This invention relates to light fixtures and, more particularly, to light fixtures using light-emitting diodes (LEDs).
In recent years, the use of light-emitting diodes (LEDs) in development of light fixtures for various common lighting purposes has increased, and this trend has accelerated as advances have been made in the field. Indeed, lighting applications which previously had typically been served by fixtures using what are known as high-intensity discharge (HID) lamps are now being served by LED light fixtures. Such lighting applications include, among a good many others, roadway lighting, factory lighting, parking lot lighting, and commercial building lighting.
High-luminance light fixtures using LED modules as light source present particularly challenging problems. One particularly challenging problem for high-luminance LED light fixtures relates to heat dissipation. Among the advances in the field are the inventions of U.S. Pat. Nos. 7,686,469 and 8,070,306.
Improvement in dissipating heat to the atmosphere is one significant objective in the field of LED light fixtures. It is of importance for various reasons, one of which relates to extending the useful life of the lighting products. Achieving improvements without expensive additional structure and apparatus is much desired. This is because a major consideration in the development of high-luminance LED light fixtures for various high-volume applications, such as roadway lighting, is controlling product cost even while delivering improved light-fixture performance.
In summary, finding ways to significantly improve the dissipation of heat to the atmosphere from LED light fixtures would be much desired, particularly in a fixture that is easy and inexpensive to manufacture.
The present invention relates to improved LED lighting fixtures. In certain embodiments, the LED lighting fixture includes a frame and an LED assembly secured with respect to the frame. The frame defines a forward open region and a rearward region. The rearward region has a rearmost portion adapted for securement to a support member. The LED assembly is positioned within the open forward region with open spaces remaining between the LED assembly and the frame. The LED assembly includes an LED illuminator secured with respect to an LED-supporting region of a heat sink with heat-dissipating surfaces extending from the LED-supporting region. In certain embodiments, the heat sink and the frame are formed as a single piece.
The fixture may also have an enclosure which is within the rearward region and defines a chamber enclosing electronic LED power circuitry. In some of such embodiments, the enclosure has upper and lower shells.
In certain embodiments, the upper shell and the frame are formed as a single piece. In some of such embodiments, the heat sink, the upper shell and the frame are formed as a single piece. The single piece may be a metal casting.
In some versions, the lower shell is movably secured with respect to the upper shell. In some of such versions, the lower shell is a one-piece polymeric structure. This allows the LED power circuitry to include an antenna which is fully enclosed within the chamber along with circuitry for wireless control of the fixture.
In some embodiments, the heat sink is open to ambient-fluid flow and includes a central portion and peripheral portions. The central portion includes the LED-supporting region. The peripheral portions have peripheral heat-dissipating surfaces along lateral sides of the heat sink.
The central portion may have a plurality of fins protruding in a direction opposite the LED illuminator. In some of such embodiments, the heat sink includes at least one central-portion opening facilitating ambient-fluid flow to and from the heat-dissipating surfaces of the central portion. The fins of the central portion may define between-fin channels open at the front ends of such fins. In some embodiments, the rear ends of such fins are configured to permit ambient-fluid flow (e.g., water drainage) from the between-fin channels to the at least one central-portion opening, thereby facilitating liquid drainage therefrom. The at least one central-portion opening may be adjacent to the enclosure.
In some embodiments, the LED-supporting region of the heat sink has a surface opposite the LED illuminator, i.e., the surface from which the fins of the central portion of the heat sink project, which is especially adapted to facilitate liquid drainage. In some of such embodiments, when the fixture is mounted in its usual use orientation, such surface slopes downwardly toward at least two of the sides of the heat sink, thereby facilitating liquid drainage in such side directions. Such surface may slope downwardly toward at least three of the sides of the heat sink and, in some embodiments, the surface slopes downwardly toward each of four sides of the heat sink
In those embodiments in which the surface opposite the LED illuminator includes fins projecting therefrom, the surface opposite the LED illuminator includes between-fin surfaces. Such between-fin surfaces, when the fixture is its usual use orientation, are inclined off-horizontal, thereby to facilitate liquid drainage from between such fins.
In some embodiments, the LED assembly may have a circular plan-view configuration, and the surface opposite the LED illuminator, i.e., the top surface of the heat sink may be curved or domed in a manner facilitating drainage in multiple directions therefrom.
