as) United States
`a2) Patent Application Publication co) Pub. No.: US 2012/0262921 Al
`
` Boomgaardenet al. (43) Pub. Date: Oct. 18, 2012
`
`
`US 20120262921A1
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`oy‘ob
`
`D00601
`
`(52) US. Ch. eee ceeceeceeeeeteneeeeeseeeseeeeneees 362/249.02
`
`(57)
`
`ABSTRACT
`
`(54) LOW PROFILE LIGHT AND ACCESSORY KIT
`FOR THE SAME
`Inventors:
`MarkPenley Boomgaarden,
`
`(75)
`
`Satellite Beach, FL (US); Michael
`Balestracci, Satellite Beach, FL
`(US); Rick LeClair, Melbourne, FL
`(US); Wei Sun, Indialantic, FL
`(US); David Henderson,
`Indialantic, FL (US); Shane
`Sullivan, Indialantic, FL (US)
`
`(73) Assignee:
`
`LIGHTING SCIENCE GROUP
`CORPORATION,Satellite Beach,
`FL (US)
`
`(21) Appl. No.:
`
`13/476,388
`
`(22)
`
`Filed:
`
`May 21, 2012
`
`.
`ooo,
`A luminaire includes a heat spreader; a heat sink; an LED
`light source; a power supply; an electrical supply line having
`a first end connected to the power supply, and a second end
`connected to a plug-in connector; and, an optic securely
`retained relative to the heat spreader or heat sink. An acces-
`sory kit includesa first pre-wired jumperincluding a pair of
`insulated electrical wires having a first plug-in connector
`electrically connected at one end and an Edison baseelectri-
`cally connected at the other end; and/or, a second pre-wired
`Related U.S. Application Data jumperincludingapair of insulated electrical wires having a
`second plug-in connectorelectrically connected at one end
`and unconnected wire ends at the other end. The plug-in
`connector of the first pre-wired jumper and the secondpre-
`wired jumper are each configuredto electrically engage with
`the plug-in connectorofthe electrical supply line.
`
`
`
`(63) Continuation-in-part of application No. 12/775,310,
`filed on May 6, 2010, now Pat. No. 8,201,968.
`
`(60) Provisional application No. 61/248,665, filed on Oct.
`5, 2009.
`
`100
`
`115
`
`110
`
`PETITIONERS, Ex. 1021
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`PETITIONERS, Ex. 1021
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`Patent Application Publication
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`Oct. 18, 2012 Sheet 1 of 17
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`US 2012/0262921 Al
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`Patent Application Publication
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`Oct. 18, 2012 Sheet 2 of 17
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`Patent Application Publication
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`Oct. 18, 2012 Sheet 3 of 17
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`US 2012/0262921 Al
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`110 115
`
`FIG. 5
`
`
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`PETITIONERS, Ex. 1021
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`PETITIONERS, Ex. 1021
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`Patent Application Publication
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`Oct. 18, 2012 Sheet 4 of 17
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`Patent Application Publication
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`Oct. 18, 2012 Sheet 5 of 17
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`US 2012/0262921 Al
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`145
`
`
`FIG. 10
`
`FIG, 11
`
`PETITIONERS, Ex. 1021
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`PETITIONERS, Ex. 1021
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`

`

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`Patent Application Publication
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`Oct. 18, 2012 Sheet 6 of 17
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`US 2012/0262921 Al
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`200
`
`
`
`135
`
`
`
`FIG. 13
`
`PETITIONERS, Ex. 1021
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`PETITIONERS, Ex. 1021
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`Patent Application Publication
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`Oct. 18,2012 Sheet 7 of 17
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`US 2012/0262921 Al
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`
`
`9TOI
`
`PETITIONERS, Ex. 1021
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`PETITIONERS, Ex. 1021
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`
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`Patent Application Publication
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`Oct. 18, 2012 Sheet 8 of 17
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`US 2012/0262921 Al
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`
`
`
`
`
`FIG. 20
`
`oS
`
`FIG, 21
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`PETITIONERS, Ex. 1021
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`Patent Application Publication
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`Oct. 18, 2012 Sheet 9 of 17
