US008201968B2
`
`(12) United States Patent
`US 8,201,968 B2
`(10) Patent No.:
`Maxik et al.
`(45) Date of Patent:
`Jun. 19, 2012
`
`(54)
`
`(75)
`
`LOW PROFILE LIGHT
`
`Inventors: Fredric S. Maxik, Indialantic, FL (US);
`Raymond A. Reynolds, Satellite Beach,
`FL (US); Addy S. Widjaj a, Palm Bay,
`FL (US); Mark Penley Boomgaarden,
`Indian Harbour Beach, FL (US); Robert
`Rafael Soler, Cocoa Beach, FL (US);
`James L. Schellack, Cocoa Beach, FL
`(US)
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`2009/0086474 A1 *
`4/2009 Chou ............................ 362/230
`2009/0141506 A1*
`6/2009 Lan et a1.
`...................... 362/351
`
`EP
`WO
`
`FOREIGN PATENT DOCUMENTS
`1950491 A1
`7/2008
`2008137732 A1
`11/2008
`
`OTHER PUBLICATIONS
`
`(73)
`
`Assignee: Lighting Science Group Corporation,
`Satellite Beach, FL (US)
`
`EP International Search Report for Application No. 101744498;
`Dated Dec. 14, 2010.
`
`(*)
`
`Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 98 days.
`
`(21)
`
`Appl. No.: 12/775,310
`
`(22)
`
`Filed:
`
`May 6, 2010
`
`(65)
`
`(60)
`
`(51)
`
`(52)
`(58)
`
`Prior Publication Data
`
`US 2011/0080727 A1
`
`Apr. 7, 2011
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`Related U.S. Application Data
`
`Provisional application No. 61/248,665, filed on Oct.
`5, 2009.
`
`Int. Cl.
`
`(2006.01)
`F21V 1/00
`(2006.01)
`F21 V29/00
`U.S. Cl.
`......... 362/235; 362/294; 362/147; 362/373
`Field of Classification Search .................. 362/ 147,
`362/148, 149, 150, 404, 294, 373, 547, 365
`See application file for complete search history.
`
`* cited by examiner
`
`Primary Examiner 7 Ali Alavi
`(74) Attorney, Agent, or Firm 7 Cantor Colburn LLP
`
`(57)
`
`ABSTRACT
`
`A luminaire includes 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 combination, have an overall height H and an overall out-
`side dimension 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.
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`23 Claims, 13 Drawing Sheets
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`PETITIONERS, Ex. 1022
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`PETITIONERS, Ex. 1022
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`US. Patent
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`Jun. 19, 2012
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`Sheet 1 of 13
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`US 8,201,968 B2
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`FIG. I
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`US. Patent
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`Jun. 19, 2012
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`Sheet 2 of 13
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`US 8,201,968 B2
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`FIG. 3
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`US. Patent
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`Jun. 19, 2012
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`Sheet 3 of 13
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`US 8,201,968 B2
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`115
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`US. Patent
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`Jun. 19, 2012
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`Sheet 4 of 13
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`US 8,201,968 B2
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`FIG. 9
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`US. Patent
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`Jun. 19, 2012
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`Sheet 5 of 13
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`US 8,201,968 B2
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`145
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`FIG. I]
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`US. Patent
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`Jun. 19, 2012
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`Sheet 6 of 13
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`US 8,201,968 B2
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`WON
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`U.S. Patent
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`Jun. 19, 2012
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`Sheet 7 of 13
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`US 8,201,968 B2
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`QNGEN
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`nN65%
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`US. Patent
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`Jun. 19, 2012
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`Sheet 8 of 13
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`US. Patent
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`Jun. 19, 2012
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`Sheet 9 of 13
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`US 8,201,968 B2
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`140'
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`105
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`FIG. 22
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`FIG. 23
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`US. Patent
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`Jun. 19, 2012
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`Sheet 10 of 13
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`US 8,201,968 B2
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`145'“
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`145'
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`FIG. 25
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`215'
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`FIG. 26
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`U.S. Patent
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`Jun. 19, 2012
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`Sheet 11 0f 13
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`US 8,201,968 B2
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`RNENE
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`US. Patent
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`Jun. 19 2012
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`Sheet 12 of 13
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`FIG. 28
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`U.S. Patent
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`1
`LOW PROFILE LIGHT
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`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`This application claims the benefit of US. Provisional
`Application Ser. No. 61/248,665, filed Oct. 5, 2009, which is
`incorporated herein by reference in its entirety.
`
`BACKGROUND OF THE INVENTION
`
`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
`metal can-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 of fixture. 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 ofpossible 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
`
`An embodiment of the invention includes a luminaire hav-
`
`ing a heat spreader and a heat sink thermally coupled to and
`disposed diametrically outboard ofthe 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
`heat spreader and the heat sink. A light source is disposed in
`thermal communication with the heat spreader,
`the light
`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
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`US 8,201,968 B2
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`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 ofthe 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.
