Patent Application
20140268692
1. Field of the Invention
The invention relates to lighting troffers and, more particularly, to indirect lighting troffers that are well-suited for use with solid state lighting sources, such as light emitting diodes (LEDs).
2. Description of the Related Art
Troffer-style fixtures are ubiquitous in commercial office and industrial spaces throughout the world. In many instances these troffers house elongated fluorescent light bulbs that span the length of the troffer. Troffers may be mounted to or suspended from ceilings. Often the troffer may be recessed into the ceiling, with the back side of the troffer protruding into the plenum area above the ceiling. Typically, elements of the troffer on the back side dissipate heat generated by the light source into the plenum where air can be circulated to facilitate the cooling mechanism. U.S. Pat. No. 5,823,663 to Bell, et al. and U.S. Pat. No. 6,210,025 to Schmidt, et al. are examples of typical troffer-style fixtures.
Door frame troffers are typically mounted to and recessed into a ceiling. A door frame troffer can be installed by attaching one side of the troffer to the ceiling to form a hinge. One or more (in the case of a rectangular troffer, up to three) unhinged sides of the troffer can have attachment mechanisms such as latches. When the troffer is swung about the hinged side into a closed position, the latches can secure the troffer to the ceiling. Troffers that are installed in this manner often include a housing such as a metal back box which protrudes into the plenum. Troffers can also sometimes be installed as retrofit systems to work with components already present in a building, such as a metal back box or a back box used with a fluorescent troffer. Door frame troffers are discussed generally in U.S. Pat. No. 8,038,318 to Plunk.
More recently, with the advent of the efficient solid state lighting sources, these troffers have been used with LEDs, for example. LEDs are solid state devices that convert electric energy to light and generally comprise one or more active regions of semiconductor material interposed between oppositely doped semiconductor layers. When a bias is applied across the doped layers, holes and electrons are injected into the active region where they recombine to generate light. Light is produced in the active region and emitted from surfaces of the LED.
LEDs have certain characteristics that make them desirable for many lighting applications that were previously the realm of incandescent or fluorescent lights. Incandescent lights are very energy-inefficient light sources with approximately ninety percent of the electricity they consume being released as heat rather than light. Fluorescent light bulbs are more energy efficient than incandescent light bulbs by a factor of about 10, but are still relatively inefficient. LEDs by contrast, can emit the same luminous flux as incandescent and fluorescent lights using a fraction of the energy.
In addition, LEDs can have a significantly longer operational lifetime. Incandescent light bulbs have relatively short lifetimes, with some having a lifetime in the range of about 750-1000 hours. Fluorescent bulbs can also have lifetimes longer than incandescent bulbs such as in the range of approximately 10,000-20,000 hours, but provide less desirable color reproduction. In comparison, LEDs can have lifetimes between 50,000 and 70,000 hours. The increased efficiency and extended lifetime of LEDs is attractive to many lighting suppliers and has resulted in their LED lights being used in place of conventional lighting in many different applications. It is predicted that further improvements will result in their general acceptance in more and more lighting applications. An increase in the adoption of LEDs in place of incandescent or fluorescent lighting would result in increased lighting efficiency and significant energy saving.
Other LED components or lamps have been developed that comprise an array of multiple LED packages mounted to a printed circuit board (PCB), substrate or submount. The array of LED packages can comprise groups of LED packages emitting different colors, and specular or other reflector systems to reflect light emitted by the LED chips. Some of these LED components are arranged to produce a white light combination of the light emitted by the different LED chips.
In order to generate a desired output color, it is sometimes necessary to mix colors of light which are more easily produced using common semiconductor systems. Of particular interest is the generation of white light for use in everyday lighting applications. Conventional LEDs cannot generate white light from their active layers; it must be produced from a combination of other colors. For example, blue emitting LEDs have been used to generate white light by surrounding the blue LED with a yellow phosphor, polymer or dye, with a typical phosphor being cerium-doped yttrium aluminum garnet (Ce:YAG). The surrounding phosphor material “downconverts” some of the blue light, changing it to yellow light. Some of the blue light passes through the phosphor without being changed while a substantial portion of the light is downconverted to yellow. The LED emits both blue and yellow light, which combine to yield white light.
