Patent Grant
11629844
Modern lighting devices have electronic light sources for emitting light, such as one or more light emitting diode (LED) components. Typically, the brightness of an LED light source is at least partially related to the speed in which heat can be transferred away from the LED component. For example, it may be desirable to maintain the temperature of the LED under about 105° Celsius for improved or maximum light output and efficiency. However, certain lighting devices such as, but not limited to, room or area lighting devices, may be configured to be mounted in an enclosed environment, such as in a housing and/or in a recess of a ceiling, wall or other structure. In those or other contexts, the lighting device may be mounted in a thermally contained or poorly ventilated environment that can inhibit the ability to quickly transfer heat away from the LED. Accordingly, it can be desirable to provide lighting device configurations that allow for sufficient transfer of heat from the LED light source to maintain the temperature of the light source at or below a threshold temperature during operation and, particularly, during operation in a thermally contained or poorly ventilated environment.
Lighting device assemblies of various examples described herein can be configured to have good heat transfer characteristics (to transfer and dissipate heat away from the LED), while also allowing the lighting device assembly to be located within a housing and/or within a recess or opening in a ceiling, wall or other object. In other examples, the lighting device assembly may be surface mounted on a surface of a ceiling, wall or other object, or mounted on a pedestal or other support structure extending from a ceiling, wall, or other object. In yet other examples, the lighting device assembly may be mounted in other suitable locations or environments.
An example of a trim member for a lighting device module includes an annular body. The annular body has a first end portion that is connectable to a housing of the lighting device module and that has a light receiving opening arranged to receive light from the lighting device module when the first end portion is connected to the housing of the lighting device module. The annular body has a second end portion opposite to the first end portion, and that is configured to be positioned outside of the housing of the lighting device module when the first end portion is connected to the housing of the lighting device module. The second end portion has a light emitting opening. The annular body has a central channel defining a light passage extending through the annular body, from the light receiving opening to the light emitting opening. The annular body has a first curved or tapered surface extending from the light receiving opening toward the light emitting opening, where the first curved or tapered surface has a diameter that increases toward the light receiving opening. The annular body has a second curved or tapered surface extending from the first curved or tapered surface to the light emitting opening, where the second curved or tapered surface has a diameter that increases toward the light emitting opening.
In further examples of the trim member, the first curved or tapered surface is light-reflective and is configured to reflect a peripheral portion of light from the lighting device module back toward the housing of the lighting device module, while allowing a central portion of light from the lighting device module to pass through the central channel.
In further examples of the trim member, the first curved or tapered surface has a light reflective material, coating or treatment.
In further examples of the trim member, the second curved or tapered surface has a black or light absorbing material, coating or treatment.
In further examples of the trim member, the second curved or tapered surface has a light reflective material, coating or treatment.
In further examples of the trim member, the second end portion of the annular body has an annular lip that extends outward from the annular body, and the lip is configured to abut against a panel in which the lighting device module is installed, when the first end portion is connected to the housing of the lighting device module.
In further examples of the trim member, the annular lip has a plurality of openings configured to receive a plaster material for plastering the annular lip to the panel.
In further examples of the trim member, the first end portion of the annular body has at least one groove, recess, protrusion or rib that is configured to receive or be received in a corresponding at least one a protrusion, rib, groove or recess in the housing of the lighting device module, to connect the first end portion of the annular body to the housing of the lighting device module.
In further examples of the trim member, the first end portion of the annular body has a diameter that is small enough to fit within a light emitting opening of the housing of the lighting device module, when the first end portion is connected to the housing of the lighting device module.
Further examples relate to a lighting device module, including a housing of a lighting device module, the housing containing a light source for emitting light. The lighting device module further includes a trim member having an annular body including a first end portion that is connected to the housing of the lighting device module, where the first end portion has a light receiving opening that is arranged to receive light from the lighting device module when the first end portion is connected to the housing of the lighting device module. The trim member further has a second end portion opposite to the first end portion, and that is configured to be positioned outside of the housing of the lighting device module when the first end portion is connected to the housing of the lighting device module, where the second end portion has a light emitting opening. The trim member has a central channel defining a light passage extending through the annular body, from the light receiving opening to the light emitting opening. The trim member has a first curved or tapered surface extending from the light receiving opening toward the light emitting opening, the first curved or tapered surface having a diameter that increases toward the light receiving opening. The trim member further has a second curved or tapered surface extending from the first curved or tapered surface to the light emitting opening, the second curved or tapered surface having a diameter that increases toward the light emitting opening.
In further examples of the lighting device module, the first curved or tapered surface is light-reflective and is configured to reflect a peripheral portion of light from the lighting device module back toward the housing of the lighting device module, while allowing a central portion of light from the lighting device module to pass through the central channel.
In further examples of the lighting device module, the second curved or tapered surface has a black or light absorbing material, coating or treatment.
In further examples of the lighting device module, the second curved or tapered surface has a light reflective material, coating or treatment.
In further examples of the lighting device module, the second end portion of the annular body has an annular lip that extends outward from the annular body, and the lip is configured to abut against a panel in which the lighting device module is installed, when the first end portion is connected to the housing of the lighting device module.
In further examples of the lighting device module, the annular lip has a plurality of openings configured to receive a plaster material for plastering the annular lip to the panel.
Further examples relate to a method of making a lighting device module with a trim member, where the method includes arranging a light source in a housing of a lighting device module for emitting light from the housing, and connecting a first end portion of an annular body to the housing of the lighting device module, where the first end portion has a light receiving opening to receive light from the housing of the lighting device module. The method further includes positioning a second end portion of the annular body outside of the housing of the lighting device module when the first end portion is connected to the housing of the lighting device module, the second end portion having a light emitting opening. The method further includes providing the annular body with a first curved or tapered surface extending from the light receiving opening toward the light emitting opening, the first curved or tapered surface having a diameter that increases toward the light receiving opening. The method further includes providing the annular body with a second curved or tapered surface extending from the first curved or tapered surface to the light emitting opening, the second curved or tapered surface having a diameter that increases toward the light emitting opening.
