( 19 ) United States
`( 12 ) Patent Application Publication ( 10 ) Pub . No .: US 2021/0025580 A1
`( 43 ) Pub . Date :
`Jan. 28 , 2021
`CURLETT et al .
`
`US 20210025580A1
`
`IN
`
`( 54 ) LIGHTWEIGHT LED LIGHTING SYSTEMS
`FOR PERMANENT AND SEMI - PERMANENT
`MOUNTING ON ELEVATED STRUCTURES
`HAVING INTEGRATED SUPPORT AND
`THERMAL TRANSFER FEATURES
`
`( 71 ) Applicant : CLEANTEK INDUSTRIES INC . ,
`Rockyview ( CA )
`
`( 72 )
`
`Inventors : Joshua CURLETT , Calgary ( CA ) ;
`Hugues WANLIN , Canmore ( CA )
`
`( 21 ) Appl . No .:
`( 22 ) PCT Filed :
`( 86 ) PCT No .:
`§ 371 ( c ) ( 1 ) ,
`( 2 ) Date :
`
`17 / 045,345
`Apr. 4 , 2019
`PCT / CA2019 / 050410
`
`Oct. 5 , 2020
`
`Related U.S. Application Data
`( 60 ) Provisional application No. 62 / 652,747 , filed on Apr.
`4 , 2018 , provisional application No. 62 / 669,852 , filed
`on May 10 , 2018 , provisional application No. 62/673 ,
`440 , filed on May 18 , 2018 .
`
`Publication Classification
`
`( 51 ) Int . Ci .
`F21V 29/61
`E21B 15/00
`F21V 29/67
`F21V 29/89
`F21S 8/04
`F21V 21/30
`( 52 ) U.S. CI .
`CPC
`
`( 2006.01 )
`( 2006.01 )
`( 2006.01 )
`( 2006.01 )
`( 2006.01 )
`( 2006.01 )
`F21V 29/61 ( 2015.01 ) ; E21B 15/00
`( 2013.01 ) ; F21V 29/67 ( 2015.01 ) ; F21Y
`2115/10 ( 2016.08 ) ; F21S 8/043 ( 2013.01 ) ;
`F21V 21/30 ( 2013.01 ) ; F21V 29/89 ( 2015.01 )
`( 57 )
`ABSTRACT
`The invention relates to lightweight LED lighting systems
`for permanent and semi - permanent mounting on elevated
`structures , the lighting systems having integrated support
`and thermal transfer features . The systems are particularly
`suited for elevated mast systems and specifically for mast
`systems that are repeatedly lifted and lowered such as
`drilling and service rig masts . Specifically , the invention
`improves a ) the weight / lumen ratios of LED lamp assem
`blies and LED lighting systems , b ) the net added weight of
`LED lighting systems , c ) the footprint of LED light systems
`and / or d ) obviates the need for removing LED lighting
`systems or their sub - assemblies when transporting mast
`systems .
`
`Ortops
`
`640
`
`64d
`
`66
`
`64a
`
`68
`
`64b
`
`62
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 1 of 32
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`US 2021/0025580 A1
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`10
`
`20
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`14a
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`14
`
`16
`
`14a
`
`12
`
`24
`
`24
`
`munun
`
`22
`
`18
`
`FIGURE 1A
`PRIOR ART
`
`14a
`
`16
`
`000
`oo 8
`o
`
`12
`
`22
`
`FIGURE 1B
`PRIOR ART
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`Patent Application Publication
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`US 2021/0025580 A1
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`32
`
`XATA
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`30
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`30e
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`30d
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`30a
`30b
`
`30c
`
`FIGURE 2
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 3 of 32
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`US 2021/0025580 A1
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`40
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`40
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`32
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`40
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`30
`
`FIGURE 2A
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 4 of 32
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`US 2021/0025580 A1
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`40e
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`DIODO
`
`
`
`DLO DLO
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`40
`
`40a
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`40a
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`40b
`
`400
`
`FIGURE 2B
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 5 of 32
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`US 2021/0025580 A1
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`40f
`
`40
`
`40a
`
`BODO Doo
`BIDDIC
`ODDE
`QOQO
`SNN Qona
`DSD
`DBDG Bilo
`IDD 0 ODL
`DOOG
`DOO agos
`Do
`@@@@
`OD Q000 ?
