Patent Grant
7645052
1. Field
Example embodiments in general relate to a combination ceiling tile integrated with a light emitting diode (LED) fixture, a LED fixture and a ceiling tile configured to receive one ore more LED strips thereon.
2. Description of the Related Art
Lighting systems are responsible for about 35 percent of the electricity costs in a typical commercial building and 10 percent in industrial settings. Conventional fluorescent lamps such as T8 lamps with electronic ballast are used for new fixtures and retrofits in typical settings such as commercial office buildings, schools, and in industrial lighting. The inside of a fluorescent lamp includes electrodes and a gas containing argon and mercury vapor. A stream of electrons flows through the ionized gas from one electrode to the other, to collide with the mercury atoms and excite them. As the mercury atoms move from the excited state back to the unexcited state, the atoms give off ultraviolet photons. The photons hit the phosphor coating on the inside of the fluorescent tube, and this phosphor creates visible light photons.
Fluorescent bulbs are fabricated in several sizes, examples including 2′, 3′, 4′ and 8′ lengths for straight tubes, and 8″ and 12″ circular shapes. The straight tubes have a cycle life of about 20,000 hours (7-10 years, on average), whereas the circular bulbs are rated at an average life of about 12,000 hours. The straight tubes are often bundled in sets of 2-4 lamps within a housing known as a troffer that is integrated within a ceiling tile space, typically taking up the space of one or two standard 2′×2′ ceiling tile spaces or a single 2′×4′ standard ceiling tile space.
However, the use of fluorescent lighting poses several problems. For example, fluorescent lamps require a ballast to stabilize the lamp and to provide the initial striking voltage required to start the arc discharge. Additionally, because the arc is quite long relative to higher-pressure discharge lamps, the amount of light emitted per unit is low, so fluorescent lamps are typically large. Further, some find the color spectrum produced by fluorescent lighting harsh and displeasing.
One common problem is that the mercury inside a fluorescent tube tends to migrate to one end of the tube, leading to only one end of the lamp producing most of the light. Moreover, the disposal of phosphor and the small amounts of mercury in the tubes poses an environmental issue.
Fluorescent lamps typically operate best around room temperature (for example, about 68 degrees Fahrenheit or 20 degrees Celsius). At much lower or higher temperatures, lamp efficiency decreases; at low temperatures (below freezing) standard fluorescent lamps may not start. Special fluorescent lamps are therefore needed for reliable service outdoors in cold weather.
Another common problem with fluorescent lighting is that fluorescent lamps do not give out a steady light. Instead, and particularly toward the end of tube life, the lamps often flicker (fluctuate in intensity) at a rate that depends on the frequency of the driving voltage. While this is not easily discemable by the human eye, it can cause a strobe effect. This annoying “disco strobe” effect is particularly common with fluorescents at the end of tube life. The strobe effect poses a safety hazard in a workshop for example, where something spinning at just the right speed may appear stationary if illuminated solely by a fluorescent lamp.
LEDs are becoming widely used in many consumer lighting applications. In consumer applications, one or more LED dies (or chips) are mounted within a LED package or on an LED module or strip, which may make up part of a lighting fixture which includes one or more power supplies to power the LEDs. The module or strip of a fixture includes a packaging material with metal leads (to the LED dies from outside circuits), a protective housing for the LED dies, a heat sink, or a combination of leads, housing and heat sink. Various implementations of LED fixtures including one or more LED modules, arrays or strips of LEDs are becoming available in the marketplace to fill a wide range of applications, such as area lighting, indoor lighting, backlighting for consumer electronics, etc. LEDs may offer improved light efficiency, a longer lifetime, lower energy consumption, no environmental disposal issues and reduced maintenance costs, as compared to light sources such as T8 fluorescent lamps.
An example embodiment is directed to an LED ceiling tile combination. The combination may include a ceiling tile having a planar surface, and at least one LED fixture integrated with the ceiling tile so that the fixture is arranged along the same plane of the ceiling tile planar surface.