In some embodiments, the peripheral heat-dissipating surfaces include a plurality of fins extending laterally from the central portion of the heat sink with open spaces between such fins. The central portion may have a plurality of fins extending forwardly therefrom with open spaces between the fins.
In certain of such embodiments that have fins extending laterally from the central portion of the heat sink and other fins extending forwardly from the central portion of the heat sink, the heat sink is an extrusion which has been extruded in a direction orthogonal to both the forward and lateral directions. The extruded dimension of the heat sink is much less than the forward-rearward and side-to-side dimensions of the heat sink. In some versions of such embodiments, the central portion of the extrusion includes walls with inner surfaces defining a central opening in the extrusion, and in some of such versions the heat sink includes, in addition to the extrusion, a mounting plate in thermal contact with the extrusion, the LED illuminator being secured to the mounting plate.
In certain embodiments, the electronic LED power circuitry includes a caseless LED driver, the components of which are encapsulated in a protective polymeric material. Such driver may be removably secured to the upper shell.
The LED illuminator may include an LED emitter on a circuit board and an LED optical member over the emitter. The LED emitter may have an array of LED light sources spaced along the circuit board. The LED optical member may have a plurality of lenses each over a corresponding one of the LED light sources. Each LED light source may include an array of LEDs.
In another aspect of the present invention, the LED light fixture includes a non-metallic frame defining a forward open region and having a rearward region with a rearmost portion adapted for securement to a support member. An LED assembly is secured with respect to the frame and positioned within the open forward region with open spaces remaining therebetween. The LED assembly includes an LED illuminator secured with respect to an LED-supporting region of a heat sink which has heat-dissipating surfaces extending from the LED-supporting region.
The non-metallic frame may include upper and lower shells, and the rearward region of such frame may itself define a chamber enclosing electronic LED power circuitry. The non-metallic frame may be of a polymeric material. In such embodiments, the LED power circuitry may include an antenna which is fully enclosed within the chamber along with circuitry for wireless control of the fixture.
In accordance with certain aspects of the present invention, alternative embodiments of the LED lighting system can comprise one or more of the following aspects. In some embodiments, the frame comprises a central portion (which may also be referred to as a core or spine) which has an integral heat sink, at least a portion of the housing that comprises at least one compartment for wiring and/or driver circuitry separate from the LED illuminator, and a mount. The frame further comprises a peripheral portion spaced from the central portion to provide a desired form factor, e.g., such as a cobrahead or other form factor, and/or additional heat sinking In some embodiments, the core has a plurality of compartments, where in some embodiments, at least one of the compartments provides isolation from the LED illuminator. In some embodiments, the heat sink is integrated with a compartment. For example, a heat sink surface can form a compartment wall. In some embodiments, the heat sink can form an integral backlight shield. In other embodiments, the heat sink can comprise a reflective backlight shield. In some embodiments, the core is formed from a single piece of die-cast metal. In some embodiments, the core comprises the top portion of the housing, and a compartment door of metal or a polymeric material provides access, such as 180 degree access, to the compartment(s) in the housing. In some embodiments the heat sink can comprise an extruded part with lateral fins.
In some embodiments, the central portion is integrated with the heatsink, supports the housing and provides mounting to a support member. A top and/or bottom enclosure(s), which can be in the form of a clamshell, engages the core to house electronic components of LED power circuitry.
In some embodiments, the top and/or bottom enclosure can form the peripheral portion of the frame and provide a desired form factor. The top and/or bottom enclosures can be made of metal and/or a polymeric material. In certain embodiments, by using a polymeric material, such as a plastic, nylon or polycarbonate, for the enclosure(s) or doors, the fixture may be able to integrate a fully-enclosed antenna for wireless control of the fixture and be able to provide electrical isolation that allows the use of a removable LED driver. One example of such removable driver is a caseless driver board which is fully encapsulated in a protective polymeric material providing electrostatic discharge (ESD) protection to the driver board which conducts heat away from the driver board during operation.
In some embodiments, the heat sink includes fins in the space between the heat sink and peripheral portions of the frame. In some embodiments, at least one thermal connection is provided between the heatsink and the peripheral portion of the frame in a space between the heat sink and the peripheral portion of the frame. In some embodiments, open through-spaces are provided on multiple axes, e.g., at least one on a side and at least one on the front or back.