`
`42
`
`40c
`
`FIGURE 2C
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 6 of 32
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`US 2021/0025580 A1
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`42
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`44
`
`FIGURE 2D
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 7 of 32
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`US 2021/0025580 A1
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`40
`
`40a
`
`FIGURE 2E
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 8 of 32
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`US 2021/0025580 A1
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`SGDN
`DO
`BBOC
`
`QODG
`QIQB OOO
`ODE
`DDD
`
`DODG D60 DOO
`
`QBG
`
`FIGURE 2F
`
`40
`
`40a
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`44
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 9 of 32
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`US 2021/0025580 A1
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`40f
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`40e
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`42
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`40
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`40a
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`44
`
`um
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`40c
`
`FIGURE 2G
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 10 of 32 US 2021/0025580 A1
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`50
`
`30
`
`FIGURE 3
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 11 of 32 US 2021/0025580 A1
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`50
`
`30
`
`FIGURE 3A
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 12 of 32 US 2021/0025580 A1
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`www .
`
`50
`
`50e
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`50d
`
`
`
` * Luis ***
`
`50b
`
`50c
`
`52a
`
`52
`
`53
`
`500
`
`FIGURE 3B
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 13 of 32 US 2021/0025580 A1
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`GEO TUNU ZOOM DDS
`
`1922
`102
`
`50b
`
`vo
`
`MENDED PE000
`
`50f
`
`52a
`
`50c
`
`53
`
`FIGURE 3C
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 14 of 32 US 2021/0025580 A1
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`54
`
`40a
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`53
`
`FIGURE 3D
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 15 of 32 US 2021/0025580 A1
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`66
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`68
`
`60
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`64d
`
`FIGURE 4
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`64a
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`70a
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`70
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 16 of 32 US 2021/0025580 A1
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`640
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`64d
`
`66
`
`64a
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`68
`
`64b
`
`62
`
`FIGURE 4A
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`mm
`
`68
`
`FIGURE 4B
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`68
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`1 12
`
`64e
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`69
`
`64d
`
`FIGURE 4C
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`0
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`64d
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`69
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`64e
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`68
`
`FIGURE 4D
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`Jan. 28 , 2021 Sheet 20 of 32 US 2021/0025580 A1
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`30e
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`705
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`70b
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`70
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`30d
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`30
`
`70c
`
`FIGURE 5
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`16
`
`36 9 WJECJE
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`16
`
`100a
`
`100
`
`102
`
`100b
`
`100a
`
`FIGURE 6A
`
`100b
`
`FIGURE 6
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`200
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`212
`212e
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`206
`
`212a
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`208
`
`204
`
`212e
`
`210
`
`202
`
`FIGURE 7
`
`?
`
`0
`
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`200
`
`2065 206a
`2060
`
`206
`
`208
`
`200
`206b '
`
`FIGURE 7A
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`Patent Application Publication
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`Jan. 28 , 2021 Sheet 24 of 32 US 2021/0025580 A1
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`202
`
`202
`
`202
`
`210
`
`210
`
`* Y .
`
`202
`
`210
`
`b
`
`C
`
`210
`
`INS
`
`a
`
`212e
`
`A
`
`î
`
`200
`
`d
`
`212e
`
`FIGURE ZB
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`Jan. 28 , 2021 Sheet 25 of 32 US 2021/0025580 A1
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`212e
`
`214
`
`200
`
`214
`
`212e
`
`212
`
`***
`
`HUN
`
`air
`
`202
`
`FIGURE 7C
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`Jan. 28 , 2021 Sheet 26 of 32 US 2021/0025580 A1
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`202
`
`202b
`
`BP
`
`1
`1
`1
`1
`1
`1
`1
`
`202c
`
`1
`1
`1
`
`222
`
`202a
`
`220
`
`224
`
`225
`
`SECTION B - B
`SCALE 1 : 2
`
`FIGURE 7D
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`202
`
`2020
`
`?