In further examples of the method, the first curved or tapered surface is light-reflective and is configured to reflect a peripheral portion of light from the lighting device module back toward the housing of the lighting device module, while allowing a central portion of light from the lighting device module to pass through the central channel.
In further examples of the method, the second curved or tapered surface has a black or light absorbing material, coating or treatment.
In further examples of the method, the second curved or tapered surface has a light reflective material, coating or treatment.
In further examples, the method further includes extending an annular lip outward from the second end portion of the annular body, the annular lip being configured to abut against a panel in which the lighting device module is installed, when the first end portion is connected to the housing of the lighting device module, and forming a plurality of openings in the annular lip to receive a plaster material for plastering the annular lip to the panel.
The above and other aspects and features of the present invention will become more apparent to those skilled in the art from the following detailed description of the example embodiments with reference to the accompanying drawings, in which:
Hereinafter, example embodiments will be described in more detail with reference to the accompanying drawings. The present invention, however, may be embodied in various different forms, and should not be construed as being limited to only the illustrated embodiments herein. Rather, these embodiments are provided as examples so that this disclosure will be thorough and complete, and will fully convey the aspects and features of the present invention to those skilled in the art. Accordingly, processes, elements, and techniques that are not necessary to those having ordinary skill in the art for a complete understanding of the aspects and features of the present invention may not be described. Unless otherwise noted, like reference numerals denote like elements throughout the attached drawings and the written description, and thus, descriptions thereof may not be repeated. Further, features or aspects within each example embodiment should typically be considered as available for other similar features or aspects in other example embodiments.
In the drawings, the relative sizes of elements, layers, and regions may be exaggerated and/or simplified for clarity. Spatially relative terms, such as “beneath,” “below,” “lower,” “under,” “above,” “upper,” and the like, may be used herein for ease of explanation to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or in operation, in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” or “under” other elements or features would then be oriented “above” the other elements or features. Thus, the example terms “below” and “under” can encompass both an orientation of above and below. The device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly.
It will be understood that, although the terms “first,” “second,” “third,” etc., may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section described below could be termed a second element, component, region, layer or section, without departing from the spirit and scope of the present invention.
It will be understood that when an element or layer is referred to as being “on,” “connected to,” “coupled to,” “secured to” or “attached to” another element or feature, it can be directly on, connected to, coupled to, secured to or attached to the other element or layer, or one or more intervening elements or layers may be present. In addition, it will also be understood that when an element or layer is referred to as being “between” two elements or layers, it can be the only element or layer between the two elements or layers, or one or more intervening elements or layers may also be present.
The terminology used herein is for the purpose of describing particular embodiments and is not intended to be limiting of the present invention. As used herein, the singular forms “a” and “an” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes,” and “including,” “has,” “have,” and “having,” when used in this specification, specify the presence of the stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Expressions such as “at least one of,” when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list.
As used herein, the term “substantially,” “about,” and similar terms are used as terms of approximation and not as terms of degree, and are intended to account for the inherent variations in measured or calculated values that would be recognized by those of ordinary skill in the art. Further, the use of “may” when describing embodiments of the present invention refers to “one or more embodiments of the present invention.” As used herein, the terms “use,” “using,” and “used” may be considered synonymous with the terms “utilize,” “utilizing,” and “utilized,” respectively. Also, the term “exemplary” is intended to refer to an example or illustration.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and/or the present specification, and should not be interpreted in an idealized or overly formal sense, unless expressly so defined herein.
According to various examples described herein, a lighting device system is configured as a recessed lighting device for mounting in a ceiling, wall or other structure, by recessing the lighting device within or behind a ceiling panel, wall panel or other structure. For example, the lighting device system may be configured to be installed in an opening to a plenum, duct or attic space of a ceiling, or in an inner wall space in a manner to appear flush or substantially flush with an exposed surface of a ceiling, wall or other object. In other examples, variations of the lighting device system may be configured to be installed in a manner that is not flush with an exposed surface (and, instead, is configured to be recessed or protruding from the exposed surface of a ceiling, wall, outer housing or other object), or is configured to be surface-mounted on the exposed surface of the ceiling, wall, outer housing or other object. In yet other examples, variations of the lighting device system may be configured to be mounted on a support structure (such as, but not limited to a sconce structure, pedestal, shaft or the like).
The lighting device system includes a lighting device module having a light source and an optic member that are configured to emit light in a cone or other pattern. In examples in which the optic member includes one or more lenses, where the axis of the light emission may correspond to an optical axis of the one or more lenses. In other examples, the axis of the light emission may correspond to a center of the light cone or pattern emitted by the light source and optic member.
Particular examples are configured to provide sufficient thermal communication and heat dissipation characteristics to help maintain the temperature of the light source at or below a desired threshold temperature for improved operation. In addition to thermal communication, the lighting device system and module may be configured for ease of manufacture, assembly or servicing. In particular examples, the lighting device system and module may be configured to allow adjustment of a direction of light emission from the lighting module about multiple axis.