In some embodiments, the core can be made at least in part of a polymeric material. In some embodiments, a polymeric mounting arrangement can be used to mount the lighting fixture to a pole. In some embodiments, the entire core is made of a polymeric material.
In some embodiments, a mounting arrangement is provided with an outside fulcrum which allows for a smaller aperture off the back and better clearance for the pole. In some embodiments, the fixture includes a fulcrum outside a fixture interior which provides advantages such as allowing a smaller aperture for a support-member entry into the fixture interior as well as easier access to the interior by providing more room for clearance of a compartment door.
The smaller entry aperture may eliminate the need for a splash guard which is typically required for UL listed outdoor light fixtures, while still providing for the possibility of a splash-guard arrangements.
In some embodiments, the enclosure(s), door and/or housing can be molded and can comprise an integral backlight shield or reflector.
In certain embodiments of the invention in which the frame defines forward and rearward regions of the fixture, the frame defines a projected forward-region area and the LED assembly is secured in the forward region with open space between the LED assembly and the frame. The LED assembly itself defines a projected LED-assembly area which is no more than about 75% of the projected forward-region area. In other words, the forward region of the fixture is quite open. In some of such embodiments, the projected LED-assembly area is no more than about 60% of the projected forward-region area.
The projected area of open space is at least about 50% of the projected LED-assembly area. In some embodiments, the projected area of open space is at least about 60% of the projected LED-assembly area, and in some the projected area of open space is about two-thirds of the projected LED-assembly area.
The openness aspect of this invention can be further described as follows, using reference to an illuminator plane defined by the LED illuminator (an imaginary plane) directly facing the area to be illuminated. The intersection of the LED assembly with the illuminator plane defines an LED-assembly area, and the intersection of the outer perimeter of the light fixture with the illuminator plane defines a fixture area.
Using such parameters, one or more through-spaces in the fixture area are such that total through-space area in the illuminator plane is at least about 15% of the fixture area; and in some embodiments the total through-space area in the illuminator plane is at least about 40% of the fixture area. Described differently, the total through-space area in the illuminator plane is at least about 50% of the LED-assembly area. In some embodiments, the total through-space area in the illuminator plane is at least about 60% of the LED-assembly area; and in some embodiments the total through-space area in the illuminator plane is about two-thirds of the projected LED-assembly area.
In some embodiments, the LED assembly has substantially straight opposite lateral sides in plan view. The open space may include substantially mirror-imaged areas on opposite lateral sides of the LED assembly. In certain of such embodiments, the frame has substantially curved outward edges defining the forward region in a footprint which is substantially similar in configuration to the footprint of so-called “cobrahead” non-LED light fixtures.
In some embodiments of the light fixture which in plan view has central and outward portions, the central portion includes (a) a housing enclosing LED power circuitry, (b) a heat sink secured with respect to the housing and supporting an LED illuminator and (c) a mount adapted for securement to a support member. In some of such embodiments, the outward portion defines an outer plan-view shape of the fixture and is secured to the central portion with through-space(s) between the central and outward portions.
In some embodiments, the through-space(s) is/are at least along the heat sink In some of such embodiments, the through-space(s) along the heat sink is/are on opposite sides thereof. There are may be at least two through-space(s), including at least one on each of the opposite sides of the heat sink
In certain embodiments, the through-space(s) is/are along opposite sides of the central portion, at least portions of such through-space(s) beings along the housing. In some of such embodiments, the through-space(s) is/are along at least a portion of the housing.
The outward portion has an outer perimeter which in plan view may be substantially similar to the footprint of a cobrahead non-LED light fixture.
The term “ambient fluid” as used herein means air and/or water around and coming into contact with the light fixture.
The term “projected,” as used with respect to various portions and areas of the fixture, refers to such portions and areas of the fixture in plan views.
As used herein in referring to portions of the devices of this invention, the terms “upward,” “upwardly,” “upper,” “downward,” “downwardly,” “lower,” “upper,” “top,” “bottom” and other like terms assume that the light fixture is in its usual position of use.