In another known approach, light from a violet or ultraviolet emitting LED has been converted to white light by surrounding the LED with multicolor phosphors or dyes. Indeed, many other color combinations have been used to generate white light.
Because of the physical arrangement of the various source elements, multicolor sources often cast shadows with color separation and provide an output with poor color uniformity. For example, a source featuring blue and yellow sources may appear to have a blue tint when viewed head on and a yellow tint when viewed from the side. Thus, one challenge associated with multicolor light sources is good spatial color mixing over the entire range of viewing angles. One known approach to the problem of color mixing is to use a diffuser to scatter light from the various sources.
Another known method to improve color mixing is to reflect or bounce the light off of several surfaces before it is emitted from the lamp. This has the effect of disassociating the emitted light from its initial emission angle. Uniformity typically improves with an increasing number of bounces, but each bounce has an associated optical loss. Some applications use intermediate diffusion mechanisms (e.g., formed diffusers and textured lenses) to mix the various colors of light. Many of these devices are lossy and, thus, improve the color uniformity at the expense of the optical efficiency of the device.
Many current luminaire designs utilize forward-facing LED components with a specular reflector disposed behind the LEDs. One design challenge associated with multi-source luminaires is blending the light from LED sources within the luminaire so that the individual sources are not visible to an observer. Heavily diffusive elements are also used to mix the color spectra from the various sources to achieve a uniform output color profile. To blend the sources and aid in color mixing, heavily diffusive exit windows have been used. However, transmission through such heavily diffusive materials causes significant optical loss.
Some recent designs have incorporated an indirect lighting scheme in which the LEDs or other sources are aimed in a direction other than the intended emission direction. This may be done to encourage the light to interact with internal elements, such as diffusers, for example. One example of an indirect fixture can be found in U.S. Pat. No. 7,722,220 to Van de Ven which is commonly assigned with the present application.
Many different types and designs of indirect fixtures are possible, as shown by U.S. Pat. No. 7,722,220 to Van de Ven and U.S. patent application Ser. No. 12/873,303 to Edmond, et al. and entitled “Troffer-Style Fixture,” both of which are commonly assigned with the present invention and fully incorporated by reference herein. One challenge in designing all fixtures, and particularly indirect lighting fixtures, is to create a large luminous area. For instance, some of the troffers described in U.S. patent application Ser. No. 12/873,303 have a luminous area defined by the dimensions of the light engine, which is relatively small compared to the area of the troffer as a whole. The mixing chamber of such a troffer is also defined by the dimensions of the light engine. Typically a larger mixing chamber results in a more uniform emission.
Modern lighting applications often demand high power LEDs for increased brightness. High power LEDs can draw large currents, generating significant amounts of heat that must be managed. Many systems utilize heat sinks which must be in good thermal contact with the heat-generating light sources. Troffer-style fixtures generally dissipate heat from the back side of the fixture that extends into the plenum. This can present challenges as plenum space decreases in modern structures. Furthermore, the temperature in the plenum area is often several degrees warmer than the room environment below the ceiling, making it more difficult for the heat to escape into the plenum ambient.
One embodiment of a troffer comprises a housing with a door frame, a back reflector, and at least one light bar comprising a mount surface. The mount surface is capable of having at least one light emitter mounted thereto. The region between the at least one light bar and the back reflector defines a mixing chamber.
One embodiment of a troffer comprises a door frame with a back reflector and at least one light bar mounted thereto. The light bar comprises a mount surface. The region between the light bar and the back reflector defines a mixing chamber.
One method of assembling an indirect lighting troffer comprises the following steps. First, an inner surface of an original housing is coated with a reflective material. Then a first side of a door frame is mounted to a first side of the original housing to form a hinge. A second side of the door frame is connected to a second side of the original housing. At least one light bar comprising an emitter is mounted to the door frame.
Embodiments of the present invention provide a troffer-style fixture that is particularly well-suited for use with emitters such as solid state light sources, and in particular light emitting diodes (LEDs). The troffer can comprise a door frame with light bars running therebetween. The light bars can comprise mount surfaces with emitters mounted thereon. The light bars themselves can also serve as heat sinks, and a portion of the heat sink can be exposed to the ambient environment below the ceiling plane. A back reflector defines a reflective surface of the troffer. In some embodiments, one or more lens plates can be secured within the perimeter of the door frame. The interior cavity of the troffer between the reflector and the area defined by the door frame serves as a mixing chamber for the troffer where light can be mixed and/or shaped before it is emitted. Lens plates, if present, can help to further mix and/or shape the emitted light.