Lighting Device System 100
A perspective view of an example of a lighting device system 100, in an assembled state and attached to or installed on a panel 101 is shown in
In the example of
In certain examples, the housing includes a cover member 112 that covers the lighting device module 102, the heat sink 104, the biasing device 106 and the driver electronics 108. The cover member 112 may be a box-like structure having an open side (the bottom side in
The lighting device system 100 may include additional components, including those described below. In other examples, the lighting device system 100 may include more than one lighting device module 102 and, in yet further examples, may include a corresponding more than one heat sink 104, biasing device 106 and/or driver electronics 108. While
Lighting Device Module 102
The lighting device module 102 is configured to be selectively installed in and received by the rest of the lighting device system 100, as shown in
In particular examples, the rest of the lighting device system 100 (as described below) is initially installed in a ceiling, wall or other structure, adjacent a hole or opening formed through the panel 101. Then, the lighting device module 102 may be slid at least partially through the opening and into the lighting device system 100 (in the upward direction of
From the installed state, the lighting device module 102 may be selectively slid out or partially out of the lighting device system 100 (in the downward direction of
By configuring the lighting device module 102 to be selectively slid into or out of the lighting device system 100, through a single, relatively small opening in the panel 101, one or more benefits may be achieved. For example, such configurations can allow the lighting device system 100 to be concealed behind the panel 101 (e.g., within an inner ceiling space, an inner wall space, a plenum or duct space or an inner space of another object), while a relatively small opening is provided for light from the lighting device module 102 to pass. Alternatively or in addition, such configurations can allow the lighting device module 102 to be installed in the rest of the lighting device system 100, and to be selectively removed from the rest of the lighting device system 100, through the relatively small opening in the panel 101, for example, to replace, inspect, adjust or service the lighting device module 102. In particular examples, the lighting device module 102 is configured to provide one or more of those advantages, while also providing a good (relatively high or fast rate) of thermal communication for thermal transfer and dissipation of heat from the lighting device module 102 to the heat sink 104, when the lighting device module 102 is installed in the lighting device system 100.
The lighting device module 102 is shown in side, cross-section views in
In the example in
In other examples, the module housing 120 may have other suitable shapes including, but not limited to cylindrical with other cross-section shapes (such as, but not limited to oval, rectangular or other polygonal or combined cross section shape), spheroid, cuboid, or the like. A cylindrical shape can be beneficial as being able to contain components of the lighting device module 102 described herein, yet also fit through a relatively small, round (or oval, rectangular or other polygonal) shaped hole in the panel 101, for installing or removing the lighting device module 102 to or from the lighting device system 100.
In certain examples (as shown in
A two part housing can help to simplify manufacturing or assembly (or both) of the module housing 120. For example, a two part housing can be easier to form in a mold or by machining, as compared to a single, unitary component. A two part housing can form a clamshell-like housing structure that is easily connected together to contain and hold other components of the lighting device module 102. However, in other examples, the module housing 120 may be made as a single, unitary component, or may be made of more than two parts.
The module housing 120 (including the first and second housing sides 121 and 122) may be made by any suitable manufacturing process or processes including, but not limited to molding, machining, extrusion, or combinations thereof. The module housing 120 (including the first and second housing sides 121 and 122) may be made of any suitably rigid material or materials including, but not limited to metal, plastic, ceramic, composite material, or combinations thereof. In particular examples, the module housing 120 is made of a material having a good (relatively high or fast rate) of thermal dissipation capabilities such as, but not limited to a heat dissipating metal, plastic, ceramic or composite material.
The housing module 120 includes one or more rails or tracks (e.g., the rails or tracks 124 and 125 in the illustrated example) to guide the moveable heat sink member 130 along a path of motion, for adjusting a tilt direction of the light source 150 and, thus, the direction of light emission from the light source 150. In the illustrated example, each housing side 121 and 122 has a respective rail or track 124 or 125 such that, when the housing sides 121 and 122 are connected together, the rails or tracks 124 and 125 engage and support the moveable heat sink member 130 through a range of motion.
As described in further detail, below, the rails or tracks 124 and 125 protrude radially inward from an inner surface of the housing sides 121 and 122, respectively (partially into the interior volume defined by the housing sides 121 and 122). The rails or tracks 124 and 125 are configured to interface with the moveable heat sink member 130 to support and hold the heat sink member 130 within the module housing 120, yet allow the heat sink member 130 to be moved along a curved or an arced path, to adjust a tilt direction or angle of the light source 150 (and of a light emitting direction of the light source 150). In particular examples, the heat sink member 130 is supported to be moved (relative to the module housing 120) along the curved or arced path, within a range from a first position (as shown in
The moveable heat sink member 130 includes a heat sink body that has a shape and configuration to fit within the interior volume of the module housing 120, when the housing sides 121 and 122 are connected together. The body of the moveable heat sink member 130 may be made of a material having good (relatively high or fast rate) thermal dissipating capabilities such as, but not limited to a heat dissipating metal, plastic, ceramic or composite material, or combinations thereof. In certain examples, the moveable heat sink member 130 is composed of a single, unitary body of such material, for improved heat dissipating capabilities. In particular examples, the body of the moveable heat sink member 130 is made of a generally solid, unitary piece of material that is configured as described herein.
The body of the moveable heat sink member 130 has a mounting surface (the downward-facing surface in
In particular examples, the body of the moveable heat sink member 130 includes one or more channels or grooves through which one or more electrically conductive wires or other electrical conductors 196 may extend. The one or more conductors 196 may be electrically connected to the light source 150 and may extend through or along the moveable heat sink member 130, and through an opening in the module housing 120 (e.g., in the upper end of the module housing in
The light source 150 may include any suitable light emitting device or devices. In particular examples, the light source 150 includes one or more LEDs or other light source that generates heat during operation. In such examples, the one or more LEDs (or other light source) may be mounted on a circuit board or other support structure. As described herein, the moveable heat sink member 130 is configured to conduct and dissipate heat away from the light source 150, which can significantly improve the efficiency and light output of the one or more LEDs (or other heat-generating light sources). While particular examples described herein include a light source 150 having one or more LEDs, other examples may include other suitable light sources such as, but not limited to one or more halogen, halide, fluorescent, or incandescent light sources, or other electrical discharge or electroluminescence device, or the like
In particular examples, the light source 150 is fixed to and mounted in thermal communication with the mounting surface of the moveable heat sink member 130, such that the heat sink member 130 may efficiently receive and conduct heat from the light source 150. In certain examples, the surface of the moveable heat sink member 130 may be in direct contact with the light source 150, to efficiently transfer heat away from the light source 150. In certain examples in which the light source 150 includes a circuit board on which one or more light emitting devices are mounted, the circuit board may be mounted in direct contact with (e.g., generally flat or flush against the mounting surface of the heat sink member 130) to enhance the ability to transfer heat from the circuit board (or components on the circuit board) to the heat sink member 130.