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`US 2012/0262921 Al
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`105
`
`
`FIG. 22
`
`FIG, 23
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`PETITIONERS, Ex. 1021
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`Patent Application Publication
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`Oct. 18, 2012 Sheet 10 of 17
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`US 2012/0262921 Al
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`145"
`
`FIG. 24
`
`145’a
`
`FIG. 25
`
`
`
`215’
`
`FIG. 26
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`PETITIONERS, Ex. 1021
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`Patent Application Publication
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`Oct. 18,2012 Sheet 11 of 17
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`US 2012/0262921 Al
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`LeOld
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`PETITIONERS, Ex. 1021
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`PETITIONERS, Ex. 1021
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`
`

`

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`
`
`PETITIONERS, Ex. 1021
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`PETITIONERS, Ex. 1021
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`Patent Application Publication
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`Oct. 18, 2012 Sheet 13 of 17
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`US 2012/0262921 Al
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`
`
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`PETITIONERS, Ex. 1021
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`Patent Application Publication
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`Oct. 18, 2012 Sheet 14 of 17
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`US 2012/0262921 Al
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`
`
`505™
`
`560
`
`FIG. 32
`
`559
`
`PETITIONERS, Ex. 1021
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`PETITIONERS, Ex. 1021
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`Patent Application Publication
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`FIG. 34
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`Oct. 18, 2012 Sheet 15 of 17
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`US 2012/0262921 Al FIG. 33
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`a300
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`PETITIONERS, Ex. 1021
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`Oct. 18, 2012 Sheet 16 of 17
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`300'
`
`Patent Application Publication
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`US 2012/0262921 Al
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`PETITIONERS, Ex. 1021
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`Patent Application Publication
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`Oct. 18, 2012 Sheet 17 of 17
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`US 2012/0262921 Al
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`445'
`
`30
`
`FIG.36B
`
`FIG.37B 440"——
`FIG.37A
`
`445'
`
`0'302'
`
`in FIG.36A
`
`PETITIONERS, Ex. 1021
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`

`

`US 2012/0262921 Al
`
`Oct. 18, 2012
`
`LOW PROFILE LIGHT AND ACCESSORYKIT
`FOR THE SAME
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`[0001] This application is a continuation-in-part of U.S.
`application Ser. No. 12/775,310, filed May 6, 2010, which
`claims the benefit of U.S. Provisional Application Ser. No.
`61/248,665, filed Oct. 5, 2009, both ofwhich are incorporated
`herein by reference in their entirety.
`
`BACKGROUND OF THE INVENTION
`
`in thermal communication with the heat spreader, the light
`source having a plurality of light emitting diodes (LEDs). A
`powerconditioner is disposed in electrical communication
`with the light source, the power conditioner being configured
`to receive AC voltage from an electrical supply line and to
`deliver DC voltage to the plurality of LEDs, the power con-
`ditioner being so dimensionedasto fit within at least oneof:
`anominally sized four-inch canlightfixture; and, anominally
`sized four-inch electrical junction box.
`[0007] An embodiment of the invention includes a lumi-
`naire having a heat spreader, a heat sink thermally coupled to
`and disposed diametrically outboard of the heat spreader, an
`outer optic securely retained relative to at least one of the heat
`spreader andthe heat sink, a light source disposed in thermal
`[0002] The present disclosure relates generally to lighting,
`communication with the heat spreader, and an electrical sup-
`particularly to low profile lighting, and more particularly to
`ply line disposed in electrical communication with the light
`low profile downlighting for retrofit applications.