Another example embodiment is directed to an LED fixture which includes at least one LED strip integrated with a planar surface having a thickness so that the LED strip is arranged along the same plane of the planar surface. The fixture includes a support structure for the at least one LED strip. The planar surface includes an opening through which a part of the support structure extends to secure the LED strip to the backside of the planar surface.
Another example embodiment is directed to a ceiling tile which includes a panel having one of a generally rectangular or square shape. The panel has a thickness, a facing surface, a backside surface and at least one opening formed through its thickness. At least one LED strip is integrated with the ceiling tile so that the LED strip is arranged along the same plane of the ceiling tile facing surface.
Another example embodiment is directed to a ceiling tile having a panel which is configured in one of a generally rectangular or square shape. The panel has a thickness, a facing surface, a backside surface and at least one opening formed through its thickness. A slider mount assembly is affixed within the opening on the facing surface of the panel. The assembly includes a power connector at an end thereof and is configured to receive an LED strip therein. A removable power supply is attached to the power connector.
Example embodiments will become more fully understood from the detailed description given herein below and the accompanying drawings, wherein like elements are represented by like reference numerals, which are given by way of illustration only and thus are not limitative of the example embodiments.
Example embodiments illustrating various aspects of the present invention will now be described with reference to the figures. As illustrated in the figures, sizes of structures and/or portions of structures may be exaggerated relative to other structures or portions for illustrative purposes only and thus are provided merely to illustrate general structures in accordance with the example embodiments.
Furthermore, various aspects of the example embodiments may be described with reference to a structure or a portion being formed on other structures, portions, or both. For example, a reference to a structure being formed “on” or “above” another structure or portion contemplates that additional structures, portions or both may intervene there between. References to a structure or a portion being formed “on” another structure or portion without an intervening structure or portion may be described herein as being formed “directly on” the structure or portion.
Additionally, relative terms such as “on” or “above” are used to describe one structure's or portion's relationship to another structure or portion as illustrated in the figures. Further, relative terms such as “on” or “above” are intended to encompass different orientations of the device in addition to the orientation depicted in the figures. For example, if a device, fixture or assembly in the figures is turned over, a structure or portion described as “above” other structures or portions would be oriented “below” the other structures or portions. Likewise, if a device, fixture or assembly in the figures is rotated along an axis, a structure or portion described as “above” other structures or portions would be oriented “next to”, “left of” or “right of” the other structures or portions.
As used herein, the phrase “building material panel” refers to material panel which is used for a construction purpose, and includes, but is not limited to, ceiling panels, floor panels, wood or laminate flooring, sheetrock, plasterboard, wallboard, T-111 composite materials, brick wall or flooring structure, masonry wall or flooring structure and fiber board.
One type of building material panel is a ceiling tile. Ceiling tiles are lightweight tiles used in the interior of buildings. Ceiling tiles are typically placed on a steel grid and, depending on the tile selected, may provide thermal insulation, sound absorption, enhanced fire protection, and/or improved indoor air quality.
Also referred to as ceiling panels or drop-ceiling tiles, ceiling tiles facilitate access to wiring and plumbing above the ceiling grid, and can be easily changed, removed, or replaced as needed. Ceiling tiles are typically fabricated from perlite, mineral wool, plastic, tin, aluminum, and/or fibers from recycled paper. The tiles frequently include patterns comprised of holes to improve sound absorption properties, although many tiles have a molded surface providing a textured, sculpted, or pressed-tin look to the ceiling. Some tiles are available with decorative photo/transfer surfaces, and other tiles are approved for installation under fire suppression sprinkler heads so the sprinklers do not show, and other types of tiles are approved for use in food preparation areas.
An example combination includes a building material panel such as a ceiling tile which has a plurality of LEDs integrated therein to provide interior lighting. In this example, the ceiling tile can include one or more LED fixtures integrated therewith so that the LEDs are substantially parallel with the planar facing surface of the ceiling tile to provide lighting in the space below. However, the one or more LEDs are not limited to being parallel to the facing surface of the building material panel; the LEDs may be oriented so as to protrude below or out from the facing surface or recessed with respect to the facing surface, at an angle, and/or adjustable to a desired angle or orientation with respect to the facing surface of the building material panel.
