Patent Grant
9835298
Field of the Invention
The invention relates to a LED underwater pool light, more specifically an exemplary embodiment of an underwater LED light known as a pendant or accent light in the industry and a niche fixture for same.
Background of the Invention
Existing LED underwater pendant or accent lights have known reliability issues in remaining water tight. One example of an existing pendant light is the light produced by Nexxus Lighting and sold as the SAVI-MELODY LED light. There have been a number of issues in these popular existing designs with leaks and warranty claims based on broken seals. In existing LED lights, expansion from heat generated by the LEDs and the electronics often causes unacceptable expansion pressures on the seals and the housing of the accent or pendant light. This results in eventual fatigue and failure in the soundness of the housing. Besides rendering the LED non-functional and causing warranty claims issues, water infiltration also poses potential safety issues in submerged lighting. There are several ways to address the issue, including redesign of the thermal load carrying components, reducing heat output, or increasing thermal load diffusion into the surroundings. Thus, redesign of this type of light fixture to resolve the expansion pressure issue can also be accompanied by provision of solutions for additional cooling and/or reduction of thermal loading.
A need exists for an improved LED pendant or accent light that does not exhibit the debilitating issues with transmitted thermal expansion pressures and failure of the watertight housing which also incorporates active cooling within a fixture that provides a safe and watertight connection as well as improves ease of installation. The instant invention provides for an improved light that is more reliable and has better thermal energy transport away from the thermal sources and a fixture to aid in same as well as improve installation efficiency and safety. In addition, installation of these types of lights is generally completed through fishing an electrical line through to the fixture. Often the smallest obstruction in the line can cause installation issues. A need exists for improved designs in the fixtures to assist in installation of the fixture and guidance of the electrical line to the fixture.
An aspect of the invention is to provide a more efficient heat sink that accommodates thermal expansion and reduces pressure on water tight seals in an underwater LED pendant or accent light.
A further aspect of the invention is to provide a further thermally conductive cooling path in an underwater LED pendant or accent light that allows heat to radiate from the heat sink into the body of water through a thermal pathway provided in the underwater LED pendant or accent light.
Yet another aspect of the invention is provision of a water gap within the installation to provide direct contact of the housing with the water in the installation and allow increased cooling across a greater surface area.
Still a further aspect of the invention is provision of a niche sleeve which is placed within an installation tube and provides a wire guide portion to facilitate more efficient installation of the wiring for the accent light, the wire then being coupled through the housing of the light and the housing of the light being installed within the niche sleeve with a watertight seal to prevent contact with the power source wire and a water gap between the niche sleeve and the housing.
Another aspect of the invention is an improved method of installing a light within an installation tube in a water feature allowing the installation tube to be left at a convenient length protruding from the water feature wall, the tube being cut to length, a niche sleeve being installed with a facia to provide a finished look to the outlet and providing an installation point for the accent light.
The invention includes an article of manufacture, an apparatus, a method for installing the article, and a method for using the article in an installation.
The method of the invention includes a method of using a heat sink in a submerged accent light to provide reduced pressure on the water tight light housing, having the steps of assembling a water tight accent or pendant light having a lens, a coupling to a power source, an electrical section, an at least one LED, and the heat sink assembled and contained in the housing; providing an at least one thermal expansion slot in the heat sink and a thermal conductive path from the heat sink to the housing and lens such that the thermal expansion slot permits thermal expansion of the heat sink as it absorbs heat from the at least one LED and the electronics section; and installing and cooling the submerged accent light in an installation in a body of water through the thermal conductive path.
The apparatus of the invention includes an underwater pendant or accent light in contact with a body of water. The apparatus having a housing with an at least one water tight end fitting at a first end of the housing and an at least one lens at a second end of the housing. An electronics section including an at least one controller contained within the housing and coupled to a power source. An at least one LED is coupled to the electronics section. An at least one heat sink is coupled to the at least one LED and the electronics section, the heat sink thermally coupled to and mounting the at least one LED and thermally coupled to the electronics section such that heat is communicated through the at least one heat sink, the heat sink having an at least one thermal expansion slot to accommodate thermal expansion of the heat sink as it absorbs heat, wherein the heat sink is in thermal communication through a thermal path with the housing and transmits the absorbed heat through the housing and lens to the body of water.