Because LED sources are relatively intense when compared to other light sources, they can create an uncomfortable working environment if not properly diffused. Fluorescent lamps using T8 bulbs typically have a surface luminance of around 21 lm/in2. Many high output LED fixtures currently have a surface luminance of around 32 lm/in2. Some embodiments of the present invention are designed to provide a surface luminance of not more than approximately 32 lm/in2. Other embodiments are designed to provide a surface luminance of not more than approximately 21 lm/in2. Still other embodiments are designed to provide a surface luminance of not more than approximately 12 lm/in2. Some embodiments are designed to have a max/min ratio of less than about 3.5. Other embodiments are designed to have a max/min ration of less than about 3.
Some fluorescent fixtures have a depth of 6 in., although in many modern applications the fixture depth has been reduced to around 5 in. In order to fit into a maximum number of existing ceiling designs, some embodiments of the present invention are designed to have a fixture depth of 5 in or less.
Embodiments of the present invention are designed to efficiently produce a visually pleasing output. Some embodiments are designed to emit with an efficacy of no less than approximately 65 lm/W. Other embodiments are designed to have a luminous efficacy of no less than approximately 76 lm/W. Still other embodiments are designed to have a luminous efficacy of no less than approximately 90 lm/W.
One embodiment of a fixture for installation into a ceiling space is designed such that at least 75% of the visible surface of the fixture is luminous. Other embodiments are designed such that at least 90% of the visible surface is luminous. Still other embodiments are designed such that at least 95% of the visible surface is luminous.
One embodiment of a door frame troffer can be installed as a retrofitting system and replace, for example, fluorescent components. After removing fluorescent components, a housing may or may not still be present, such as above the ceiling plane and into the plenum of a building. If a housing is still present, then the housing can be coated or painted with an appropriate reflective material. The door frame troffer without a housing can then be installed and use the coated or painted housing as a back reflector. If a housing is not present, then a troffer comprising a housing can be installed.
Door frame troffers can also be installed using a hinge-and-latch method. One side of the troffer can be attached to a section of ceiling to form a hinge. The body of the troffer can then be swung such that the door frame is flush with the ceiling plane, and latches on one or more of the unhinged sides can then be connected to the ceiling to secure the door frame troffer.
Embodiments of the present invention are described herein with reference to conversion materials, wavelength conversion materials, phosphors, phosphor layers and related terms. The use of these terms should not be construed as limiting. It is understood that the use of the term phosphor, or phosphor layers is meant to encompass and be equally applicable to all wavelength conversion materials.
It is understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. Furthermore, relative terms such as “inner”, “outer”, “upper”, “above”, “lower”, “beneath”, and “below”, and similar terms, may be used herein to describe a relationship of one element to another. It is understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.
Although the ordinal terms first, second, etc., may be used herein to describe various elements, components, regions and/or sections, these elements, components, regions, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, or section from another. Thus, unless expressly stated otherwise, a first element, component, region, or section discussed below could be termed a second element, component, region, or section without departing from the teachings of the present invention.
As used herein, the term “source” can be used to indicate a single light emitter or more than one light emitter functioning as a single source. For example, the term may be used to describe a single blue LED, or it may be used to describe a red LED and a green LED in proximity emitting as a single source. Thus, the term “source” should not be construed as a limitation indicating either a single-element or a multi-element configuration unless clearly stated otherwise.
The term “color” as used herein with reference to light is meant to describe light having a characteristic average wavelength; it is not meant to limit the light to a single wavelength. Thus, light of a particular color (e.g., green, red, blue, yellow, etc.) includes a range of wavelengths that are grouped around a particular average wavelength.
Embodiments of the invention are described herein with reference to cross-sectional view illustrations that are schematic illustrations. As such, the actual thickness of elements can be different, and variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances are expected. Thus, the elements illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region of a device and are not intended to limit the scope of the invention.