The LED fixture includes one or more LEDs mounted on a carrier such as a metal core printed circuit board (MCPCB) strip. Secondary optics or reflectors can be provided over and around the LEDs to shape the total light output of the LED strip. Different LED strips having different LEDs, optics and/or reflector arrangements for different light shapes can be interchangeable within a particular building material panel.
In one example, a combination building material panel with LEDs such as an LED ceiling tile is applicable to indoor lighting applications such as within an office building, home, covered outdoor space, etc. The brightness and/or performance of the LED ceiling tile or LED fixture can be adjusted by adding, subtracting and/or replacing LED strips and/or power supplies attached thereto for driving the LEDs.
The mount 210 (also occasionally referred to herein as a support structure) includes a T-bar having a horizontal surface 214 to which the LED strip 200 is attached and a vertical leg 212. The T-bar provides a heat spreading function for the LED strip 200 thereon. The mount 210 further includes a pair of metal tabs 220 oriented perpendicular to the T-bar at horizontal surface portion 214 so as to be flush with a backside surface 108 of the ceiling tile 100.
The power supplies may be constant current drivers 300 which supply constant but adjustable current with variable voltage, depending on the number of LEDs. For example, the driver 300 can drive the LEDs at currents from 350 mA (equivalent to 1 W), yielding at least 80 lumens of light, or up to 1000 mA (equivalent to 4 W), for 176 lumens typical, if more light output is needed. An example power supply 300 can be a switch mode, switching LP 1090 series power supply manufactured by MAGTECH, such as the MAGTECH LP 1090-XXYZ-E series switchmode LED driver, for example. Another example driver could be an ML-350 driver for powering the LEDs 205 on the LED strip 200 at a constant 350 mA current.
The driver 300 has an adjustable voltage range and the type of driver depends on the voltage drop of each of the LEDs 205 in series in the combination LED ceiling tile 1000. The type of power supply 300 used does not matter; a variable power supply such as the LP 1090 can be automatically variable between 90 and 240 volts depending on the particular application for the combination LED ceiling tile.
In the example combination 1000 shown in
The LED strip 200 can be attached or otherwise integrated with a standard 2′×2′ ceiling tile for example, which can hold approximately 8-10 LED strips 200, producing a total light output in a range between approximately 5,600 to 9,000 lumens per 2′×2′ area. A standard 2′×4′ ceiling tile can hold approximately 16-20 LED strips 200, producing a total light output in a range between approximately 11,200 up to 18,000 lumens per 2′×4′ area.
Any heat buildup is limited due to the LED strips 200 being arranged in spaced relation across the facing surface 106 of the ceiling tile 100, so as to provide desirable air flow between adjacent strips 200. The air flow can be maintained around each strip 200 due in part to the spacing of the mount 210; the thickness of the mount 210 dictates the air flow allowed. In an example, the thickness of the mount 210 can be about ¼″. In an alternative, one or more vents (not shown) can be added to the ceiling tile 100 if additional air flow is desired.
If desired, the LEDs 205 may be configured to emit any desired color light. The LEDs 205 may be blue LEDs, green LEDs, red LEDs, different color temperature white LEDs such as warm white or cool or soft white LEDs, and/or varying combinations of one or more of blue, green, red and white LEDs 205. In an example, warm white or cool or soft white LEDs are typically used for indoor area lighting such offices. White LEDs may include a blue LED chip phosphor for wavelength conversion. Additionally, one, some or all LEDs 205 can be fitted with a secondary optic that shapes the light output in a desired shape, such as circle, ellipse, trapezoid or other pattern.
One or more individual LEDs 205 may be slanted at different angles, at the same angles, in groups of angles which differ from group to group, etc. For example, the shape of the light output may be varied by the angle of the LEDs from normal. Accordingly, one, some, or all strips 200 or groups of strips 200 on a ceiling tile, each having LEDs 205 thereon can be mounted at different angles to the planar, facing surface of the ceiling tile 100. Additionally, a given strip 200 may be straight or curved, and may be angled with respect to one or more dimensions. In another example, each LED 205, groups or strips 200 of LEDs may include the same or different secondary optics and/or reflectors.