`
`Z ?
`
`202b
`
`224
`
`222b
`
`222a
`
`222
`
`FIGURE ZE
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`222
`
`222a
`
`222
`
`FIGURE 77
`
`222b
`
`FIGURE 7G
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`224
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`224
`
`Jan.28.2021 Sheet 29 of 32 US 2021/0025580 A1
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`222a ?????
`?
`
`FIGURE 7H
`
`222c
`
`FIGURE 71
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`224
`
`FIGURE 7J
`
`220
`
`o
`
`230a
`
`FIGURE 7K
`
`230
`
`220
`
`o
`
`230b
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`LED
`203a
`
`LED
`203b
`
`LED
`2030
`
`Power / Thermo
`Board
`203
`
`7
`.
`
`202
`
`Fan
`254f
`
`Driver LI
`254a
`
`Driver
`254b
`
`Driver
`2540
`
`Fan Circuit
`354d
`
`Junction
`Box
`254
`
`Fan
`254e
`
`-To IA
`
`212
`
`Power in
`208V
`3 phase
`7-8kW
`30A ( max )
`252
`
`250
`
`FIGURE 8
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`9
`
`FIGURE 9
`
`FIGURE 9A
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`US 2021/0025580 A1
`
`1
`
`Jan. 28 , 2021
`
`LIGHTWEIGHT LED LIGHTING SYSTEMS
`FOR PERMANENT AND SEMI - PERMANENT
`MOUNTING ON ELEVATED STRUCTURES
`HAVING INTEGRATED SUPPORT AND
`THERMAL TRANSFER FEATURES
`
`FIELD OF THE INVENTION
`[ 0001 ] The invention relates to lightweight LED lighting
`systems for permanent and semi - permanent mounting on
`elevated structures , the lighting systems having integrated
`support and thermal transfer features . The systems are
`particularly suited for elevated mast systems and specifically
`for mast systems that are repeatedly lifted and lowered such
`as drilling and service rig masts . Specifically , the invention
`improves a ) the weight / lumen ratios of LED lamp assem
`blies and LED lighting systems , b ) the net added weight of
`LED lighting systems , c ) the footprint of LED light systems
`and / or d ) obviates the need for removing LED lighting
`systems or their sub - assemblies when transporting mast
`systems .
`
`BACKGROUND OF THE INVENTION
`[ 0002 ] LED lighting systems are well known and have a
`large number of applications . They are advantaged over past
`incandescent , fluorescent and metal halide systems in many
`applications for their energy consumption , robustness and
`durability .
`[ 0003 ]
`In industrial applications , LED lighting systems
`continue to be used extensively and are becoming more
`common place for both portable and permanent applications
`and their associated markets . In the portable market , and in
`particular , the construction and energy industries , there are
`certain areas where LED lighting systems are not wide
`spread due to various technical problems and / or limitations
`in certain applications . Although LED technology can sup
`ply lighting needs at a fraction of the energy consumption of
`metal halide technology , a drawback is the amount of metal
`required to dissipate and draw heat away from high - power
`LED lamps . As such , in many cases the cost and weight of
`LED lighting systems can make them a challenging option
`for retrofit structures that were originally built for metal
`halide lighting systems and / or mounting LED lighting sys
`tems to structures that were not designed to support the
`weight of LED lighting systems .
`[ 0004 ]
`Specifically , the combined weight of an LEDs ,
`lamp housings and heat sinks ( collectively referred to herein
`as an LED lamp assembly ) together with mounting brackets
`and all support frames required for configuring a plurality of
`LED lamp assemblies to an existing structure can limit or
`prevent
`retrofit or a new build thus preventing lower
`energy LED technology to be deployed in some applica
`tions .
`[ 0005 ] One example of a system that has had limited
`application of LED technology is oil industry drilling and
`service rigs and specifically mounting lighting on the crown
`or upper mast region of a drilling rig or service rig mast . As
`is known , drilling and service rigs and their masts are
`sophisticated and costly pieces of equipment designed for
`the complex task of drilling wells and servicing wells . Given
`the nature and location of drilling and service operations ,
`drilling and service sites are operated around the clock and
`at all times of the year . As such , there is a need for effective
`lighting solutions on and around these rigs that meet the high
`
`demands and tough working environment of a rig including
`long term exposure to heat , cold and precipitation .