`source. The heat spreader, heat sink and outer optic, in com-
`[0003] Light fixtures come in many shapesandsizes, with
`bination, have an overall height H and an overall outside
`some being configured for new workinstallations while oth-
`dimension D suchthat the ratio of H/D is equalto or less than
`ers are configuredfor old work installations. New workinstal-
`0.25. The defined combination is so dimensionedas to: cover
`lations are not limited to as many constraints as old work
`an opening defined by a nominally sized four-inch canlight
`installations, which must take into account the type of elec-
`fixture; and, cover an opening defined by a nominally sized
`trical fixture/enclosure or junction box existing behind a ceil-
`four-inch electrical junction box.
`ing or wall panel material. With recessed ceiling lighting,
`[0008] An embodiment of the invention includes a lumi-
`sheet metal can-type light fixtures are typically used, while
`surface-mountedceiling and wall lighting typically use metal
`naire having a housing with a light unit and a trim unit. The
`
`or plastic junction boxesofavariety of sizes and depths. With light unit includesa light source, and thetrim unit is mechani-
`the advent of LED (light emitting diode) lighting, there is a
`cally separable from the light unit. A means for mechanically
`great need to not only provide new work LED lightfixtures,
`separating the trim unit from the light unit provides a thermal
`but to also provide LEDlightfixturesthat are suitable for old
`conduction path therebetween. The light unit has sufficient
`workapplications, thereby enablingretrofit installations. One
`thermal mass to spread heat generated by the light source to
`way of providing old work LED lighting is to configure an
`the means for mechanically separating, and the trim unit has
`LED luminaire in such a mannerasto utilize the volume of
`sufficient thermal massto serve as a heatsink to dissipate heat
`generated bythe light source.
`[0009] An embodiment of the invention includes a lumi-
`naire for retrofit connectionto an installed lightfixture having
`aconcealed in-use housing. The luminaire includes a housing
`having 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 oftheinstalled lightfixture.
`[0010] An embodiment of the invention includes a lumi-
`naire and accessory kit combination. The luminaire includes
`a heat spreader; a heat sink; an LED light source; a power
`[0005] An embodiment of the invention includes a lumi-
`supply; an electrical supply line havingafirst end connected
`naire having a heat spreader and a heat sink thermally coupled
`to the power supply, and a second end connectedto a plug-in
`to and disposed diametrically outboard of the heat spreader,
`connector; and, an optic securely retainedrelative to the heat
`an outer optic securely retained relative to at least one of the
`spreader or heat sink. The accessory kit includesa first pre-
`heat spreader andthe heatsink, and a light source disposed in
`wired jumper including a pair of insulated electrical wires
`thermal communication with the heat spreader,
`the light
`havingafirst plug-in connectorelectrically connected at one
`source having a plurality of light emitting diodes (LEDs). The
`end and an Edison base electrically connected at the other
`heat spreader, the heat sink and the outer optic, in combina-
`end; and/or, a second pre-wired jumper including a pair of
`tion, have an overall height H and an overall outside dimen-
`insulated electrical wires having a second plug-in connector
`sion D such that the ratio of H/D is equalto or less than 0.25.
`electrically connected at one end and unconnected wire ends
`The combination defined by the heat spreader, the heat sink
`at the other end. The plug-in connectorof the first pre-wired
`and the outer optic, is so dimensionedas to: cover an opening
`jumperandthe second pre-wired jumperare each configured
`defined by a nominally sized four-inch can lightfixture; and,
`to electrically engage with the plug-in connectorof the elec-
`cover an opening defined by a nominally sized four-inch
`trical supply line.
`electrical junction box.
`[0006] An embodiment of the invention includes a lumi-
`naire having 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 andtheheat sink. A light source is disposed
`
`space available within an existing fixture (can-typefixture or
`junction box). However, such configurations typically result
`in unique designs for each type andsize offixture. Accord-
`ingly, there is a need in theart for an LED lighting apparatus
`that overcomes these drawbacks.