The optic holder 160 may comprise an annular body, frame, housing or other structure that is configured to hold and retain the optic member 170 and to connect and be fixed to the moveable heat sink member 130 (or to the frame that holds the light source 150 on the heat sink member 130). The optic holder 160 may be made of any suitable rigid material or materials including, but not limited to plastic, metal, ceramic, composite material, or combinations thereof. The optic holder 160 may be made by any suitable manufacturing process including, but not limited to molding, machining, extrusion, or combinations thereof. The optic holder 160 may be secured to the moveable heat sink member 130 (or to the frame) by any suitable connection mechanism including, but not limited to, threaded fasteners 162 (as shown in
The optic member 170 may be a lens, filter, or other optical device that passes light, and affects a characteristic of the light being passed. In certain examples, the optic member 170 includes a lens configured to focus light toward one or more focus points or centers of focus. In some examples, the optic member 170 may have a configuration for directing light through a relatively small aperture or opening in the trim member 195. Some examples of such optic members that may be employed for optic member 170 are described in the Applicant's U.S. Pat. No. 10,900,654 (which is incorporated herein by reference, in its entirety). In other examples, the optic member 170 may include other suitable lens configurations.
In particular examples, the optic member 170 has a light-receiving side that faces the light source 150 and is configured to receive (and receives) light generated from the light source 150. The optic member 170 also has a light-emitting side that faces the open end (the downward-facing end in
The second optic member 180 may be a lens, filter, or other optical device that passes light, and affects a characteristic of the light being passed. In certain examples, the second optic member 180 includes a Fresnel lens, or other lens that spreads or evens out light passing through the lens. The second optic holder 190 may be an annular or semi-annular body or bracket configured to attach to the optic holder 160 and hold and retain the second optic 180 in a fixed position between the second optic holder 190 and the optic holder 160. The second optic holder 190 may be attached to the optic holder 160 by any suitable connection mechanism including, but not limited to, threaded fasteners 192 (as shown in
When assembled as shown in
The body of the moveable heat sink member 130 has a first groove or channel 132 extending transverse to the direction of the axis A, on one side of the body with respect to the axis A. The body of the moveable heat sink member 130 may have a second groove or channel 133 (corresponding to the groove or channel 132) on the opposite side of the body with respect to the axis A. The grooves or channels 132 and 133 are configured to receive the rails or tracks 124 and 125 protruding from the housing sides 121 and 122, respectively, when the housing sides 121 and 122 are connected together. When the rails or tracks 124 and 125 are received within the grooves or channels 132 and 133, the body of the heat sink member 130 is retained and held within the module housing 120, and may be slid along the rails or tracks 124 and 125, to change the tilt direction of orientation or the position of the heat sink member 130 relative to the axis A of the module housing 120 (and of the module 102).
In particular examples, the rails or tracks 124 and 125 are configured to engage and contact one or more of the walls of the grooves or channels 132 and 133 in the heat sink member 130, and to remain engaged and in contact throughout the range of motion of the heat sink member 130 relative to the module housing 120. In other examples, other portions of the body of the heat sink member 130 are configured to engage and contact (and remain engaged and in contact) with the housing sides 121 and 122, during or throughout the range of motion of the heat sink member 130. In certain examples, those features engage in sufficient thermal contact to provide a good (relatively high or fast rate of) thermal conduction for the transfer of heat from the heat sink member 130 to the housing sides 121 and 122, for dissipation as described herein.
Accordingly, heat generated by the light source 150 may be transferred to the moveable heat sink member 130, and from the heat sink 130 to the housing sides 121 and 122, for dissipation. By providing a good thermal contact between the light source 150 and the moveable heat sink member 130, and also between the walls of the grooves or channels 132 and 133 in the heat sink member 130 and rails or tracks 124 and 125 in the module housing 120 throughout the range of movement of the heat sink member 130, thermal energy may be conducted away from the light source 150 relatively quickly, while also allowing the heat sink member 130 (with the light source 150) to be moveably adjustable within the module housing 120.
In particular examples, the moveable heat sink member 130 includes or operates with one or more biasing members 140 configured to force at least one wall of the groove or channel 132 and at least one wall of the groove or channel 133 against a surface of the rail or track 124 and a surface of the rail or track 125, respectively. By forcing the groove or channel surfaces of the heat sink member 130 against the rail or track features of the housing sides 121 and 122, the moveable heat sink member 130 may be held in good thermal communication with the module housing 120, while allowing the heat sink member 130 to be adjustably slid along the rails or tracks 124 and 125.
In the example in
The first ball plunger mechanisms 140 may press against the upper surfaces of the rail or track 125 and force the bottom surface 132a of the groove or channel 132 against the bottom surface of the rail or track 125. Similarly, the second ball plunger mechanisms 140 may press against the upper surfaces of the rail or track 124 and force the bottom surface (out of view in
During assembly, the first and second ball plunger mechanisms 140a and 140b may be inserted and secured within corresponding passages drilled or otherwise formed through sections of the heat sink member 130 (e.g., the sections that overhang the grooves or channels 132 and 133 in
In other examples, more than one ball plunger mechanism 140a and 140b may be provided for each groove or channel 132 and 133. In other examples, instead of (or in addition to) ball plunger mechanisms extending from the upper wall, one or more ball plunger mechanisms 140a and 140b may be provided on and extending from the lower wall of each groove or channel 132 and 133 in the heat sink member 130, to engage and press against the bottom surface of the rails or tracks 124 and 125 and force the top surfaces of those rails or tracks against the upper surfaces of the grooves or channels 132 and 133. Yet other examples may include other mechanisms for biasing one or more surfaces of the grooves or channels 132 and 133 against one or more surfaces of the rails or tracks 124 and 125 for improved thermal coupling and/or frictional engagement including, but not limited to, one or more springs, spring material, resilient material, magnetic coupling or combinations thereof.