`
`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;
`FIG. 3 depicts a bottom view of the luminaire of FIG. 1;
`FIG. 4 depicts a side view of the luminaire of FIG. 1;
`FIG. 5 depicts a top view ofa heat spreader assembly, a heat
`sink, and an outer optic in accordance with an embodiment of
`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 embodiment ofthe invention;
`FIG. 9 depicts a top view of another alternative heat
`spreader assembly in accordance with an embodiment of the
`invention;
`FIG. 10 depicts a top view of yet another alternative heat
`spreader assembly in accordance with an embodiment of the
`invention;
`FIG. 11 depicts a bottom view of a heat spreader having a
`power conditioner in accordance with an embodiment of the
`invention;
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`US 8,201,968 B2
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`3
`FIG. 12 depicts a section view ofa luminaire in accordance
`with an embodiment of the invention;
`FIG. 13 depicts a bottom view of a heat sink having
`recesses in accordance with an embodiment of the invention;
`FIGS. 14-18 depict isometric views of existing electrical
`can-type light fixtures and electrical junction boxes for use in
`accordance with an embodiment of the invention;
`FIGS. 19-21 depict a side view, top view and bottom view,
`respectively, of a luminaire similar but alternative to that of
`FIGS. 2-4, in accordance with an embodiment of the inven-
`tion;
`FIGS. 22-23 depict top and bottom views, respectively, of
`a heat spreader having an alternative power conditioner in
`accordance with an embodiment of the invention;
`FIG. 24-26 depict in isometric, top and side views, respec-
`tively, an alternative reflector to that depicted in FIGS. 10 and
`12;
`FIG. 27 depicts an exploded assembly view of an alterna-
`tive luminaire in accordance with an embodiment of the
`invention;
`FIG. 28 depicts a side view of the luminaire of FIG. 27;
`FIG. 29 depicts a back view of the luminaire of FIG. 27;
`and
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`FIG. 30 depicts a cross section view of the luminaire of
`FIG. 27, and more particularly depicts a cross section view of 25
`the outer optic used in accordance with an embodiment of the
`invention.
`
`DETAILED DESCRIPTION OF THE INVENTION
`
`30
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`Although the following detailed description contains many
`specifics for the purposes of 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 35
`ofthe invention are set forth without any loss of generality to,
`and without imposing limitations upon, the claimed inven-
`tion.
`An embodiment of the invention, as shown and described
`by the various figures and accompanying text, provides a low 40
`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 dimensioned for retrofit installation on stan- 45
`dard can-type light fixtures used for recessed ceiling lighting,
`and on standard ceiling or wall junction boxes (J-boxes) used
`for ceiling or wall mounted lighting. The luminaire is also
`suitable for new work installation.
`While embodiments of the invention described and illus- 50
`
`trated herein depict an example luminaire for use as a down-
`light when disposed upon a ceiling, it will be appreciated that
`embodiments of the invention also encompass other lighting
`applications, such as a wall sconce for example.
`While embodiments of the invention described and illus- 55
`
`trated herein depict example power conditioners having visu-
`ally defined sizes, it will be appreciated that embodiments of
`the invention also encompass other power conditioners hav-
`ing other sizes as long as the power conditioners fall within
`the ambit of the invention disclosed herein.
`
`Referring to FIGS. 1-26 collectively, a luminaire 100
`includes a heat spreader 105, a heat sink 110 thermally
`coupled to and disposed diametrically outboard of the heat
`spreader, an outer optic 115 securely retained relative to at
`least one ofthe heat spreader 105 and the heat sink 110, a light
`source 120 disposed in thermal communication with the heat
`spreader 105, and an electrical supply line 125 disposed in
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`electrical communication with the light source 120. To pro-
`vide for a low profile luminaire 100, the combination of the
`heat spreader 105, heat sink 110 and outer optic 115, 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. In an example
`embodiment, height H is l .5 -inches, and outside dimension D
`is a diameter of 7-inches. Other dimensions for H and D are
`
`contemplated such that the combination of the heat spreader
`105, heat sink 110 and outer optic 115, are configured and
`sized so as to; (i) cover an opening defined by an industry
`standard can-type light fixture having nominal sizes from
`three-inches to six-inches (see FIGS. 14 and 15 for example);
`and, (ii) cover an opening defined by an industry standard
`electrical junction box having nominal sizes from three-
`inches to six-inches (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 ofthe
`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, which will be
`discussed further below. Securement of the luminaire 100 to
`
`a junction box may be accomplished by using suitable fas-
`teners 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
`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 ofthe heat spreader as the plurality ofLEDs 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 ofthe heat spreader 105, with holes through the heat
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`US 8,201,968 B2
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`5
`spreader or insulated electrical traces across the surface ofthe
`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 efliciency 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 or an
`industry-standard nominally sized wall/ceiling junction box.
`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 efliciently 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 ofthe luminaire, where the
`light intensity of the light source when viewed at the outer
`optic drops to 50% ofits 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
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`deg-Kelvin. Other LEDs with or without phosphor encapsu-
`lation may be used to produce other color temperatures as
`desired.