`[ 0006 ]
`Importantly , while rigs are generally very well
`engineered structures , designed for their primary task of
`drilling or servicing wells , they must also be designed to be
`transported between well sites , and as such are often not
`designed to accommodate secondary tasks such as support
`ing lighting systems on their masts or crowns despite the
`desirability of having effective lighting at a central and high
`location of the site . As a result , lighting systems are often
`separate from the rig and mast and , as such , are operated as
`separate and independent pieces of equipment such as trailer
`mounted portable light tower systems . Separate and inde
`pendent lighting sources can be effective in providing light
`to the site but they must be independently set up and directed
`to ensure that their light is effective at the site . This can
`increase the costs of lighting the rig as both additional
`equipment and personnel may be required . In addition ,
`pieces of equipment such as fuel powered light towers are
`often not tall enough to provide a lighting source above the
`working surfaces of a rig .
`[ 0007 ] As low watt per lumen LED technology has devel
`oped , new applications have arisen . Various prior art sys
`tems have configured high lumen lighting systems ( for
`example , 0.5 million ( MM ) to 1.5 million ( MM ) systems ) to
`the crown or upper section of a drilling rig or service rig
`mast and have shown that light can be provided to the entire
`drilling lease surface to provide a safer work area to the
`workers . For example , an LED lighting system mounted 165
`feet ( 53 m ) off the ground level where the workers need
`light , a 0.5 MM lumen LED system may not provide enough
`light on target ; however , if that same 0.5 MM lumen system
`was added to an 80 - foot ( 26 m ) mast it would likely provide
`enough light on target . However , in the latter case , a smaller
`rig can generally support less weight than the taller bigger
`rigs and so , designers of LED lighting systems will consider
`both the height of the mast in determining the required light
`output as well as the ability of the mast to support a given
`weight . Importantly , and as discussed below , a key drawback
`of LED lamps assemblies and LED lighting systems that
`mount to a rig crown or upper mast is the overall weight or
`weight to lumen ratio requirements of such systems to
`provide a specific light output .
`[ 0008 ]
`Primarily , the problem of weight at the crown or
`upper mast of a rig is that during the process of raising and
`lowering the mast at a job site ( after moving the rig between
`drilling locations ) , the extra weight of an LED lighting
`system acting at the end of the mast can subject the mast to
`enough force that the mast will bend and / or break and / or put
`additional stresses on lifting equipment . In other words ,
`because rigs are mobile systems , their overall weight and
`footprint are engineered such that both are usually mini
`mized and are not " over engineered ” to accommodate addi
`tional loads being placed on the rig . As noted previously , the
`smaller the rig the less weight it can support , but then due
`to a lower height of a smaller rig , fewer lumens are required
`to displace other means of site surface lighting .
`[ 0009 ] For example , it is desirable to keep the overall
`weight of a rig low due to road weight restrictions and
`challenges of delivering heavy rigs down roads that are not
`paved , particularly when the roads are wet that can cause
`ruts and road damage . Accordingly , drilling rigs are
`designed with upper weights limits to enable their move
`ment .
`
`C&M Oilfield Rentals Ex. 2020 - Page 34
`Ensign US Southern Drilling LLC v. C&M Oilfield Rentals LLC
`IPR2023-00804 - U.S. Patent No. 10,976,016
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`

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`
`2
`
`Jan. 28 , 2021
`
`[ 0010 ] As such , current prior art lighting systems that
`provide for example 1 MM - 1.5 MM lumens can weigh in the
`range of 2,000-2,500 lbs and , as a result , are limited from
`being installed on many drilling rigs due to the stresses that
`such systems impose on a drilling rig as it is being raised and
`lowered . While some rigs may be strong enough to allow
`this extra weight to be lifted , as noted above in some cases ,
`it is the size and capabilities of the hydraulic ram lifting
`systems that limit the ability to use higher weight systems .