The troffer 100 has a rectangular bottom-side footprint and comprises two light bars 106 which traverse the width of the fixture 100. The light bars 106 can comprise a mount surface, often on their back sides. Emitters such as light emitting diodes (LEDs) can be mounted to these mount surfaces. Light bars are discussed in detail herein. While two light bars 106 are shown in the
The troffer 100 also comprises a reflector 104. The reflector 104 serves to reflect light from the light bars 106 and through the lens plates 108. The area between the door frame 102 and/or the light bars 106 of the troffer 100 and the reflector 104 serves as an interior cavity or light mixing chamber 110. Some embodiments of reflectors are described in detail herein.
The troffer 100 also comprises lens plates 108. These lens plates 108 can occupy the areas within the door frame 102 between sections of the door frame 102 and the light bars 106. Many types of lens plates 108 can be used in the troffer 100. Some embodiments are described in detail herein.
The troffer 100 also comprises a housing 112. The housing 112 is designed to fit within a ceiling. In some cases, a housing may already be present in a ceiling prior to installation. A troffer can then be installed by attaching it to the existing housing, which can save the costs associated with completely replacing a housing. Further, while the troffer 100 comprises a separate reflector 104, in some cases a separate reflector is not needed and the housing 112 itself serves as a reflector. Some embodiments comprise both a separate reflector and a reflective housing.
While
While the reflector embodiments shown in
Reflectors according to the present invention can comprise many different materials. In one embodiment of the present invention, the reflector comprises a diffuse reflective surface. In some embodiments of the present invention, a reflector can comprise a polymeric or film material designed to reflect light emitted from an emitter on a light bar. In some embodiments the reflector surface can be white. In some embodiments the reflector comprises a white plastic, such as white plastic sheet(s) or one or more layers of microcellular polyethylene terephthalate (“MCPET”), and in some embodiments the reflector comprises white paper. In some embodiments reflector can comprise a white film, such as White97™ Film available from WhiteOptics, LLC, of New Castle, Del. In other embodiments the reflector can comprise metal, including but not limited to WhiteOptics™ Metal, available from WhiteOptics, LLC, or similar materials. In some embodiments, the reflector can be a plastic or metal device that is coated or painted with a reflective material or another base material coated with a reflective material. Materials can also include specular reflectors which can help directly control the angle of redirected light rays, Lambertian reflectors, and combinations of diffuse, specular, and Lambertian reflectors.
In some embodiments, the texturing can be imparted to the reflector 456 by roughening the interior or exterior surface of the reflector. As in the case of imprinting, polycarbonate can be used. Also as in the case of imprinting, the intensity of the roughening can vary spatially relative to the center of the reflector and/or the positioning of the light source. The roughening can be accomplished in a number of different ways, regardless of whether the reflector is initially made by extrusion or by some other method.
The textured reflector 456 can provide color mixing and reduce color hot spots and reflections in a light fixture that uses multiple color emitters. As an example some fixtures include blue-shifted yellow plus red (BSY+R) LED systems, wherein the LED light source includes at least two groups of LEDs, wherein one group emits light having a dominant wavelength from 435 to 490 nm, and another group emits light having a dominant wavelength from 600 to 640 nm. In such a case, one group can be packaged with a phosphor, which, when excited, emits light having a dominant wavelength from 540 to 585 nm. In some embodiments, the first group emits light having a dominant wavelength from 440 to 480 nm, the second group emits light having a dominant wavelength from 605 to 630 nm, and the troffer emits light having a dominant wavelength from 560 to 580 nm.
As just one example of a textured reflector according to embodiments of the invention, thin extruded high reflectivity PC plates can have a pattern imprinted as part of the extrusion process, and the plates can be pressed onto an un-textured extruded PC back reflector substrate. One example of an imprinted pattern is a prismatic pattern, which can include repeated prismatic elements extending in all directions. Such a pattern can also be used in a lens material. Another example of an imprinted pattern is a cut keystone pattern. Alternatively, the entire reflector can be extruded with an imprinted pattern on the inside or bottom surface of the reflector. Either type of imprinting can be accomplished with a textured drum as part of the extrusion process. A roughening pattern can also be applied by roughening a reflector or a plate to be pressed on to a reflector substrate with sand blasting, sanding, or another roughening technology.