`
`[0004] This background information is provided to reveal
`information believed by the applicant to be of possiblerel-
`evance to the present invention. No admission is necessarily
`intended, nor should be construed, that any of the preceding
`information constitutes prior art against the present invention.
`
`BRIEF DESCRIPTION OF THE INVENTION
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0011] Referring to the exemplary drawings wherein like
`elements are numbered alike in the accompanying Figures,
`abbreviated in eachillustration as “Fig.”:
`
`PETITIONERS, Ex. 1021
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`US 2012/0262921 Al
`
`Oct. 18, 2012
`
`FIG. 1 depicts an isometric top view of a luminaire
`[0012]
`in accordance with an embodimentof the invention;
`[0013]
`FIG. 2 depicts a top view of the luminaire of FIG.1;
`[0014]
`FIG. 2 depicts a bottom view of the luminaire of
`FIG.1;
`FIG. 4 depicts a side view ofthe luminaire ofFIG.1;
`[0015]
`[0016] FIG.5 depicts a top view of a heat spreader assem-
`bly, a heat sink, and an outer optic in accordance with an
`embodimentof the invention;
`[0017]
`FIG.6 depicts an isometric view ofthe heat spreader
`of FIG. 5;
`[0018]
`FIG. 7 depicts a partial isometric view of the heat
`sink of FIG.5;
`[0019]
`FIG. 8 depicts a top view of an alternative heat
`spreader assembly in accordance with an embodimentof the
`invention;
`[0020]
`FIG. 9 depicts a top view of anotheralternative heat
`spreader assembly in accordance with an embodimentof the
`invention;
`[0021]
`FIG. 10 depicts a top view of yet anotheralternative
`heat spreader assembly in accordance with an embodiment of
`the invention;
`[0022]
`FIG. 11 depicts a bottom view of a heat spreader
`having a power conditioner in accordance with an embodi-
`mentof the invention;
`[0023]
`FIG. 12 depicts a section view of a luminaire in
`accordance with an embodimentof the invention;
`[0024]
`FIG. 13 depicts a bottom view ofa heat sink having
`recesses in accordance with an embodimentofthe invention;
`[0025]
`FIGS. 14-18 depict isometric viewsofexisting elec-
`trical can-typelightfixtures and electrical junction boxes for
`use in accordance with an embodimentof the invention;
`[0026]
`FIGS. 19-21 depicta side view, top view and bottom
`view, respectively, of a luminaire similar but alternative to
`that of FIGS. 2-4, in accordance with an embodimentofthe
`invention;
`[0027]
`FIGS. 22-23 depict top and bottom views, respec-
`tively, of a heat spreader having an alternative power condi-
`tioner in accordance with an embodiment of the invention;
`[0028]
`FIG. 24-26 depict in isometric, top and side views,
`respectively, an alternative reflector to that depicted in FIGS.
`10 and 12;
`[0029]
`FIG. 27 depicts an exploded assembly view of an
`alternative luminaire in accordance with an embodiment of
`the invention;
`[0030]
`FIG. 28 depicts a side view of the luminaire of FIG.
`27;
`[0031]
`27;
`[0032] FIG.30 depicts a cross section view ofthe luminaire
`of FIG. 27, and moreparticularly depicts a cross section view
`of the outer optic used in accordance with an embodimentof
`the invention;
`[0033]
`FIG. 31 depicts an accessory kit in accordance with
`an embodimentofthe invention;
`[0034]
`FIG. 32 depicts a formed spring included in the
`accessory kit of FIG. 31;
`[0035]
`FIG. 33 depicts a top-down view of a luminaire
`similar to that depicted in FIG. 27, and illustrative of an
`assembly of a formed spring of FIG. 32 onto the luminaire;
`[0036]
`FIG. 34 depicts a side view of the luminaire of FIG.
`RR
`FIG. 35 depicts an exploded assembly view of the
`[0037]
`luminaire of FIGS. 33 and 34;
`
`FIG. 29 depicts a back view ofthe luminaire of FIG.
