular, the heat
`sink 310 is configured to conduct heat away from the LEDs
`and red-shifted light that essentially matches blackbody
`radiation. The emitted light approximates or emulates
`even when the lighting fixture 100 is installed in an insulated
`
`PETITIONERS, Ex. 1015
`
`

`

`US 7,993,034 B2
`
`7
`ceiling environment. The heat sink 310 is composed of any
`material configured to conduct and/or convect heat, such as
`die cast metal.
`FIG. 9 is an elevational cross-sectional top view of the
`exemplary heat sink 310. FIG. 10 illustrates a thermal scan of 5
`the exemplary heat sink 310 in operation. With reference to
`FIGS. 3-10, the bottom surface 310a of the heat sink 310
`includes a substantially round member 310b with a protrud(cid:173)
`ing center member 310c on which the LED package 305 is
`mounted. In certain exemplary embodiments, the center 10
`member 31 Oc includes two notches 3 lOd that provide a path(cid:173)
`way for