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`Referring to FIG. 13, a back surface 185 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 local-
`ized air movement within the respective recess due at least in
`part to localized air temperature gradients and resulting local-
`ized air pressure gradients. Without being held to any particu-
`lar 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 temperatures in the associated
`broad end, due to the difference of proximity ofthe surround-
`ing “heated” walls ofthe associated recess. It is contemplated
`that the presence of such air temperature gradients, with
`resulting air pressure gradients, within a given recess 190,
`195 will cause localized air movement 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 ofrecesses 195 are disposed in an alternating
`fashion around the circumference of the back 185 of the heat
`
`sink 1 1 0, it is contemplated that further enhancements in heat
`transfer will be achieved, either by the packing density of
`recesses achievable by nesting one recess 190 adjacent the
`other 195, or by alternating the direction vectors of the local-
`ized air temperature/pres sure gradients to enhance overall air
`movement. In an embodiment, the first plurality of recesses
`190 have a first depth into the back surface of the heat sink,
`and the second plurality of recesses 195 have a second depth
`into the back surface of the heat sink, the first depth being
`different from the second depth, which is contemplated to
`further enhance heat transfer.
`
`FIGS. 14-18 illustrate typical industry standard can-type
`light fixtures for recessed lighting (FIGS. 14-15), and typical
`industry standard electrical 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 of alternative 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 so as to 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 optical effects.
`
`PETITIONERS, Ex. 1022
`
`PETITIONERS, Ex. 1022
`
`

`

`US 8,201,968 B2
`
`7
`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 unit from the light unit providing
`a thermal 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 sufiicient 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
`
`retrofit connection to an installed light fixture 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 by the 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 spreader
`305 (the heat spreader 305 and heat sink 310 are collectively
`herein referred to as base 302), an outer optic 315 securely
`retained relative to at least one of the heat spreader 305 and
`the heat sink 310, a light source (LED) 120 disposed in
`thermal communication with the heat spreader 305, and an
`electrical supply line 125 disposed in electrical communica-
`tion with the light source 120. The integrally formed heat
`spreader 305 and heat sink 310 provides for improved heat
`flow from the LED 120 to the heat sink 310 as the heat flow
`
`path therebetween is continuous and uninterrupted as com-
`pared to the luminaire 100 discussed above.
`To provide for a low profile luminaire 300, the combination
`of the heat spreader 305, heat sink 310 and outer optic 315,
`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 (best
`seen by reference to FIG. 28). In an example embodiment,
`height H is 1.5-inches, and outside dimension D is a diameter
`of 7—inches. Other dimensions for H and D are contemplated
`such that the combination of the heat spreader 305, heat sink
`310 and outer optic 315, are so configured and dimensioned
`as to; (i) cover an opening defined by an industry standard
`can-type light fixture having nominal sizes from three-inches
`to six-inches (see FIGS. 14 and 15 for example); and, (ii)
`cover an opening defined by an industry standard electrical
`junction box having nominal sizes from three-inches to six-
`inches (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 300 has the back surface of the heat
`spreader 305 substantially planar with the back surface of the
`heat sink 310, thereby permitting the luminaire 300 to sit
`substantially flush on the surface of the ceiling/wall material.
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`8
`Alternatively, small standoffs 200 (see FIG. 12 in combina-
`tion with FIG. 27 for example) may be used to promote air
`movement around the luminaire 300 for improved heat trans-
`fer to ambient, as discussed above.
`Securement of the luminaire 300 to a junction box (see
`FIGS. 16-18 for example) may be accomplished by using a
`bracket 400 and suitable fasteners 405 (four illustrated)
`through appropriately spaced holes 410 (four illustrated) in
`the bracket 400. Securement of the base 302 to the bracket
`
`400 is accomplished using suitable fasteners 415 (two illus-
`trated) through appropriately spaced holes 420 (two used,
`diametrically opposing each other, but only one visible) in the
`base 302, and threaded holes 425 (two illustrated) in the
`bracket 400. Securement of the optic 315 to the base 302 is
`accomplished using suitable fasteners 430 (three illustrated)
`through appropriately spaced holes 435 (three used, spaced
`120 degrees apart, but only two illustrated) in tabs 445 of the
`optic 315, and threaded holes 440 (three used, spaced 120
`degrees apart, but only two illustrated) in the base 302. A trim
`ring 470 circumferentially snap-fits over the optic 315 to hide
`the retaining fasteners 430, the holes 435 and the tabs 445.
`The snap-fit arrangement of the trim ring 470 relative to the
`optic 315 is such that the trim ring 470 can be removed in a
`pop-off manner for maintenance or other purposes.
`Securement of the luminaire 300 to a can-type fixture (see
`FIGS. 14-15 for example) may be accomplished by using two
`torsion springs 450 each loosely coupled to the bracket 400 at
`a pair of notches 455 by placing the circular portion 460 of
`each torsion spring 450 over the pairs ofnotches 455, and then
`engaging the hook ends 465 of the torsion spring 450 with
`suitable detents in the can-type fixture (known detent features
`of can-type light fixtures are depicted in FIGS. 14-15). In an
`embodiment, the circula