`
`FIGS. 36A and 36B are side view depictions of a
`[0038]
`first position (not engaged) and a secondposition (engaged),
`respectively, of an engagement tab of an optic snap-fitting
`into an engagement opening of a base, where both the optic
`and the base are part of the luminaire of FIG. 35; and
`[0039]
`FIGS. 37A and 37Bare plan view depictions of an
`alternative arrangement to that depicted in FIGS. 36A and
`36B, respectively, and more specifically are depictions of a
`first position (not engaged) and a secondposition (engaged),
`respectively, of an engagementtab of an optic rotationally-
`fitting into an engagement opening of a base, where both the
`optic and the baseare part of the luminaire of FIG. 35.
`
`DETAILED DESCRIPTION OF THE INVENTION
`
`[0040] Although the following detailed description con-
`tains many specifics for the purposesofillustration, anyone of
`ordinary skill in the art will appreciate that many variations
`and alterations to the following details are within the scope of
`the invention. Accordingly, the following preferred embodi-
`ments of the invention are set forth without any loss of gen-
`erality to, and without imposinglimitations upon, the claimed
`invention.
`
`[0041] An embodiment of the invention, as shown and
`described by the various figures and accompanyingtext, pro-
`vides a low profile downlight, more generally referred to as a
`luminaire, having an LED light source disposed on a heat
`spreader, which in turn is thermally coupled to a heat sink that
`also servesas the trim plate of the luminaire. The luminaireis
`configured and dimensionedforretrofit installation on stan-
`dard can-typelight fixtures used for recessedceiling lighting,
`and on standardceiling or wall junction boxes (J-boxes) used
`for ceiling or wall mounted lighting. The luminaire is also
`suitable for new workinstallation. Retrofit installation of the
`luminaire is accomplished utilizing an accessory kit that
`includes a pre-wired electrical jumper and mounting hard-
`ware. For installations involving a can-typefixture, the pre-
`wired jumper includes a plug-in connectorelectrically con-
`nected to an Edison base via flexible insulated wires For
`installations involving a J-box, the pre-wiredjumperincludes
`a plug-in connectorelectrically connected to flexible insu-
`lated wires that may or may notbe pre-stripped, or partially
`pre-stripped, on the opposing end.
`[0042] While embodiments of the invention described and
`illustrated herein depict an example luminaire for use as a
`downlight when disposed upona ceiling, it will be appreci-
`ated that embodiments of the invention also encompass other
`lighting applications, such as a wall sconce for example.
`[0043] While embodiments of the invention described and
`illustrated herein depict example power conditioners having
`visually defined sizes,
`it will be appreciated that embodi-
`ments of the invention also encompass other power condi-
`tioners having other sizes as long as the power conditioners
`fall within the ambit of the invention disclosed herein.
`
`[0044] 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 andthe heat sink 110, a light
`source 120 disposed in thermal communication with the heat
`spreader 105, and an electrical supply line 125 disposed in
`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 suchthat
`
`PETITIONERS, Ex. 1021
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`US 2012/0262921 Al
`
`Oct. 18, 2012
`
`the ratio of H/D is equal to or less than 0.25. 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
`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, such as a four-inch can or a six-
`inch can for example (see FIGS. 14 and 15 for example); and,
`(i1) cover an opening defined by an industry standardelectri-
`cal junction box having nominal sizes from three-inches to
`six-inches, such as a four-inch J-box or a six-inch J-box for
`example (see FIGS. 16 and 17 for example). Since can-type
`light fixtures and ceiling/wall mount junction boxes are
`designed for placement behind a ceiling or wall material, an
`example luminaire has the back surface of the heat spreader
`105 substantially planar with the back surface ofthe heat sink
`110, thereby permitting the luminaire 100to sit substantially
`flush on the surface ofthe ceiling/wall material. Alternatively,
`small standoffs 200 (see FIG. 12 for example) may be used to
`promote air movement around the luminaire 100 for
`improvedheattransfer to ambientair, which will be discussed
`further below. Securementof the luminaire 100 to a junction
`box may be accomplishedby using suitable fasteners through
`appropriately spaced holes 150 (see FIG. 8 for example), and
`securementof 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-typefixture.
