Patent Application
20150098214
The present invention relates to the field of lighting assembly. More specifically, the present invention relates to LED (light emitting diode) hosing structure and materials.
Typically LED assembly comprises complicated stamped structures and often with many screws. The typically LED assembly also include many parts, which adds more manufacturing labors and costs.
An LED assembly and the method of manufacturing the same. The LED assembly comprises a housing body, one or more LED light emitting component hosting areas, a power unit hosting compartment, one or more light diffusing elements, and a cover.
In an aspect, a method of manufacturing a LED assembly comprises coupling formed sheet metal to form a housing body, wherein the housing body comprising at least two recesses, coupling at least one LED lighting element with each of the at least two recesses, enclosing a power supply, and coupling one or more diffusing lens to each of the LED lighting element.
In some embodiments, the housing body comprises at least three pieces of metal sheets. In other embodiments, the two recesses are at the two sides of the power supply. In some other embodiments, each of the two recesses comprises a flat area coupling with the LED lighting element. In some embodiments, the method further comprises assembling the housing body without using a screw.
In another aspect, a lighting assembly comprising a housing body having an enclosed power supply compartment and a portion of the housing body form a thermal barrier between the power supply and one or more LED panels. In some embodiments, the housing body is formed by attaching formed metal sheets to one another. In other embodiments, the LED panels are provided or with one or more diffusing lens. In some other embodiments, the LED panels are at two sides of the power supply. In some embodiments, the housing body comprises two recesses couples with two LED lighting elements. In other embodiments, the lighting assembly further comprises a cover, wherein the cover covers the power supply compartment holding the power supply. In some other embodiments, the cover is a perforated stamped piece. In some embodiments, the housing body comprises a thermally reflective coating. In some other embodiments, the lighting assembly couples with an LED or LED array greater than 100 Watts.
In another aspect, a low-profile LED lighting fixture comprises a body having a thickness less than 70 mm, two lighting areas located at two sides of the fixture, a concave surface mounting area at each of the two lighting areas, and a diffusing lens covering each of the lighting areas. In some embodiments, the low-profile LED lighting fixture further comprises two rows of holes facing each other. In other embodiments, the holes are heat dissipating holes located around a power supply. In some other embodiments, the low-profile LED lighting fixture further comprises a thermal barrier between the power supply and a LED lighting element. In some embodiments, the body is formed by three pieces of formed sheet metal. In other embodiments, the diffusing lens is lower than a side wall of the body.
Other features and advantages of the present invention will become apparent after reviewing the detailed description of the embodiments set forth below.
Embodiments will now be described by way of examples, with reference to the accompanying drawings which are meant to be exemplary and not limiting. For all figures mentioned herein, like numbered elements refer to like elements throughout.
Reference is made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings. While the invention is described in conjunction with the embodiments below, it is understood that they are not intended to limit the invention to these embodiments and examples. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which can be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of the present invention, numerous specific details are set forth in order to more fully illustrate the present invention. However, it is apparent to one of ordinary skill in the prior art having the benefit of this disclosure that the present invention can be practiced without these specific details. In other instances, well-known methods and procedures, components and processes have not been described in detail so as not to unnecessarily obscure aspects of the present invention. It is, of course, appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer's specific goals, such as compliance with application and business related constraints, and that these specific goals are vary from one implementation to another and from one developer to another. Moreover, it is appreciated that such a development effort can be complex and time-consuming, but is nevertheless a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure.
In some embodiments, a cover 108 is a perforated and a stamped piece. In some embodiments, the cover 108 covers the compartment 112 holding the LED power supply 110. The compartment 112 can comprise an area 112A for attaching the LED power supply 110. The area 112A can be a flat surface.
In some embodiments, one or more diffusers 106 couple with the housing body 102. The diffusers 106 can cover the LED panel 104, which fit in front of the LED array providing a soft lighting. A person of ordinary skill in the art appreciates that the distance from the diffusers 106 to the LED panel 104 is adjustable. In some embodiments, the diffusers 106 can be instantly replaceable for different lighting effects, such as brighter/dimmer and with lighting patterns.
In some embodiments, the structure and construction of the LED assembly 100 provides an enclosed and snug-fit compartment for efficient heat dissipation.
Further, the curvature structure 112B of the enclosure 112 provides a relatively large thermal barrier between the power supply 110 and the LED panel 104, which allows the emitting of 100+ Watt incandescent equivalent light, which is superior than the typical LED assembly allowing LEDs in the scale of 10-20 Watts. Furthermore, the diamond shape enclosure 112 has a top portion 112C that serves as a cover to enclose the power supply 110 preventing the exposure of the power supply 110.
In some embodiments, a thermally reflective coating is formed on the lighting exposed fixture, such as the surface 104A such that the thermal stress in the power supply compartment is reduced or minimized. In some embodiments, the cover of the assembly/fixture comprises structures that can enhance convective cooling using temperature differentials between the power supply 110 and the immediate ambient atmosphere.
The LED assembly can be utilized to illuminate and used as an indoor lighting. The wattage can include 65 Watts, 130 Watts, and 195 Watts. In some embodiments, the LED assembly comprises dimming drivers.
In operation, the manufacturing of the LED assembly can be done by assembling the housing body, securing the LED panels and diffusing lens, and place a cover on.
The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of principles of construction and operation of the invention. Such reference herein to specific embodiments and details thereof is not intended to limit the scope of the claims appended hereto. It is readily apparent to one skilled in the art that other various modifications can be made in the embodiment chosen for illustration without departing from the spirit and scope of the invention as defined by the claims.
This application claims priority under 35 U.S.C. §119(e) of the U.S. Provisional Patent Application Ser. No. 61/887,838, filed Oct. 7, 2013 and titled, “METHOD AND APPARATUS FOR ENHANCED THERMAL ISOLATION OF LOW-PROFILE LED LIGHTING FIXTURES FOR COMMERCIAL AND RESIDENTIAL APPLICATIONS,” which is also hereby incorporated by reference in its entirety for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 61887838 | Oct 2013 | US |