`While larger hydraulic lifting systems may be utilized , this
`can also represent a significant additional cost to an operator .
`For service rigs the same issues apply , but as this style of rig
`is generally smaller , they may only need 0.25 MM - 0.75 MM
`lumens and may weigh 400-1,000 lbs . Thus , while the net
`added weight is lower for a service rig , as with the heavier
`drilling rigs , the weight to lumen ratio needs to be within a
`range to mitigate the above issues .
`[ 0011 ] Another consideration is the time and equipment
`required to install a lighting system on a mast and the current
`requirement of having to remove the LED lighting system
`for transport due to the positioning the lighting systems and
`the extent to which they will project outwardly from the
`sides of the mast . Moreover , with the high weights of these
`systems , manpower and equipment is required . In other
`words , the installation and removal of LED lighting systems
`requires the use and cost of a crane and loader for rigging in
`and rigging out , plus the extra time it takes to remove and
`reattach the LED lighting system after each move . Since the
`rig companies often are compensated by their customer on
`time efficiency , this has created a barrier to market for many
`retrofit LED lighting systems and from gaining traction in
`the market . Accordingly , there is a need for LED lighting
`systems that can be permanently and / or semi - permanently
`configured to a rig such that during transport the LED
`lighting system can remain attached or substantially attached
`to the rig , thereby reducing time for transport between well
`sites and minimizing the need and cost associated with
`loaders , cranes and additional deck space on transport
`trucks .
`Furthermore , to provide access to a higher percent
`[ 0012 ]
`age of existing drilling rigs , there is a need for lighting
`systems that reduce weight while providing sufficient light
`for rigs which typically have mast heights of 20-45 m for
`service type rigs and 30-50 + m for drilling rigs . While weight
`can be reduced by decreasing the lumen output of the
`system , lower lumen systems may not provide sufficient
`light .
`[ 0013 ] While newer systems have been developed that
`continue to reduce the weight of lighting systems greater
`than 1.0 MM lumens to around 550 kg , there remain many
`rigs where this amount of added weight is still too high .
`[ 0014 ] For the purposes of discussion , if it is assumed that
`a low weight LED lighting system or a standard prior art
`LED lighting system for configuration to the crown of
`drilling rigs and that provides 1 MM + lumens will generally
`weigh 1,200 lbs ( 500 kgs ) to 2,400 lbs ( 1,100 kgs ) . These
`figures represent a ratio of 0.55 grams or 1.10 grams ,
`respectively , of added weight / 1.0 lumen ( 0.55 : 1.0 or 1.10 :
`1.0 g / lumen respectively ) .
`[ 0015 ] As the total mass of such systems cannot be used
`on many rigs , it is desirable to decrease the ratio of added
`weight / lumen below these numbers . In addition , it is desir
`
`able to decrease the total mass of lighting systems to reduce
`or obviate the time and equipment required to prepare a rig
`for installation or transport .
`[ 0016 ]
`Specifically , for configuration to larger drilling rigs
`with mast heights in the range of 30-50 + meters wherein the
`overall lumens are preferably near or greater than 1 MM
`lumens , there is a need for the net added weight to be less
`than 1,100 lbs ( 500 kg ) , preferably less than 880 lbs ( 400 kg )
`and more preferably to around 600 lbs ( 275 kgs ) . Thus , for
`an LED lighting system of approximately 600 lbs ( 275 kg )
`and a 1 MM lumen LED lighting system , this is a ratio of
`0.27 grams / lumen . For a high lumen output LED system for
`the same drilling rig providing 1.5 MM lumens a ratio of less
`than 0.2 and preferably less than 0.18 grams / lumen is
`desirable .