The underwater pendant or accent light can also provide an at least one water tight gasket or fitting, fit between the second end of the housing and the lens to render the housing water tight. The housing, the at least one water tight end fitting, the lens, and the heat sink can be generally cylindrical. The heat sink can be constructed from a thermally conductive plastic as can the housing. The heat sink can be constructed from a thermally conductive metal or composite as can the housing.
The at least one LED can be mounted on a LED printed circuit board that can be in communication with the controller in the electronics section. The at least one thermal expansion slot can be a single thermal expansion slot that is uniform along a side of the heat sink. The at least one thermal expansion slot can be non-uniform along a side of the heat sink. The thermal expansion slot can also be a single thermal expansion slot and can further comprise an at least one semi-circular portion of the thermal expansion slot permitting a further electrical coupling to pass between the electronics section and the at least one LED. The thermal expansion slot can be more than one thermal expansion slot passing through a part or the entirety of the heat sink, the heat sink sidewall, and/or the heat sink top.
The light can include additional thermal pathway structures coupling the heat sink to at least one of the at least one LED, the electronics section, and the housing. It can also include an at least one mounting device external to the housing and providing mounting of the light in the body of water.
The apparatus of the invention also includes an accent or pendant LED light submerged in a pool or spa or water feature within a return line or niche in the pool or spa or water feature, having a generally cylindrical water tight housing constructed of a thermally conductive material having a first water tight coupling at one end of the cylindrical housing, the first water tight coupling having a connection to a power source and a second water tight coupling having a lens and at least one water tight gasket at the other end of the cylindrical housing. It also has an electronics section, including a controller, a thermocouple and a first printed circuit board in electrical communication with a second printed circuit board mounting an at least one LED and controlling the at least one LED; a generally cylindrical heat sink having an at least one thermal expansion slot thereon, the heat sink having a cylindrical sidewall and a top covering one end of the sidewall and a hollow interior within the cylindrical sidewall and below the top, the at least one thermal expansion slot extending along the length of the cylindrical sidewall and through a portion of the top. Where the at least one thermal expansion slot accommodates thermal expansion of the heat sink as it absorbs heat from the electronics section and the at least one LED with the heat sink in thermal communication through a thermal path with the housing and transmitting the absorbed heat through the housing and lens to the pool or spa or water feature.
The article of manufacture of the invention includes an accent or pendant LED light submergible in a pool or spa or water feature within a return line or niche in the pool or spa or water feature, the light having a generally cylindrical water tight housing constructed of a thermally conductive material having a first water tight coupling at one end of the cylindrical housing, the first water tight coupling having a connection to a power source and a second water tight coupling having a lens and at least one water tight gasket at the other end of the cylindrical housing with an electronics section including a first printed circuit board in electrical communication with a second printed circuit board mounting an at least one LED and controlling the at least one LED; a generally cylindrical heat sink having an at least one thermal expansion slot thereon the heat sink having a cylindrical sidewall and a top covering one end of the sidewall and a hollow interior within the cylindrical sidewall and below the top, the at least one thermal expansion slot extending along the length of the cylindrical sidewall and through a portion of the top, the method comprising the steps of assembling the at least one LED to the second printed circuit board with the heat sink and the electronics section, assembling the housing with the first water tight coupling to the end of the housing and coupling the electrical source to the electronics section, assembling the housing with the second water tight coupling having a lens and an a least one water tight gasket; and operating the light.
The apparatus of the invention includes an underwater pendant or accent light installation within a wall of a water feature having an installation tube and a niche tube having a facia section at the terminus of the niche tube in communication with the water feature and having a water inlet coupled to a water gap section. An at least one underwater pendant or accent light having a housing, a lens body, an electronics section, an at least one heat sink, and an at least one LED, the underwater pendant or accent light being coupled in a watertight fashion to a power source through the watertight coupling is contained within the niche tube such that the water gap section surrounds at least in part the housing and permits water from the water feature to circulate in contact the housing but not penetrate into the watertight electrical connection.