In the illustrated example, the rails or tracks 124 and 125 protrude radially inward from an inner wall of each of the housing sides 121 and 122 while a groove or channel 132 or 133 is provided on each side of the body of the heat sink member 130. In other examples, the location of each of the rail or track 124 and groove or channel 132, 133 may be reversed, such that the housing sides 121 and 122 have grooves or channels 132 and 133 respectively, while each side of the body of the heat sink member 130 has a protruding rail or track 124 or 125 that engages the groove or channel 132 or 133. Other examples employ other suitable movable mounting configurations for retaining and holding the heat sink member 130 within the module housing 120 for movement along an arced path.
In the illustrated example, the rails or tracks 124 and 125 are curved (e.g., curved downward, toward the left of the housing side 121 in
In certain examples (as shown in
In the example in
When the moveable heat sink member 130 is in a first position (as shown in
In certain examples, the body of the moveable heat sink member 130 may be configured with the second side (the right-facing side in
Alternatively or in addition, the module housing 120 may be provided with one or more openings 129 or other features for increasing the angle (and range of angles) at which heat sink member 130 (and the light source 150) may be oriented within the module housing 120, while reducing (or not requiring an increase) in the diameter or size of the module housing 120. In the example in
In other examples, a further opening may be provided in the module housing 120, on the opposite end of the rails 124 and 125, for example, to allow additional sliding movement of the heat sink member 130, beyond the vertical orientation shown in
As described above, openings or other features of the module housing 120, as well as the arc of the rail or tracks 124 and 125, or the shape and configuration of the heat sink member 130 (or any combination thereof), can be configured to define a desired range of possible tilt adjustment motion of the heat sink member 130 and of the light source 150 relative to the axis A of the lighting device module 102. Accordingly, various examples embodiments include module housings 120, rails or tracks 124 and 125 and heat sink members 130 having configurations as described herein, to provide a desired range of motion and accommodate a desired range of tilt adjustment.
In particular examples, the rails or tracks 124 and 125 in the module housing 120 and the grooves or channels 132 and 133 in the heat sink member (or other portions of those components) are in sufficiently tight engagement and friction fitted with each other to retain and hold the heat sink member 130 in any position on the rails or tracks 124 and 125 between and including the first and second positions in
In certain examples, the trim member 195 is provided for connection with the open end (the bottom end in
The central channel of the trim member may define an angled or partial-conical inner surface that tapers outward from a smaller diameter toward the interior of the module housing 120 and a larger diameter facing away from the module housing 120. In some examples, the tapered inner surface of the trim member 195 may be formed or coated with a reflective material for reflecting light emitted through the optic member 170. In other examples, the tapered inner surface of the trim member 195 may be formed or coated with a non-reflective material or a light absorbing material.
The first section 195a of the trim member 195 may include one or more connection features 195c that engage with one or more connection features on the module housing 120 to attach and secure the trim member 195 to the module housing 120. The one or more connection features may include, but are not limited to, one or more grooves 195c on the trim member 195 (or on the module housing 120) that engage one or more corresponding protrusions on the module housing 120 (or on the trim member 195) in a snap-fit manner. In other examples, other suitable connection features may be employed including adhesives, friction fitting, magnetic coupling, spring clamps or other fasteners or clamps, or combinations thereof.
The first section 195a of the trim member 195 may include a recess defined by an inwardly curved or tapered wall 195d. The recess has a wider opening at the open end (the upper end in
In particular examples, the surface of the recess in the wall 195d of the trim member 195 has a curvature or angle that is configured to reflect a peripheral portion of light that is emitted through the trim member 195, such that the reflected peripheral edge portion is reflected back into the lighting device module 102, toward the optic 170 or toward the inner wall surface of the module housing 120 and absorbed. In that manner the pattern of light that is emitted through the trim member 195 can be sharper with more a more defined edge, as compared to a pattern in which the peripheral edge portion is not reflected back.
In certain examples, the second portion 195b of the trim member 195 may include a lip feature that extends radially outward from the rest of the module housing 120, for example, to cover a gap or opening between parts, after installation. In certain examples, the second portion 195b of the trim member 195 may be in a viewable location after installation of the lighting device system and, thus, may be made of or provided with a decorative material, coating, color, or other aesthetic enhancement.
The second portion 195b of the trim member 195 may include a further curved or angled surface 195e that extends from the narrower opening of the recess in the wall 195d to a second open end (the lower end in
In some examples, the second portion 195b of the trim member 195 may include an extended lip feature (e.g., larger than the lip shown in
In those examples, once the trim member 195 is connected and the lighting device module 102 is installed, the plaster material may be applied to the exposed surface of the lip of the trim member 195 and a portion of the exposed surface of the panel 101 by any suitable technique, including, but not limited to spreading the material manually, for example with a spatula or other spreading tool. The plaster material may be forced through the openings in the lip of the trim member 195, to help hold and retain the plaster material to the trim member or to help conceal the trim member 195 on a ceiling, wall or other structure. In certain examples, the plaster material is configured to be applied in a wet or paste-like form, and dry or solidify after being applied to the lip of the trim member 195.