`[0045]
`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 generatesheat at the junction of each LED
`die. To dissipate this heat, the LED chip packageis disposed
`in suitable thermal communication with the heat spreader
`105, which in an embodimentis made using aluminum, and
`the heat spreader is disposed in suitable thermal communica-
`tion with the heat sink 110, which in an embodimentis also
`made using aluminum. To provide for suitable heat transfer
`from the heat spreader 105 to the heat sink 110, an embodi-
`ment employsa plurality of interconnecting threads 130, 135,
`which whentightened provide suitable surface area for heat
`transfer thereacross.
`
`[0046] Embodiments of luminaire 100 may be powered by
`DCvoltage, 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.
`[0047]
`In an embodiment, and with reference to FIG.8,
`powerconditioner 140 is disposed on the heat spreader 105 on
`asameside of the heat spreaderas the plurality of LEDs 120.
`In an embodiment, the power conditioner 140 is an electronic
`circuit board having electronic components configured to
`receive AC voltage from the electrical supply line 125 and to
`deliver DC voltage to the plurality of LEDs through appro-
`priate electrical connections on either the front side or the
`back side ofthe heat spreader 105, with holes throughthe heat
`
`spreaderor insulated electrical traces across the surface ofthe
`heat spreader being used as appropriate for the purposes.
`[0048]
`Inan alternative embodiment, and with reference to
`FIG. 9, an arc-shaped electronic-circuit-board-mounted
`powerconditioner 160 may be usedin place of the localized
`powerconditioner 140 illustrated in FIG.8, thereby utilizing
`a larger available area of the heat spreader 105 without
`detracting from the lighting efficiency of luminaire 100.
`[0049]
`Ina further embodiment, and with reference to FIG.
`11, a block-type power conditioner 165 (electronics con-
`tained within a housing) may be used on the back surface of
`the heat spreader 105, where the block-type power condi-
`tioner 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 powercon-
`ditioner 165 and the LEDs 120 are madevia wires 170, which
`may be contained within the can fixture or junction box, or
`maybeself-contained within the powerconditioner housing.
`Electrical wires 175 receive AC voltage viaelectrical connec-
`tions within the can fixture or junction box.
`[0050] Referring now to FIGS. 8-10 and 12, an embodi-
`ment 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 bevisible (i.e., uncov-
`ered) through an aperture 215 ofthe 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 providesa reflective covering that hides power
`conditioner 140, 160 from view when viewed from the outer
`optic side of luminaire 100, whileefficiently 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 embodimentthe 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 halfangle power ofthe luminaire, where the
`light intensity of the light source when viewedat the outer
`optic drops to 50% ofits maximumintensity, is evident within
`acentral diameter of the outer optic that is equal to or greater
`than 50% of the outer diameter of the outer optic.
`[0051] While FIG. 10 includes a reflector 145, it will be
`appreciated that not all embodiments of the invention dis-
`closed herein may employa 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 condi-
`tioner 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 dis-
`tribution and/or focusing for example.
`[0052] Referring to FIG. 12, an embodiment includes an
`inner optic 180 disposed over the plurality of LEDs 120.
`Employing an inner optic 180 not only provides protection to
`the LEDs 120 during installation ofthe 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 standaloneele-
`
`PETITIONERS, Ex. 1021
`
`PETITIONERS, Ex. 1021
`
`

`

`US 2012/0262921 Al
`
`Oct. 18, 2012
`
`ment, or integrally formed with the reflector 145. In an
`embodiment, the LEDs 120 are encapsulated in a phosphor of
`a type suitable to produce a color temperature output of 2700
`deg-Kelvin. Other LEDs with or without phosphor encapsu-
`lation may be used to produce other color temperatures as
`desired.