The niche tube can be coupled to the niche facia which is coupled to the lens body with the water inlet therein such that water from water feature cools the lens body as well as the housing and thereby the underwater pendant or accent light. An at least one wire guide section in communication with the watertight electrical coupling can be included.
An at least one flange section at the terminus of the water gap formed between the niche tube and the housing closest to the watertight coupling can also be provided. An at least one sealing member can be spaced between the housing and the flange section.
The at least one heat sink can further contain an expansion slot therein. An at least one set of threads coupling the electrical source with the pendant or accent light can be provided. An at least one threaded coupling coupling the lens body to the housing and at least one threaded coupling coupling the facia and lens body can be provided. The niche tube can also be affixed within the installation tube with at least one of an at least one friction coupling, mechanical fastener, and an adhesive. The wire guide section can provides a further watertight area between the water tight section and the electrical connector.
The method of the instant invention includes a method of assembling an accent light or pendant light within the wall of a water feature, including slidingly engaging an installation tube with a niche sleeve in said wall of said water feature, forming a water tight electrical connection with the niche sleeve, coupling an at least one accent light with a housing and an at least one lens body to the housing such that it forms a watertight electrical connection and can power said accent light therewith and engaging the lens body with a niche collar and niche sleeve where a water gap is provided between the niche sleeve and the housing to allow water to penetrate into the niche sleeve through openings in the lens body being held by the niche collar and the water gap cools the housing of the at least one accent light.
The method of the invention further includes a method of installing accent light or pendant light within the wall of a water feature, including installing an installation tube in said wall of said water feature, cutting said tube flush with said wall, installing a niche sleeve with an at least one wire guide therein into the installation tube, threading an electrical source coupling wire through the installation tube and the nice sleeve, coupling an at least one watertight electrical coupling to the electrical source coupling wire, inserting the coupling into the sleeve to create a watertight coupling with an electrical source, coupling a housing of an accent light, having a lens assembly attached thereto, in a watertight fashion to the watertight coupling with the electrical source, and installing a niche collar around the housing and to the niche sleeve such that a water gap is provided to allow water to flow from the water feature in and around the housing and cool the housing and the lens assembly. The method can further include affixing the niche tube within the installation tube. The affixing of the niche tube can include affixing the niche tube with at least one of an at least one friction coupling, mechanical fastener, and adhesives.
Moreover, the above objects and advantages of the invention are illustrative, and not exhaustive, of those which can be achieved by the invention. Thus, these and other objects and advantages of the invention will be apparent from the description herein, both as embodied herein and as modified in view of any variations which will be apparent to those skilled in the art.
Embodiments of the invention are explained in greater detail by way of the drawings, where the same reference numerals refer to the same features.
A watertight fitting 50 coupling the light to a power source (not shown) is provided at one end of the watertight housing 20. The water tight fitting 50 may also render the light self contained with a power source, such as a battery, incorporated into the light or coupled to an alternative source of power through an appropriate coupling. On the other end of the watertight housing 20 as shown, a set of optional external threads 25 are provide for mounting the light in the body of water. The external threads 25 are used with or without a mounting device (not shown) to hold the light within the body of water within the pool or water feature. Additional methods of retaining the accent light may be utilized for example, but not limited to, adhesives, wedges, or similar mechanisms or materials. A set of internal threads 75 are provided inside the housing to retain the lens 70. An at least one water tight gasket or fitting 80, 90 is placed between the screw on lens or lens body 70 and the inside threads 75. In the exemplary embodiment shown, a set of o-ring gaskets 80, 90 are provided and fit between the lens 70 and the watertight housing 20. Various types and numbers of gaskets or fittings can be utilized or the end may be a unitary construction incorporating the lens or optic without departing from the spirit of the invention to attach the lens or lens body 70 to the housing 20 and provide a water tight seal. The housing 20, is positioned in the body of water so that the lens 70 points into the body of water to provide a pleasing lighting affect. This can occur, for instance, in recesses provided in the body of water or within piping for the body of water (not shown), for instance a water return on a pool or spa or water feature.