The components of the lighting device module 102 may be made by any suitable manufacturing processes, including those described herein. The components may be assembled by securing the optic member 170 in the optic holder 160. In addition, the light source 150 is secured to the mounting surface (the downward-facing surface in
The heat sink member 130, with the above-mentioned components assembled thereon, is placed in one housing side 121 or 122, with one of the grooves or channels 132 or 133 in alignment and engagement with one of the rails or tracks 124 and 125 (and with a biasing device 140 engaged with that rail or track as described herein). In addition, the electrical conductors 196 extending from the heat sink member 130 are aligned with and placed in one or more channels or grooves (e.g., channel 121a) in the housing side 121 or a similar channel in housing side 122. Those channels define conductor passages through the module housing 120, when the housing sides 121 and 122 are connected together). Then, the other housing side 121 or 122 is placed over the heat sink member 130 (and over above-mentioned components that are assembled on the heat sink member), with the other groove or channel 132 or 133 in alignment and engagement with the other rail or track 124 or 125 (and with another biasing device 140 engaged with that rail or track as described herein). In that arrangement, one or more screws or other fasteners 128 may be inserted through fastener openings in one of the housing sides 121 or 122 and threaded (or otherwise attached) to one or more corresponding openings (or other connection feature) on the other housing side 121 or 122. Alternatively or in addition, one or more tensioned rings or bands 123 may be placed around the outer peripheral surface of assembled housing sides 121 and 122 to retain or help retain the housing sides together.
In certain examples, the assembled lighting device module 102 may be electrically connected to the driver electronics 108, via the electrical conductors 196. Before or after connecting the lighting device module 102 to the driver electronics 108, the assembled lighting device module 102 may be inserted through an opening formed in a panel 101, for installing the lighting device module 102 in a ceiling, wall or other structure. In particular examples, the driver electronics 108 may be installed on the panel 108, or on a base plate 110 that is configured to be supported (or is supported) on the panel 108 (such as, but not limited to, a side of the panel 108 that is within or facing toward an attic or ceiling space, an inner wall space, a plenum or duct space or the like.
In particular examples, the driver electronics 108, as well as the biasing device and the heat sink member 104 are installed on a surface of the panel 101, for example during or after construction of a ceiling, wall or other structure. In some examples, those components may be mounted on the base plate 110 (which may be mounted to the surface of the panel 101) and, in further examples, the cover member 112 may be mounted over those components. The heat sink member 104 may be mounted and supported adjacent an opening in the panel 101. As discussed herein the opening in the panel 101 has a size and shape through which the assembled module housing 120 may fit (for example, by sliding the assembled module housing 120 through the opening in the panel 101 and into the lighting device system 100 (e.g., in the axial A direction, or upward direction of
Other Components of the Lighting Device System 100
The heat sink member 104 includes a heat sink body be made of a material having good (relatively high or fast rate) thermal dissipating capabilities such as, but not limited to a heat dissipating metal, plastic, ceramic or composite material, or combinations thereof. In certain examples, the heat sink member 104 is composed of a single, unitary body of such material, for improved heat dissipating capabilities. In particular examples, the body of the heat sink member 104 is made of a generally solid, unitary piece of material that is configured as described herein. In some examples, as illustrated, the body of the heat sink member 104 may include one or more (or a plurality of) fins or other shaped features to help dissipate heat from the body of the heat sink member 104.
The body of the heat sink member 104 has a mounting surface (the bottom surface in
The body of the heat sink member 104 has at least one contact surface 104a that is arranged to abut and contact a portion of the outer surface of the module housing 120, when the lighting device module 102 is installed in the lighting device system 101. In particular examples the contact surface 104a extends transverse (such as, but not limited to perpendicular to) the mounting surface of the heat sink member 104, and is arranged to abut along a side portion of the module housing 120.
In the example in
The module housing 120 is configured to abut and contact the contact surface 104a of the heat sink member 104 to transfer heat from the module housing 120 to the heat sink member 104. The amount of surface area of the module housing 120 in contact with the contact surface 104a of the heat sink member 104 (and, thus, the heat transfer capability) is increased by one or both of the curvature of the contact surface 104a extending around a portion of the module housing 120, or the axial length of the contact surface 104a extending along the entire (or substantially the entire) axial length of the module housing 120.
In the example in
The biasing device 106 may include a spring, a spring-biased plunger, a spring biased ball, a resilient material or other structure that is configured to abut against the outer surface of the module housing 120 of the lighting device module 102 and push the module housing 120 toward the contact surface 104a of the heat sink member 104, when the lighting device module 102 is installed in the lighting device system 101. In the illustrated example, the spring and plunger or ball are supported in a plunger housing that is secured to the base plate 110 or to the panel 101 by any suitable connection mechanism including, but not limited to adhesives, welding, threaded fasteners, clamps, or other fasteners.
In the example in
The driver electronics 108 electrically connect with the light source 150 in the lighting device module 102, through the conductors 196. The driver electronics 108 also electrically connect with a source of electrical power through further conductors 197. The further conductors 197 may connect to an AC power line or other power source that is provided in the ceiling, the wall or the other structure in which the lighting device system 100 is installed. In the illustrated example, the further conductors 197 comprises electrical wire conductors that extend from the driver electronics 108 to electrical connectors that electrically couple the further conductors 197 to AC power source conductors present in an installation environment. The driver electronics 108 are configured to convert power provided through the conductors 197 from the power source, to a suitable power for driving the light source 150.
In particular examples, the light source 150 includes an LED, and the driver electronics 108 includes one or more LED drivers to drive the LED light source 150. In some examples, the driver electronics 108 (or other electronics within the lighting device system 100) may include a processor to execute instructions stored on memory (e.g., non-transient computer readable media) to process data and/or to control various functions of the lighting device (e.g., temperature, light output, color of light, direction of light, focus of light, and/or the like).
The components of the lighting device system 100 may be made by any suitable manufacturing processes, including those described herein. For example, a lighting device module 102 may be made and assembled as described above. The lighting device module 102 and other components of the lighting device system 100 may be assembled and installed on a panel 101 of a ceiling, a wall or another structure at an installation site, in any suitable assembly and installation process, such as but not limited to the following example.