Some embodiments of troffers according to the present invention comprise one or lenses or lens plates. Lens plates can serve to provide physical protection to components within the troffer, such as LEDs. Lens plates can achieve this by, for example, preventing physical damage or dust accumulation, which can negatively affect the troffer's emission efficiency, intensity, and/or profile. Lens plates also serve to improve the uniformity of the troffer emission. Depending upon the type of emitters and the reflector used in a troffer, bright “hotspots” of light can sometimes be seen on the reflector above the emitter sources. These hotspots are sometimes undesirable and can negatively affect emission uniformity. Lens plates can help to reduce the appearance of these hotspots to a viewer by spreading the Light reflected from these hotspots across a wider viewing area. In some cases the light reflected from these hotspots can be spread across the entire luminaire. Even in troffers wherein no hotspots or insubstantial hotspots are formed, lens plates can help to diffuse light, broaden the troffer's emission profile, focus the troffer's emission profile, and/or create a more uniform appearance.
In one embodiment, the lens plate are faceted. Faceted lenses can use bumps or pips to scatter light in a predictable manner. Close-up views of faceted lens plates according to the present invention are shown in
One embodiment of a lens plate used in a troffer according to the present invention comprises extruded acrylic with either a diffuser built into the acrylic or a diffuser film coating. Other embodiments of lens plates that can be used in the present invention include diffuse lenses, which scatter all incident light. Further embodiments can comprise acrylics, PMMAs, and/or diffusing additives. Some embodiments can comprise clear acrylics. The types of lens plates described herein are only a few of the types of lenses that can be used, and are in no way intended to be limiting. Lenses and methods that can be used in embodiments of troffers incorporating elements of the present invention are described in detail in U.S. patent application Ser. No. 13/442,311 to Lu et al. and filed Apr. 9, 2012, which is commonly assigned with the present application and incorporated by reference herein in its entirety.
While embodiments of troffers according to the present invention comprising lens plates have been described above, some troffers according to the present invention do not comprise lenses. A combination of other components of the troffer, such as emitters and reflectors, may be used to achieve an effect similar to that of a lens. One embodiment of a troffer according to the present invention that does not comprise a lens comprises louvers. A troffer comprising louvers can comprise separate light bars, such as light bars above the louvers. Alternatively, the louvers actually serve as the light bars and have emitters mounted thereon. Louvers can be both functional louvers serving as heat sinks and with emitters mounted thereon, optical louvers designed to diffuse light, or both. Fixtures and troffers comprising louvers are described in detail in U.S. patent application Ser. No. 13/453,924 to Pickard et al. and entitled “Parabolic Troffer-Style Light Fixture,” which is commonly assigned with the present application and is fully incorporated by reference herein. Embodiments without a lens can provide a low cost alternative to embodiments with lens plates.
A typical solid state light fixture will incorporate a heat sink that sits above the ceiling plane to dissipate conducted LED heat into the environment. Temperatures above office and industrial ceilings in a non-plenum ceiling regularly reach 35° C. As best shown in
A light bar with an exposed heat sink such as the heat sink 602 is advantageous for several reasons. For example, air temperature in a typical office room is much cooler than the air above the ceiling, obviously because the room environment must be comfortable for occupants; whereas in the space above the ceiling, cooler air temperatures are much less important. Additionally, room air is normally circulated, either by occupants moving through the room or by air conditioning. The movement of air throughout the room helps to break the boundary layer, facilitating thermal dissipation from the heat sink 602. Also, a room-side heat sink configuration prevents improper installation of insulation on top of the heat sink as is possible with typical solid state lighting applications in which the heat sink is disposed on the ceiling-side. This guard against improper installation can eliminate a potential fire hazard.
While the light bars and heat sinks discussed above comprise connection areas in which a lens plate can fix, some embodiments of troffers according to the present invention do not comprise these connection areas. Instead, one or more light bars can be attached to the bottom surface of a lens plate using a variety of methods. In such a troffer, it is possible to reduce the number of lens plate and in some cases have only a single lens plate.