In other examples, the LED strips 200 can be mounted at varying ranges of angles, and different optical elements or no optical elements may be used with the LED strips 200 mounted at differing ranges of angles. The angles of the LED strips 200 and/or individual LEDs 205 with or without optical elements can be fixed or varied in multiple dimensions. Therefore, one or more LED strips 200 can be set at selected angles (which may be the same or different for given strips 200) to the facing surface of the ceiling tile 100, so as to produce any desired illumination pattern.
Example configurations of angled LEDs 205 or angled LED strips 200 are described in detail in co-pending and commonly assigned U.S. patent application Ser. No. 11/519,058, to VILLARD et al, filed Sep. 12, 2006 and entitled “LED LIGHTING FIXTURE”, the relevant portions describing the various mounting angles of LED strips 200 and/or LEDs 205 being hereby incorporated in its entirety by reference herein.
The sleeve 400 includes a mount body 410 which is configured to receive the LED strip in slidable relation thereon. The mount body 410 includes a slot 420 for receiving the vertical leg 212 of the T-bar in which the LED strip 200 is affixed.
A plastic sleeve 400 is merely one example, the slider bracket assembly can be made of other materials such as aluminum, copper, ceramic, etc. As shown in
The slot 420 provides access for the leg 212 of the T-bar and is used to provide sound thermal conduction for the LED fixture 200. To install an LED strip 200 into the sleeve 400, the LED strip 200 can be tilted and slid in to snap into the mount body 410 such that the power connectors 225 and 425 engage for electrical connectivity. Accordingly, an LED strip 200 would slip and snap into the plastic sleeve 400. In an alternative, ceiling tiles 100 can be manufactured and sold with an installed sleeve 400 with our without the driver 300 attached thereto.
Additionally, the removable power supply 300 in
Referring to
The mount 210 can be configured as an integral one-piece part, or an off-the-shelf T-bar can be selected connected to metal tabs 220 by welding, rivets, etc.
The example embodiments are not limited to a combination LED ceiling tile. In an alternative, the example LED fixture or strip 200 can be integrated with any planar surface having a thickness so that one or more LEDs, groups of LEDs or one or more LED strips 200 are arranged along the same plane of the planar surface which faces a space to illuminate. In an example, the mount or support structure 210 can be removably secured within an opening of the planar surface, so that at least a part of the support structure 210 extends into or through the opening to secure the LED strip to a backside of the planar surface. The aforementioned planar surface can be part of any building material panel as heretofore described. Moreover, the LEDs, groups of LEDs or LED strips 200 can be oriented so as to protrude below or out from the planar surface or recessed with respect to the planar surface, at an angle, and/or adjustable to a desired angle or orientation with respect to the planar surface of the building material panel.
The planar surface having a thickness can be one of a wall, a ceiling and a ceiling tile. For example, LEDs, groups of LEDs or LED strips 200 can be arranged on a standard 4′×8′ piece of drywall, plasterboard, wallboard or other materials which are used to make walls or ceilings of interior spaces. In another alternative, the drywall, plasterboard, wallboard, etc can be manufactured and sold with an installed sleeve 400 with or without the driver 300 attached thereto, as shown in
The example embodiments of the present invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as departure from the spirit and scope of the example embodiments of the present invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
| Number | Name | Date | Kind |
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| 2704835 | Heller | Mar 1955 | A |
| 6203180 | Fleischmann | Mar 2001 | B1 |
| 6540373 | Bailey | Apr 2003 | B2 |
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| 7367685 | Moll | May 2008 | B2 |
| 20070263379 | Dowling | Nov 2007 | A1 |
| 20080232116 | Kim | Sep 2008 | A1 |
| 20090147504 | Teeters | Jun 2009 | A1 |
| Number | Date | Country | |
|---|---|---|---|
| 20080266843 A1 | Oct 2008 | US |