In descriptions of this invention, including in the claims below, the terms “comprising,” “including” and “having” (each in their various forms) and the term “with” are each to be understood as being open-ended, rather than limiting, terms.
The figures illustrate exemplary embodiments of LED light fixtures in accordance with this invention. Common or similar parts in different embodiments are given the same numbers in the drawings; the light fixtures themselves are often referred to by the numeral 10 followed by different letters with respect to alternative embodiments.
LED assembly 40 includes a heat sink 42 and an LED illuminator 41 secured with respect to heat sink 42. Heat sink 42 includes an LED-supporting region 43 with heat-dissipating surfaces 44 extending from LED-supporting region 43. LED illuminator 41 is secured with respect to LED-supporting region 43. As shown in
In fixtures utilizing a plurality of emitters, a plurality of LEDs or LED arrays may be disposed directly on a common submount in spaced relationship between the LEDs or LED arrays each of which is overmolded with a respective primary lens. These types of LED emitters are sometimes referred to as chip-on-board LEDs. LED optical member 29 is a secondary lens placed over the primary lens. In embodiments with a plurality of LED emitters (packages), optical member 29 includes a plurality of lenses 28 each positioned over a respective one of the primary lenses. The plurality of secondary lenses 28 are shown molded as a single piece 29 with a single flange surrounding each of the plurality of lenses 28.
LED light fixture 10 has a housing 17 and LED assembly 40 is secured with respect to housing 17. Housing 17 has an enclosure 13 which is within rearward region 32 and defines a chamber 14 enclosing electronic LED power circuitry 15. As shown in
With lower shell 35 being of polymeric material, a wireless signal can be received by the antenna which is fully enclosed within chamber 14 along with circuitry for wireless control of the fixture. Such circuitry with the antenna may be included as part of LED driver 150. The advantage of the fully enclosed antenna is also available on other embodiments of this invention having enclosures, all or portions of which are non-metallic material.
Housing 17 includes a main portion 171 which includes upper shell 34 and lower shell 35 and also includes a forward portion 172 extending forwardly from main portion 171. (Forward portion 172 of housing 17 is the forward portion of frame 30.) In main portion 171, upper shell 34 forms a housing body 176 and lower shell 35 serves as a cover member 350 movably secured with respect to housing body 176 .
As shown in
The nature of the hinging securement is seen in
As shown in
As seen in
Light fixture 10B of the third embodiment, shown in
A fourth embodiment of this invention is illustrated in
The embodiments of
The “short” extrusions of the heat sinks of the fourth and fifth embodiments are facilitated by structure shown best in
The laterally- and forwardly-extending fins are open to free flow of ambient fluid (air and water), and their position and orientation serve to promote rapid heat exchange with the atmosphere and therefore rapid cooling of the LED illuminator during operation. Upwardly-flowing air and downwardly-flowing water (in the presence of precipitation) facilitate effective cooling, and reduce the need for upwardly-extending fins on top of the heat sinks.
Certain aspects are illustrated best by reference to the first embodiment, particularly as shown in
In the second embodiment illustrated in
Referring again to the first embodiment,
Housing upper shell 34 and heat sink 42 are formed as a single piece, whereby the housing upper shell facilitates heat dissipation. The heat sink, the frame and the housing upper shell are formed as a single piece.
In addition to the above-described sloping, LED light fixture 10 has various advantageous structural taperings. As seen best in
As shown in
The various embodiments disclosed herein each illustrate one aspect of the present invention particularly related to the frame and open character of the fixtures. This is discussed in particular with respect to the first embodiment, and in particular with reference to
More specifically, the first embodiment includes the following projected areas:
When describing the openness aspect of this invention using reference to the illuminator plane P indicated in
Using such parameters, the total through-space area in the illuminator plane is slightly over 15% of the fixture area. And, if the light fixture is configured such that the enclosure with its LED power circuitry, rather than being beside the LED assembly, is offset above or otherwise away from the LED assembly (such as being in the support member), then the total through-space area in the illuminator plane may be at least about 40% of the fixture area. Described differently, the total through-space area in illuminator plane P is about two-thirds of the projected LED-assembly area.