Within the water tight housing 20 an at least one LED 30 is provided. The at least one LED 30 is potted with a thermally conductive potting material on an LED printed circuit board 60. The at least one LED 30 potted on the LED printed circuit board 60 is further potted and/or coupled, both mechanically and thermally, to a heat sink 40. The LED printed circuit board 60 can be further secured to the heat sink 40 by an at least one affixing device 100, shown in the exemplary embodiment as mounting screws 100. The mounting screws 100 fit into pre-drilled mounting points 65 in the heat sink 40. The coupling of the LED printed circuit board 60 is provided such that it can expand with the heat sink 40 as the heat sink 40 absorbs heat. A non limiting example to accommodate the expansion is to provide a further slot in the LED printed circuit board 60. Another non-limiting example is to select a printed circuit board or mounting screws that can accommodate loading and/or flexing from the expansion. Various other mechanical and non-mechanical changes can be made to accommodate the expansion and are well within the spirit of the invention.
The heat sink 40 is composed of thermally conductive material. In the exemplary embodiment of the invention shown, the heat sink 40 is constructed of, for instance but certainly not limited to, a thermally conductive metal, such as copper, brass, or aluminum, or a thermally conductive plastic in the exemplary embodiment shown. The heat sink 40 may also be comprised of a composite, a metal alloy or any suitable material with the desired thermal properties to allow for thermal loading and transmission.
In the exemplary embodiment shown, as better seen in
In the exemplary embodiment shown, the at least one thermal expansion slot is a single thermal expansion slot 45 with a uniform width throughout. In further embodiments, more than one thermal expansion slot can be provided. Similarly, in still further embodiments modifications to the width of the at least one thermal expansion slot 45 and variations in the uniformity of the at least one thermal expansion slot 45 are contemplated and well within the spirit of the invention. For instance, the at least one thermal expansion slot 45 can include semi-circular cutouts to provide for clearance of connecting wires and the like, see for instance
The thermal expansion slot 45 in the light provides a path for expansion as the heat sink 40 absorbs heat from the components of the light. The expansion slot 45 reduces pressure from the expansion of the heat sink 40 on the water tight housing 20. The space in the expansion slot 45 allows for the ends of the heat sink 40 to move through the thermal expansion and through the movement reduce the width of the expansion slot 45, thus reducing outward pressure on the water tight housing 20. This, in turn, results in less potential for rupture or cracking occurring in the water tight housing 20.
The heat sink 40 is thermally coupled to the LED printed circuit board 60 which is thermally coupled to the at least one LED 30. The whole arrangement is thermally coupled to the housing 20 and the lens body 70, such that a thermal pathway is expediently provided for direct conductive transmission of heat from the pendant or accent light into the body of water as a heat dump. In an exemplary embodiment, a thermally transmissive compound is used to provide a thermal path for the heat through out the coupled components, for instance a thermal past or potting compound. Special thermal pathway structures, such as micro heat pipes, can also be added to provide additional thermal transmission throughout the light. The thermal path to the water surrounding the housing 20 allows for the use of higher power LEDs. Additionally, although the instant invention provides improved thermal transmission, a thermocouple limiter is provided in the electronics section 10, for instance on the printed circuit board with the controller, to prevent thermal damage if, for some reason, temperatures exceed the maximum limits of the electrical components.
The light is assembled with the water tight fitting 50 coupled to a power source (not shown) and secured to one end of the watertight housing 20 and the lens or lens body 70 is screwed into the internal threads 75 with the at least one gasket member 80, 90 with the heat sink 40, the at least one LED 30, and the LED printed circuit board 60 mounting the at least one LED. These are coupled together or held in place with a thermal compound, such as a thermally transmissive paste. The LED printed circuit board 60 is coupled to the electrical section 10 and the controller contained therein on a printed circuit board, in this instance the same board as LED printed circuit board 60. Thus in the exemplary embodiment shown, the at least one LED printed circuit board 60 has the controller controlling the at least one LED 30. In further embodiments, the controller may be incorporated on its own printed circuit board or on a circuit board that is in communication with the accent light and controlled as a slaved light to a master controller in a pool light control system.