Many different types of emitters can be used in embodiments of the present invention. In some embodiments the emitters are solid state emitters such as LEDs or LED packages. Many different LEDs can be used such as those commercially available from Cree Inc., under its DA, EZ, GaN, MB, RT, TR, UT and XT families of LED chips. Further, many different types of LED packages can be used in embodiments of the present invention. Some types of chips and packages are generally described in U.S. patent application Ser. No. 12/463,709 to Donofrio et al., entitled “Semiconductor Light Emitting Diodes Having Reflective Structures and Methods of Fabricating Same,” U.S. patent application Ser. No. 13/649,052 to Lowes et al., entitled “LED Package with Encapsulant Having Planar Surfaces,” and U.S. patent application Ser. No. 13/649,067 to Lowes et al., entitled “LED Package with Multiple Element Light Source and Encapsulant Having Planar Surfaces,” all of which are commonly assigned with the present application and all of which are fully incorporated by reference herein in their entirety. The emitters can emit many different colors of light, with some emitters emitting white light (or chips emitting blue light, part of which is converted to yellow light to form a white light combination). One embodiment of a package that can be used in a lamp according to the present invention comprises a substantially box shaped encapsulant, which results in a package emission that is broader than Lambertian. Many of these packages are shown and described in U.S. patent application Ser. No. 13/649,067 to Lowes et al. It is understood that in some embodiments the LED can be provided following removal of its growth substrate. In other embodiment, the LED's growth substrate can remain on the LED, with some of these embodiments having a shaped or textured growth substrate. In some embodiments when the LED's growth substrate remains on the LED, the LED is flip-chip mounted onto a light strip or mount surface.
In some embodiments, the LEDs can comprise a transparent growth substrate such as silicon carbide, sapphire, GaN, GaP, etc. The LED chips can also comprise a three dimensional structure and in some embodiments, the LEDs can have structure comprising entirely or partially oblique facets on one or more surfaces of the chip.
In one embodiment, at least some of the emitters are LED chips and/or packages which can, in some embodiments, have an emission pattern that is broader than Lambertian, such as, for example, those described in U.S. patent application Ser. Nos. 13/649,052 and 13/649,067. In another embodiment, these LED chips and/or packages are used in combination with standard Lambertian emitters. In another embodiment, the emitters are phosphor-coated LEDs such as, for example, those described in U.S. patent application Ser. Nos. 11/656,759 and 11/899,790, both to Chitnis et al. and both entitled “Wafer Level Phosphor Coating Method and Devices Fabricated Utilizing Method,” both of which are commonly assigned with the present application and both of which are fully incorporated by reference herein. In one embodiment the emitters these aspects and are phosphor-coated LED chips and/or packages with emission patterns that are broader than Lambertian. In another embodiment, these LEDs emit in the blue spectrum and are covered in a yellow phosphor, resulting in a white emission. In another embodiment the emitters have a Lambertian emission profile.
The mount surface 604 provides a substantially flat area on which one or more light sources 612 can be mounted. In some embodiments, the light sources 612 will be pre-mounted on the light strips 610.
In another embodiment, the emitters emit different types of light. In one such embodiment, some of the emitters are BSY (blue shifted yellow) LEDs while the rest are red LEDs, resulting in a warm white lamp emission. Some such embodiments are shown in
In the
Further, in some embodiments clusters may not be evenly distributed along a light bar. For example, a troffer according to the present invention can comprise a concentrated area of emitters, such as where light bars intersect. Examples of concentrated areas of emitters are described in U.S. patent application Ser. No. 13/429,080 to Edmond et al. and entitled “Modular Indirect Troffer,” which is commonly assigned with the present application and fully incorporated by reference herein.
Embodiments of troffers according to the present invention can comprise remote phosphors which convert some of emitted light to a different color. A remote phosphor could be placed, for example, over the light bars or coated onto the reflector. Troffers comprising a remote phosphor are described in U.S. patent application Ser. No. 13/088,690 to Medendorp et al. and entitled “LED Luminaire Including a Thin Phosphor Layer Applied to a Remote Reflector,” which is commonly assigned with the present application and fully incorporated by reference herein.