`
`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.
`[0053] Referring to FIG. 13, a back surface 185 of an
`embodimentof the heat sink 110 includesa first plurality of
`[0058]
`From the foregoing,
`it will be appreciated that
`embodiments of the invention also include a luminaire 100
`recesses 190 orientedinafirst direction, and a secondplural-
`ity of recesses 195 oriented in a second opposing direction,
`with a housing (collectively referred to by reference numerals
`each recess of the first plurality and the second plurality
`105, 110 and 115) havingalight unit (collectively referred to
`having a shape that promotes localized air movement within
`by reference numerals 105 and 115) and a trim unit 110, the
`the respective recess dueat least in part to localized air tem-
`light unit including a light source 120, the trim unit being
`perature gradients and resulting localized air pressure gradi-
`mechanically separable from the light unit, a means for
`ents. Without being held to any particular theory, it is con-
`mechanically separating 130, 135 the trim unit from the light
`templatedthat a teardrop-shapedrecess 190, 195 each having
`unit providing a thermal conduction path therebetween, the
`a narrow end and an opposing broad end will generate local-
`light unit having sufficient thermal mass to spread heat gen-
`ized air temperatures in the narrow end that are higher than
`erated by the light source to the means for mechanically
`localized air temperatures in the associated broad end, due to
`separating, the trim unit having sufficient thermal mass to
`the difference of proximity ofthe surrounding “heated”walls
`serve as a heat sink to dissipate heat generated by the light
`source.
`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
`enhancethe 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 secondplurality of
`recesses 195 are disposed in an alternating fashion around the
`circumference of the back 185 of the heat sink 110, it is
`contemplated that further enhancements in heat transfer will
`be achieved, either by the packing density ofrecesses achiev-
`able by nesting one recess 190 adjacent the other 195, or by
`alternating the direction vectors of the localized air tempera-
`ture/pressure 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 ofthe heat sink, thefirst depth being different from the
`second depth, which is contemplated to further enhance heat
`transfer.
`
`From the foregoing,it will also be appreciated that
`[0059]
`embodiments ofthe invention further include a luminaire 100
`for retrofit connection to an installed light fixture having a
`concealed in-use housing (see FIGS. 14-18 for example), the
`luminaire including a housing 105, 110, 115 having a light
`unit 105, 115 and a trim unit 110, the light unit comprising a
`light source 120, the trim unit being mechanically separable
`from the light unit, the trim unit defining a heat sinking
`thermal management element configured to dissipate heat
`generated bythe light source that is completely 100% exter-
`nal of the concealed in-use housing of the installed light
`fixture. As used herein, the term “concealed in-use housing”
`refers to a housing that is hidden behind a ceiling or a wall
`panel once the luminaire of the invention has been installed
`thereon.
`
`[0060] Reference is now madeto 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
`retainedrelative 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.
`[0061]
`To provide for a low profile luminaire 300, the com-
`bination of the heat spreader 305, heat sink 310 and outer
`optic 315, have an overall height H and an overall outside
`dimension D suchthat the ratio of H/D is equalto 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
`dimensionedasto; (1) cover an opening defined by an industry
`
`PETITIONERS, Ex. 1021
`
`FIGS. 14-18 illustrate typical industry standard can-
`[0054]
`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
`invention are configured and sized for use with such fixtures
`of FIGS. 14-18.
`
`FIGS. 19-21illustrate an alternative luminaire 100'
`[0055]
`having a different form factor(flat top,flat outer optic, smaller
`appearance) as compared to luminaire 100 of FIGS. 1-4.
`[0056]
`FIGS. 22-23 illustrate alternative electronic power
`conditioners 140', 165' having a differe