`[ 0017 ] To achieve these levels of lighting with current
`LED lamps assemblies , a typical lighting system may
`include an array of 10-50 LED lamp assemblies , again
`depending on the applicable height of the LED lighting
`system while in use , each typically weighing in the range of
`17.5-33 lbs ( 8-15 kg ) based on typical designs as shown in
`FIGS . 14 and 1B . The weights of lamps described in the
`preceding sentence are for illustration and are not meant to
`be limiting
`[ 0018 ]
`Specifically , FIGS . 1A and 1B show the various
`components of a typical prior art LED lamp assembly 10 as
`including an LED housing 12 , LED solid state light board 14
`having LEDs ( i.e. high power LEDs ) 14a , reflectors 16 , heat
`sink 18 , housing cover 20 , associated mounting brackets 22 ,
`optional cooling fans ( not shown ) and power cables 24. As
`noted above , due to the need for each LED lamp assembly
`to be robust and durable , a typical LED lamp assembly will
`have a separate housing , heat sink and brackets that are
`connected to one another during assembly . However , each of
`these components is generally heavy when assembled and
`when incorporated into an array of lamp assemblies can
`represent a significant weight . As noted , various prior art
`systems may also utilize a cooling fan to direct cooling air
`over one or more LEDs . As such , as the total weight of the
`LED lighting system includes the lamp assemblies as well as
`all the supporting frames , electrical cables , connectors , etc. ,
`the end result is that the desired ratios of grams / lumen as
`described above cannot be achieved with current designs .
`[ 0019 ] As indicated , each LED lamp assembly 10 includes
`a heat sink 18 to ensure that heat generated by the LEDs is
`properly dissipated to ensure the LEDs are operated within
`the required temperature ranges and do not exceed recom
`mended operating temperatures as set by a LED manufac
`turer . Moreover , it is generally desirable to manage power
`consumption for a given light output in lumens to ensure
`both efficiency and the longevity of the LEDs . Accordingly ,
`an LED manufacturer will generally recommend that the
`temperature at the semi - conductor junction of each LED be
`maintained within a preferred temperature range to maintain
`power efficiency but also LED longevity . While a LED may
`be operated at a higher junction temperature ( up to a
`maximum temperature before burning out ) , the power effi
`ciency will drop off ( i.e. higher watts being consumed per
`lumen of light intensity ) and the longevity of the LED will
`drop . Hence , for practical purposes , high power LEDs are
`rarely operated at temperatures higher than the recom
`mended temperatures .
`[ 0020 )
`Table 1 shows typical specifications of a high
`performance LED .
`
`C&M Oilfield Rentals Ex. 2020 - Page 35
`Ensign US Southern Drilling LLC v. C&M Oilfield Rentals LLC
`IPR2023-00804 - U.S. Patent No. 10,976,016
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`

`US 2021/0025580 A1
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`3
`
`Jan. 28 , 2021
`
`TABLE 1
`Typical Specifications of a High Performance LED ( Cree
`XHP 70. Cree Canada Corp , Mississauga , Ontario )
`Property
`Size
`Voltage
`Max Drive Current
`
`Parameter
`
`Max Power
`Max Light Outp
`Max Efficiency at
`Binning Conditions
`Typical Forward
`Voltage
`Maximum Reverse
`Voltage
`Viewing Angle
`Maximum Junction
`Temperature
`
`7 by 7 mm
`6 V or 12 V
`4.8 A ( 6V )
`2.4 A ( 12 V )
`28.8 W
`4022 lm
`150 lm / W
`
`5.8 V White @ 2100 mA ( 6 V )
`11.6 V White @ 1050 mA ( 12 V )
`-5 V
`
`120 °
`150 ° C.
`
`[ 0021 ] As can be seen in this example , the maximum
`junction temperature is 150 ° C. However , in a typical
`operating scenario , it would be recommended to not operate
`the lamp at temperatures greater than about 80 ° C.
`[ 0022 ] For an LED described in Table 1 , an array of 16
`LEDs within a housing 12 would have a maximum power
`requirement of about 460 W but would normally be oper
`ating at about 50-60 % of maximum power thus consistently
`utilizing about 230-276 W of power . With the radiant
`efficiency of the LEDs typically being between 20 % and
`45 % , this means that approximately 55-80 % of the input
`power will be lost as heat . Assuming a 75 % heat loss , this
`means 180-206 W of power is continuously being lost as
`heat which to prevent junction temperatures from rising
`must be efficiently removed .