Before or during assembly and installation, a light passage opening is formed in the panel 101, where the opening has a size and dimension to allow the lighting device module 102 to pass. In particular examples, the lighting device module 102 has a generally cylindrical shape with an outer diameter, and the opening in the panel is formed as a round shape with the same or slightly larger diameter as the outer diameter of the lighting device module 102 to allow the lighting device module 102 to be easily slid through the opening, in its axial direction. In other examples as described herein, the outer dimension of the lighting device module 102 may be oval, polygonal, or of other shapes, and the shape of the opening in the panel may be formed of a corresponding shape.
In some examples, the base plate 110 is provided. The base plate 110 has an opening of a size and shape that corresponds to the size and shape of the opening formed in (or to be formed in) the panel 101. The base plate 110 is mounted on one surface of the panel 101 (the upward-facing surface in
The heat sink member 104 is mounted on a surface of the base plate 110 (the upward-facing surface in
The driver electronics 108 are mounted on the base plate 110. In certain examples, the driver electronics 108 is formed as a module, and the mounting bracket 109 secures the driver electronics module 108 to the same surface of the base plate on which the biasing device 140 is mounted. In other examples, the driver electronics 108 may be mounted to the cover 112 or another component.
The electrical conductors 197 from the driver electronics 108 are electrically connected to power source conductors provided at the installation site. In some examples, the power source conductors are passed through openings in the cover 112 and then connected to the electrical conductors 197 of the driver electronics 108. Then the cover 112 may be secured to the base plate 110, to enclose the driver electronics 108 and the heat sink member 104.
The driver electronics is electrically connected to the lighting device module 102, through the electrical conductors 196. In certain examples, the electrical conductors 196 include one or more electrical connectors 196a that allow a first section of the electrical conductors 196 extending from the driver electronic 108 to be connected with a second section of the electrical conductors 196 extending from the lighting device module 102. For example, the first section of the electrical conductors 196 may be passed through (or made accessible through) the aligned openings in the panel 101 and the base plate 110, before the cover 112 is attached to the base plate 110.
While the lighting device module 102 is located on the opposite side of the panel 101 relative to the driver electronics 108, the first section of the electrical conductors 196 may accessed through the aligned openings in the panel 101 and the base plate 110, and may be connected to the second section of the electrical conductors 196, via the electrical connectors 196a. In that manner, the lighting device module 102 may be electrically connected to the driver electronics 108, and the driver electronics may be electrically connected to power source conductors at an installation site
In some examples, the electrical connector 196a may be inserted in (or may be fixed in) one of the housing sides 121 and 122 (or in an opening in the top of the module housing 120), as shown in
Once the lighting device module 102 is electrically connected to the driver electronics 108, the lighting device module 102 may be positioned axially with the aligned openings, and may be slid through the aligned openings (e.g., in the upward direction in
Once the rotational adjusted position of the lighting device module 102 about the axis A is selected, the lighting device module 102 may be slid further into the aligned openings (e.g., manually or with a tool), until the lip or flange 195b of the trim member 195 engages (or is positioned adjacent) a surface of the panel 101 (the downward-facing surface in
In certain examples, the lighting device module 102 is automatically secured in the lighting device system 100, by sliding the lighting device module 102 into the aligned openings in the panel 101 and the base plate 110. For example, the biasing device 106 may be configured to provide a sufficient bias force on the lighting device module 102 to retain the lighting device module 102 in the lighting device system 100 by frictional engagement with the biasing member and with the contact surface 104a of the heat sink member 104. In those examples, the frictional engagement may be sufficient to retain the lighting device module 102 (against gravity), but may be overcome by applying a force (e.g., a manual force or a force with a tool) in the axial direction to pull the lighting device module 102 out of (or partially out of) the aligned openings in the panel 101 and the base plate 110. In other examples, one or more other connection mechanisms may be employed to secure the lighting device module 102 in the lighting device system 100 including, but not limited to, other friction fitting configurations, snap connections, magnetic coupling, clamps, other fasteners, combinations thereof, or the like. In certain examples, plaster material may be spread over and pushed through openings in the lip portion of the trim member 195, as discussed above and in Applicant's U.S. Pat. No. 10,900,654 (cited and incorporated herein, above).
When the lighting device module 102 is connected to the driver electronics 108 and is secured in the lighting device system 100 as shown in
In particular examples, during operation of the lighting device system 100, heat generated by the light source 150 of the lighting device module 102 is efficiently transferred away from the light source 150. As discussed above, in certain examples of the lighting device module 102, the light source 150 is mounted in good (relatively high or fast rate) of thermal communication with a mounting surface of the moveable heat sink member 130. The moveable heat sink member 130 is made of a material for good thermal conduction. In addition, the moveable heat sink member 130 is biased against the housing sides 121 and 122 (by the biased engagement of the rails or tracks 124 and 125 with the grooves or channels 132 and 133) to more effectively convey heat from the moveable heat sink member 130 to the module housing 120.
The module housing 120 is made of a material for good thermal conduction. In addition, the module housing 120 is pressed against the contact surface 104a of the heat sink member 104 by the biasing member 106, to more effectively convey heat from the module housing 120 to the heat sink member 104. The heat sink member 104 is made of a material for good thermal conduction and effectively draws heat from the module housing 120. In addition, the heat sink member is mounted in thermal contact with the base plate 110, to transfer heat from the heat sink member 104 to the base plate 110. The base plate 110 is mounted flat against the panel 101 and may transfer and dissipate heat to the panel 101 and into the environment on the other side of the panel 101. Accordingly, thermal energy may be efficiently transferred from the light source 150, to the base plate 110 and the panel 101, for dissipation. By improving the rate of transfer of heat away from the light source 150, the light source 150 may produce light more efficiently and may last longer.
As discussed above, in further examples, the base plate 110 may be omitted. In those examples, the heat sink member 104 may be configured to mount onto the panel 101 and to transfer heat directly to the panel 101, for dissipation by the panel 101. The heat sink member 104 may be connected to the panel 101 by any suitable connection mechanism including, but not limited to one or more drywall fasteners, threaded fasteners, adhesives, clamps, or other fasteners (e.g., represented by fasteners 200 and 202).
