Embodiments of the present invention relate to a light engine for recessed positioning within the opening of a pan or mounting frame.
Light fixtures for recessed positioning within a ceiling are capable of emitting a single, fixed light distribution. They are not designed to permit adjustment or tailoring of their distribution in the field. Rather, to alter the distribution, the existing fixture must be removed and replaced with. another fixture having the desired distribution. This is a time consuming and costly process.
Moreover, most such fixtures are fixedly secured over the ceiling opening. Servicing the electronic components of the fixture requires full access to the ceiling above the fixture. Therefore, removal and replacement of ceiling components, such as tiles and t-supports, is required to service the electronic components. Exposure to the ceiling environment is less than desirable for a variety of reasons. Environmental concerns, such as asbestos contamination and asbestos removal, become an issue when disturbing the ceiling. Moreover, the area above the ceiling collects dirt and dust which can dislodge during servicing and thereby increase the time and cost of clean-up after installation. Additionally, exposed electrical wiring is common in such areas, which creates a safety hazard for workers during servicing.
Certain embodiments of the present invention provide a light engine that includes light emitting diodes mounted on a printed circuit board, which in turn is attached to a heat sink. An optic assembly is positioned over the printed circuit board to direct the emitted light as desired. The light engine can be positioned within the ceiling within the opening of a mounting frame. In some embodiments, the light engine is retained on the mounting frame such that it can be moved clear of the mounting frame opening.
The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should not be understood to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to the entire specification of this patent, all drawings and each claim.
Illustrative embodiments of the present invention are described in detail below with reference to the following drawing figures:
a-3f show various views of embodiments of heat sinks for use with the light engines contemplated herein.
a-4c show various views of an embodiment of a printed circuit board for use with light engines contemplated herein.
d is a top plan view of an embodiment of an LED chip.
a is a top perspective view of a partially assembled light engine according to one embodiment.
b is an exploded view of the partially assembled light engine shown in
a is an exploded view of an embodiment of an optical assembly for use with the light engines contemplated herein.
b is a top perspective view of the optical assembly of
a is an exploded view of an alternative embodiment of an optical assembly for use with the light engines contemplated herein.
b is a top perspective view of the optical assembly of
a, 9b, 10a, 10b, 11a, and 11b show various embodiments of light engines positioned over and moved relative to a mounting frame opening.
The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
Embodiments of the light engine 10 (one embodiment of which is shown assembled in
While embodiments of the heat sink 16 may be an integrally-formed structure, the heat sink 16 may also be formed of independent heat sink sections 20 that are assembled together to form the heat sink 16 (see
In some embodiments, the LEDs 12 are provided on the PCB 14 using a standard SMT process with the parts inverted. The traces (not shown) are provided on the rear face 42 of the PCB 14 so as to be protected when the PCB 14 is mounted to the heat sink 16 (see
The PCB 14 (with associated LED chips 46) is mounted onto the heat sink 16 using any type of suitable mechanical retention methods (e.g., screws or other fasteners as shown in
Embodiments of the optic assembly 18 include an optic retainer 82 having one or more reflector receivers 84 for supporting one or more reflectors 86. See
In some embodiments, the optic assembly 18 includes one or more lenses 100 that are retained over the face of the optic retainer 82. In. one embodiment (see
The optic assembly 18 is positioned and mounted on the heat sink 16 so that each reflector 86 aligns with the LEDs 12 on the PCB 14 (see
The light engine 10 is positioned within the ceiling within the opening 120 of a mounting frame 122. In some embodiments, at least one pin 124 extends from opposing sides of the heat sink 16. See generally
Various slot geometries are contemplated herein. Both uni-directional and bi-directional longitudinal translation of the light engine 10 relative to the mounting frame opening 120 is contemplated herein. In some embodiments, the geometry of the slot 130 can enable hi-directional longitudinal translation of the light engine 10 as well as rotational tilting of the light engine 10. For example, the slot 130 may have a length sufficient to permit the light engine 10 to translate to the left and right of the mounting frame opening 120.
The slot path can curve at one or both of its ends to effectuate tilting of the light engine 10 as the pins 124 follow the curved path. In the illustrated embodiment of
In one embodiment (see
In some embodiments, the pins 124 that extend from each side of the heat sink 16 are not laterally aligned, but rather one pin 124 is located slightly lower on the heat sink 16 than another pin 124. When the pins 124 are in the straight portion of the slot 130 (see
In other embodiments, the slot 130 does not have a detent(s), as seen in
In certain circumstances, it may be desirable to service the light engine 10 from above the ceiling, in which case it may be necessary to remove the light engine 10 from its position over the mounting frame opening 120. In some embodiments, this may be done by disengaging from the heat sink 16 the pins 124 that extend through the slots 130 in the upright supports 126. This would allow the light engine 10 to be maneuvered for servicing. In another embodiment, the pins 124 remain engaged. in the slots 130 and the upright supports 126 are disengaged from the mounting frame 122. For example, the upright supports 126 may be secured to the mounting frame 122 with screws 150. The screws 150 may simply be removed to permit the light engine 10 with associated upright supports 126 to be maneuvered for servicing. To facilitate handling of the light engine 10 from above, a handle 154 may be mounted to the heat sink 16.
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Further modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention. Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and subcombinations are useful and may be employed without reference to other features and subcombinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications can be made without departing from the scope of the invention.
This application claims the benefit of U.S. Provisional Application No. 61/687,886, filed May 3, 2012, the entirety of which is herein incorporated by reference.
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