Within the housing, the at least one LED 30 is provided mounted on the at least one LED printed circuit board 60 and these are coupled to the heat sink 40. The heat sink 40 is in or nearly in communication with the housing 20. The controller and the printed circuit board in the electronics section 10 are located, in this embodiment, on the opposite side of the heat sink 40 from the at least one LED, within a hollow within the heat sink 40. The thermal expansion slot 45 is not shown clearly in this cross sectional view.
The mounting of the at least one LED 30 and the LED printed circuit board 60 in thermal communication with the heat sink 40 and the coupling of the controller and printed circuit board in the electronics section 10 in thermal communication with the heat sink 40 results in transmission of heat into the heat sink 40. The heat expands the heat sink 40, the thermal expansion slot 45 allowing for the transmission of the majority of the movement and therefore the pressure from expansion to go back into the heat sink 40, but the heat sink 40 is in or comes into communication with the housing 20 and a thermal bridge is formed with the housing 20 and the lens 70. This permits heat to transfer through the heat sink into the housing 20 and thereby into the water surrounding the light in the body of water. This results in effective cooling of the light and, with the thermal expansion slot 45 this cooling is accomplished without transmission of the majority of the pressures from thermal expansion of the heat sink 40 into the housing 20. This results in a more robust light with a longer operating life and improved soundness and less warranty claims as the expansion pressures from the thermal loading are significantly reduced, in fact almost removed.
A set of external threads 25 is provided and engaged by lens body 70. Lens body 70 is coupled to the niche sleeve 200 having a niche collar or facia 205 with an exposure slot or inlet 255 which opens to the water gap 250 allowing water through the inlets 255 in the niche collar 205. The niche sleeve 200 terminates at the niche collar 205 at the end of the fixture which mounts flush to the installation tube 300. In addition to the niche collar 205, a retaining member 257 with retaining slot 259 is shown in the exemplary embodiment of
Within the housing 20 an at least one LED 30 is provided. Again, as shown in previous
Within the housing 20, an electronics section 10 is also provided having a controller, again mounted on an at least one LED printed circuit board 60, and electronics for the at least one LED accent light 1. The electronics section 10 is coupled electrically through the threaded watertight electrical fitting 50 to an electrical power source (not shown) through wire 8. As seen in
At the terminus of the niche sleeve 200 opposite the lens body 70 is a further wire guide section 225. Wire guide section 225 is flared such that it provides an additional barrier to potential leaks beyond collar 205 and it assists in maintaining water tightness within the installation tube. In addition to maintaining water tightness the wire guide section 225 assists in the threading of wire 8 to the point of connection for light 1 during installation. The housing 20 with the water gap 250 isolates the water gap 250 providing overlapping flange 213 with a sealing member 211.
During construction of pool, and the walls of the pool or water future, installation tubes 300 are provided in and through the walls of the water feature. One advantage of the design of the instant invention is it permits these tubes to be run out to any convenient length extending beyond the wall 2 of the water feature. The resulting installation tube 300 can be cut flush with the wall 2 of the water feature or pool. The instant invention with its niche sleeve or tube 200 can then be inserted. A wire 8 can be run within the installation tube 300 and guided via wire guide section 225 into the niche tube 200. The wire can be pulled through, then it can be easily coupled to watertight fitting 50. The coupled wire 8 and watertight fitting 50 can then be joined to the housing 20. Alternatively, the water tight fitting may be placed and then tightened within the niche tube 200 and the housing 20 then coupled therein. In either case, the accent light 1 with housing 20 can then be inserted the niche tube 200 for final installation. In this way in addition to providing improved cooling, longer life, and improved reliability, instant invention also provides greater ease of connection and greater efficiency during installation and improved safety in electrical coupling.
The embodiments and examples discussed herein are non-limiting examples. The invention is described in detail with respect to exemplary embodiments, and it will now be apparent from the foregoing to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and the invention, therefore, as defined in the claims is intended to cover all such changes and modifications as fall within the true spirit of the invention.
This application is a continuation in part of and claims priority to U.S. patent application Ser. No. 13/206,499, filed Aug. 9, 2011, which is incorporated herein by reference.
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| Number | Date | Country | |
|---|---|---|---|
| 20130100651 A1 | Apr 2013 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13206499 | Aug 2011 | US |
| Child | 13707591 | US |