While the example shown in
An example of a lighting device system 200 having multiple lighting device modules is shown in
The lighting device modules 102 in
In the example in
In the example in
The trim panel 202 may have a shape and a size corresponding to the shape and size of the opening in the panel 101. In the example in
In some examples, the trim panel 202 has a shape and size that fits within (or partially within) the opening 101a in the panel 101. In particular examples, the trim panel 202 may have a lip 202a that remains external to the panel 101, when the trim panel is received (or partially received) in the opening 101a of the panel 101. In the example in
When installed, the trim panel 202 (or the lip 202a of the trim panel 202) may fit flush with or abutted against the exposed surface (the downward-facing surface in
The lighting device system 200 in
In the example in
When the lighting device modules 1021, 1022, 1023 and 1024 are inserted through the opening in the panel 101 (and, in some examples, in the base plate 210), each of the lighting device modules may be aligned with an associated, respective contact surface of a heat sink member 1041, 1042, 1043 or 1044, and with an associated biasing device 1061, 1062, 1063 and 1064. In that manner, each lighting device module 1021, 1022, 1023 and 1024 may be pressed against a contact surface 104a of a respective heat sink member 1041, 1042, 1043 or 1044, by the force of the associated biasing device 1061, 1062, 1063 or 1064. In particular examples, a separate respective heat sink member and a separate respective biasing device is provided for each separate, respective lighting device module 1021, 1022, 1023 and 1024. In other examples, a single heat sink member may include one or more contact surfaces for accommodating two or more of the lighting device modules. Similarly, a single biasing device may be configured to provide a biasing force on two or more of the lighting device modules.
The heat sink members 1041, 1042, 1043 or 1044 and the biasing devices 1061, 1062, 1063 or 1064 may be mounted to the panel 101 (or to the base plate 210) as described above for
Accordingly, the lighting device system 200 may be installed, electrically connected and operated in a manner similar to the lighting device system 100, but includes multiple lighting device modules 1021, 1022, 1023 and 1024. In certain examples, the lighting device system 200 may include a cover 212 corresponding to the cover 112 described above. In the example in
In certain examples, the base plate 210 may be mounted and supported for rotation between and relative to the cover 212 and the further cover 213. The base plate 210 may be mounted by any suitable mounting mechanism to the panel 101, or to the further cover 213. In certain examples, the mounting mechanism includes one or more of a guide for rotational motion, a rotational axel, a rotor or other support structure for supporting the base plate 210 for rotation relative to the cover 212 (or relative the cover 212 and a further cover 213). The rotational mounting mechanism allows the base plate 210 to be rotated (relative to the cover 212 and the further cover 213), to more easily align the opening 210a in the base plate 210 with the corresponding opening in the panel 101. More specifically, the housing covers 212 and 213 may be oriented in any suitable position, for example, to fit an available space in an attic, duct, plenum, inner wall or other space, while the base plate 210 may be rotated to align with the desired location of the opening in the panel 101.
In the example shown in
In certain examples, a second plate member 220 may be coupled to the base plate 210, by support brackets 222 and 224. Alternatively, or in addition, the second plate member 220 may be secured to the heat sink members 1041, 1042, 1043 or 1044 (e.g., the upward-facing surfaces of those heat sink members in
In the illustrated example, both the base plate 210 and the further plate 220 have round, plate-like shapes and are coupled together, coaxially. In addition, the cover 212 has a round opening on an upper surface that is configured to align with the further plate 220, when the cover 212 is attached to the further cover 213. The round opening in the cover 212 can facilitate access to and assembly of the further plate 220, brackets 222 and 224, heat sink members 1041, 1042, 1043 and 1044, and other components with the base plate 210.
A volume space between the base plate 210 and the further plate 220 contains the heat sink members 1041, 1042, 1043 and 1044, the biasing device 1061, 1062, 1063 and 1064, and the driver electronics 108. That volume space also contains at least a portion of the lighting device modules 1021, 1022, 1023 and 1024, when the lighting device modules are installed in the system 200.
In various examples described herein, certain components are described as having a cone shape, cylindrical shape, rectangular shapes, round shapes or other shape including, but not limited to the module housing 102, the trim member 195, the trim panel 202, and the panels 210 and 220. However, in other examples, those components may have other suitable shapes including, but not limited to shapes having polygonal or other circular or non-circular cross-sections or combinations thereof. In some examples, those components may have an outer shape configured to provide an aesthetically pleasing, artistic, industrial or other impression.
The foregoing description of illustrative embodiments has been presented for purposes of illustration and of description. It is not intended to be exhaustive or limiting, and modifications and variations may be possible in light of the above teachings or may be acquired from practice of the disclosed embodiments. Various modifications and changes that come within the meaning and range of equivalency of the claims are intended to be within the scope of the invention. Thus, while certain embodiments of the present invention have been illustrated and described, it is understood by those of ordinary skill in the art that certain modifications and changes can be made to the described embodiments without departing from the spirit and scope of the present invention as defined by the following claims, and equivalents thereof.
| Number | Name | Date | Kind |
|---|---|---|---|
| 3187174 | Langer | Jun 1965 | A |
| 6474846 | Kelmelis | Nov 2002 | B1 |
| 10900654 | Nguyen et al. | Jan 2021 | B1 |
| 11441768 | Portinga | Sep 2022 | B1 |
| 20050183344 | Ziobro | Aug 2005 | A1 |
| 20130322091 | Honeycutt | Dec 2013 | A1 |
| 20140071679 | Booth | Mar 2014 | A1 |
| 20170191628 | Nelkin | Jul 2017 | A1 |
| 20200132278 | Portinga | Apr 2020 | A1 |
| Number | Date | Country | |
|---|---|---|---|
| 20230045452 A1 | Feb 2023 | US |