`[ 0023 ]
`In view of the foregoing and in summary , there has
`been a need for lightweight LED lighting systems that
`provide desired light on target ( e.g. suitable , desired and
`usable light volume delivered to the area where workers
`require the light to complete tasks ) and that can be effec
`tively configured to tall structures at different and / or various
`heights from the surface of a work site ( whether smaller
`service rigs or larger drilling rigs ) . In addition , there has
`been a need for LED lamp assemblies and LED lighting
`systems with lower ratios of grams / lumens than current LED
`lighting systems whilst enabling effective heat dissipation to
`maintain recommended junction temperatures .
`[ 0024 ]
`Further still , there has been a need for LED lighting
`systems that integrate , partially - integrate and / or are other
`wise configured with or to functional features of a rig's
`upper mast and / or crown with an LED lighting system such
`that the net added weight of adding lighting to a drilling mast
`is reduced . In addition , there has been a need for LED
`lighting systems that integrate or partially - integrate with , or
`act as a substitute and / or partial substitute for , components
`and / or sub - components of a rig mast , crown , structure , or
`other such item , without limitation , that exists as part of the
`rig assembly prior to the addition and / or configuration of an
`LED lamp assemblies and / or an LED lighting system .
`Further , there has been a need for LED lighting systems that
`reduce the effective net added weight and / or minimize the
`weight / lumen ratio when compared to prior art .
`[ 0025 ]
`Further still , there remains a need for LED lighting
`systems that can be configured to a rig as a permanent and / or
`semi - permanent system thereby minimizing or eliminating
`
`the need to remove and / or partially remove the LED lamp
`assemblies and / or LED lighting system during transporta
`tion activities .
`[ 0026 ]
`In addition , there has also been a need for portable
`lighting systems for other applications including temporary
`lighting applications such as interior construction applica
`tions that provide desired lighting but that reduce both the
`size and the weight of the lighting systems .
`[ 0027 ]
`Further still , it is desirable in certain applications ,
`including the operation of drilling rigs , that the light cast
`from a high mast does not create excessive light pollution to
`areas adjacent the work site . As such , the design of a lamp
`assembly should provide relatively precise light paths that
`illuminate the desired areas but do not allow excessive light
`to escape . The design of reflectors can be adjusted to enable
`sharper boundaries between illuminated and non - illumi
`nated areas from a particular light source . However , as light
`towers become taller , the precision of these boundaries
`becomes lower for a given reflector . Tighter boundaries can
`be achieved by deeper and narrower reflectors ; however , this
`must also be balanced against the proximity of a hot LED
`near the reflector .
`
`SUMMARY OF THE INVENTION
`In accordance with the invention , there is provided
`[ 0028 ]
`an LED lighting system for configuration to a supporting
`structure , the LED lighting system comprising : a plurality of
`LED lamps and reflectors within at least one LED lamp
`assembly ; an air flow system having at least one air flow
`conduit ( AFC ) for directing air flow against each LED lamp
`assembly to effect cooling of the LED lamps and to provide
`structural support to each LED lamp assembly for connec
`tion to the supporting structure ; and wherein the LED
`lighting system has a weight / lumen ratio of less than 0.55
`g / lumen .
`[ 0029 ]
`In various embodiments , the LED lighting system
`has a weight / lumen ratio of less than 0.35 g / lumen and / or
`less than 0.25 g / lumen .
`[ 0030 ]
`In various embodiments , the LED lighting system
`provides
`er than 500,000 lumens and / or
`er than 1.0
`MM lumens .
`[ 0031 ]
`In further embodiments , each LED lamp assembly
`includes a lamp assembly housing having a plurality of
`surfaces for effecting heat transfer of heat from the LED
`lamps away from the LED lamps .
`[ 0032 ]
`In other embodiments , each AFC is operatively
`connected to a lamp assembly housing , the AFC having an
`air channel for moving cooling air through the AFC and for
`conveying heat from each LED lamp assembly away from
`each LED lamp assembly to effect cooling of each LED
`lamp assembly and to maintain an operating temperature of
`the LED lamp assembly at or below a threshold tem