While openness is discussed above with particular reference to the first embodiment, it should be noted that
Such openness in an LED light fixture offers great flexibility from the standpoint of form-factor design, e.g., allowing overall shape of the fixtures to better accommodate replacement of existing non-LED fixtures of various shapes. Several of the embodiments disclosed herein have frames which at least in their forward portions provide a footprint substantially similar to the footprint of so-called “cobrahead” light fixtures. This is achieved despite the fact that the LED assemblies used in fixtures according to the recent invention have substantially straight opposite lateral sides, as seen in the figures.
The advantages of the openness disclosed herein extend beyond form-factor concerns. Just one example includes avoiding or minimizing accumulation of snow, leaves or other materials on the fixtures.
Another aspect of the present inventive light fixtures is illustrated in
As seen in
In some prior LED devices, back-light shielding has been in the form of individual shields disposed on a non-preferential side of each LED emitter. Some of such prior shielding was positioned over the exterior of a corresponding lens. In such prior cases, over time the back-light shielding often became covered with dust or other ambient particles and simply absorbed rearward light from the respective LED emitter. Such absorption translated in decreased efficiency of light output from such LED device. In other examples, prior back-light shielding was positioned inside each lens corresponding to each individual LED emitter. While protected from contamination, such shielding resulted in lenses which were both complex and expensive to manufacture. In either type of the back-light shielding disposed on the non- preferential side of each individual LED emitter, there was still some undesired light in the rearward direction. Such light escaped the prior lens-shield configuration through unintended refraction or reflection by the lens.
In some other prior examples of back-light shielding used in light fixtures, such shields were in the form of a separate structure secured with respect to the fixture rearwardly to the illuminator. Such separate shielding structures often required complicated securement arrangements as well as interfered with the overall shape of the light fixture.
The integrated back-light shielding of the present invention, provides effective blocking of rearward light and reflection of such light away from areas of undesired illumination. The reflection provided by the integrated back-light shield of this invention facilitates higher light-output efficiency of the LED illuminator used in the LED light fixture of the present invention. The integrated nature of the back-light shielding of the present invention provides all the benefits of a single back-light shield without disruption of the overall shape of the fixture. Furthermore, the back-light shielding of the present invention is defined by surfaces which are open to air and water flow, which facilitates self cleaning of the reflective surface and minimized absorption of light received by such shield surface.
Another aspect of this invention is illustrated best in
Fulcrum 90 is part of a fulcrum member 93 which also includes support structure 95 for fulcrum 90.
The exterior fulcrum provides advantages such as allowing a smaller aperture for a support-member entry into the fixture interior 13 as well as easier access to the interior by providing more room for clearance of a compartment door. The smaller entry aperture may eliminate the need for a splash guard which is typically required for UL listed outdoor light fixtures, while still providing for the possibility of a splash-guard arrangements.
As shown in
As further seen in
This invention gives great flexibility in providing LED light fixtures for a variety of particular roadway lighting and other similar outdoor lighting purposes. The desired light-output level determined by the particular application and/or determined by dimensional constraints (e.g., pole height, area to be illuminated, and desired foot-candles of illumination in the target area) can be varied substantially by selection of the particular appropriate LED illuminator and chosen power level, with or without modification of heat-sink size, without departing from a particular desired form factor, such as the above-mentioned “cobrahead” form. The open “footprint” of the fixture of this invention allows such flexibility in a light fixture with advantageous performance characteristics, both in light output and in heat dissipation.
One example of such light fixture is the fixture referred to as the first embodiment. Such particular fixture with a chosen four LED emitters and a heat sink as shown at power level of twenty-four watts gives an output of about 2411- 2574 lumens depending on LED correlated color temperature (CCT). The same fixture with applied power of forty-two watts gives an output of about 3631-3884 lumens again depending on LED CCT. Higher lumen outputs can be achieved by corresponding adjustments in the number and nature of LED emitters with or without corresponding adjustment of the heat sink. These changes can be made with or without change in the “footprint” of the fixture.
While the principles of the invention have been shown and described in connection with specific embodiments, it is to be understood that such embodiments are by way of example and are not limiting.
This application is a continuation-in-part of patent application Ser. No. 29/444,511, filed Jan. 31, 2013. The entirety of the contents of application Ser. No. 29/444,511 is incorporated herein by reference.
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Child | 13764736 | US |