Various combinations of colors can be used for both the color emitted by the LED packages and the color emitted by the phosphor. As one example, blue-shifted yellow (BSY) LED devices can be used as the light source, and red-emitting phosphor can be used on the reflector. For example, in some embodiments, the phosphor layer on the reflector, when energized, emits light having dominant wavelength from 600 to 640 nm, or 605 to 630 nm, which in either case may be referred to as “red” light. The LEDs in the BSY LED packages that serve as the light source, when illuminated, emit light having a dominant wavelength from 435 to 490 nm, 440 to 480 nm, or 445 to 465 nm. The phosphor in the BSY LED packages emits light having a dominant wavelength from 540 to 585 nm, or 560 to 580 nm. These combinations of lighting elements can be referred to as a “blue-shifted yellow plus red” (BSY+R) system. This is but one example of a combination of lighting elements and phosphor that can be used to create substantially White light with a color rendering index (CRI) at least as good as generated by relatively loW CRI types of residential lighting. Embodiments of the invention can produce light with a CRI of at least 70, at least 80, at least 90, or at least 95. Further examples and details of mixing colors of light using solid state emitters and phosphor can be found in U.S. Pat. No. 7,213,940 to Van de Ven et al. and entitled “Lighting Device and Lighting Method,” which is commonly assigned with the present application and fully incorporated by reference herein.
Alternatively,
Embodiments like those shown in
Some troffers according to the present invention comprise a housing or metal back box prior to installation. Alternatively, some embodiments of troffers according to the present invention can be used to retrofit old lighting fixtures. For example,
To retrofit such a fluorescent fixture, the fluorescent tubes and other components can be removed. The troffer 1000 can then be installed and replace these components to provide better and more economical lighting. Emitter leads, such as LED leads, can be installed and bypass any remaining fluorescent electronics. The troffer 1000 can comprise a reflector 1004, as shown. In other embodiments, the troffer 1000 does not comprise a separate reflector. Instead, the inner surface 1054 of the housing 1050 is coated with a reflective material before the troffer 1000 is installed. The inner surface 1054 of the housing 1050 can then serve as a reflector.
In some instances, such as retrofitting an incandescent door frame troffer, a usable door frame may already be in place, in which case light bars could be snapped into place on the door frame in a desired light bar pattern. If lenses were desired, lenses could then be attached to these light bars. Retrofit kits and installation methods such as those described above can be especially useful to users who desire troffers with custom door frame dimensions and/or light bar lengths, as a user can simply order a door frame, light bars, and/or lenses to fit any space within a ceiling. Elements of retrofit light fixtures that can be incorporated into embodiments of the present invention are described in U.S. patent application Ser. No. 13/672,592 to Dixon and entitled “Recessed Light Fixture Retrofit Kit,” commonly assigned with the present application and incorporated by reference herein in its entirety.
The lines 1705a and 1705b, 1707a and 1707b, and 1709a and 1709b show the max and min of the graphs 1704, 1706, 1708, respectively, as calculated by a person of ordinary skill in the art. The troffer 1304 with a lens with a thin film has an experimental max of about 85 and an experimental min of about 26, for a max/min ratio of about 3.27. The troffer 1306 with a lens with a thick film has an experimental max of about 87 and an experimental min of about 28, for a max/min ratio of about 3.1. The troffer 1308 with a P49 lens has an experimental max of about 87 and an experimental min of about 26, for a max/min ratio of about 3.35.
The lines 1805a and 1805b, 1807a and 1807b, and 1809a and 1809b show the max and min of the graphs 1804, 1806, 1808, respectively, as calculated by a person of ordinary skill in the art. The troffer 1404 with a lens with a thin film has an experimental max of about 77 and an experimental min of about 27, for a max/min ratio of about 2.852. The troffer 1406 with a lens with a thick film has an experimental max of about 1 and an experimental min of about 28, for a max/min ratio of about 2.9. The troffer 1408 with a P49 lens has an experimental max of about 77 and an experimental min of about 24, for a max/min ratio of about 3.209. One embodiment of a troffer according to the present invention has a max/min ratio of less than about 3.5. Another embodiment of a troffer according to the present invention has a max/min ratio of less than about 3.
It is understood that embodiments presented herein are meant to be exemplary. Embodiments of the present invention can comprise any combination of compatible features shown in the various figures, and these embodiments should not be limited to those expressly illustrated and discussed.
Although the present invention has been described in detail with reference to certain preferred configurations thereof, other versions are possible. Therefore, the spirit and scope of the invention should not be limited to the versions described above.
