(12) United States Patent (10) Patent N0.: US 8,789,978 B2 Tickner Et Al

USOO8789978B2

(12) United States Patent (10) Patent N0.: US 8,789,978 B2 Tickner et al. (45) Date of Patent: *Jul. 29, 2014

(54) LIGHT EMITTING DIODE RECESSED (52) US. Cl. LIGHT FIXTURE USPC ...... 362/294; 362/364; 362/365; 362/373 _ _ (58) Field of Classi?cation Search (71) Apphcamsger?dDTIQ?$s Newngn’ if (chl; USPC ...... 362/249.02, 364, 365, 368, 294, 373 60 3V] egnel‘, eaC fee 1 , S f 1 t h t ' G A (Us); Evans Edward Thompson, ee app 10a 10n e or comp e e searc IS ory HI’ Falrbum’ GA (Us) (56) References Cited (72) Inventors: Jerold Tickner, Newnan, GA (US); U_g_ PATENT DOCUMENTS Scott David Wegner, Peachtree City, GA (US); Evans Edward Thompson, 1,197,187 A 9/1916 Crown?eld HI, Fairburn, GA (Us) 1,281,752 A 10/1918 Bailey (Continued) (73) Assignee: Cooper Technologies Company, Houston, TX (US) FOREIGN PATENT DOCUMENTS

( * ) Notice: Subject to any disclaimer, the term of this CN 2516813 10/2002 patent is extended or adjusted under 35 CN 1793719 60006 U.S.C. 154(b) by 0 days. (Continued) This patent is subject to a terminal dis- OTHER PUBLICATIONS claimer_ International Search Report ?led in PCT/US2010/042442; mailed Dec. 31, 2010. (21) Appl. No.: 13/735,655 (Continued)

(22) Flled: Jan' 7’ 2013 Primary Examiner * Thomas Sember (65) Prior Publication Data (74) Attorney, Agent, or Firm * King & Spalding LLP US 2013/0235587 A1 Sep. 12, 2013 (57) ABSTRACT thdU.S.Al - t - Dt A recessed light ?xture includes an LED module ’ which e a 6 PP lea 10n a a includes a single LED package that is con?gured to generate (63) Continuation of application No. 13/431,439, ?led on all light emitted by the recessedlight ?xture. For example, the Mar. 27, 2012, now Pat. No. 8,348,477, which is a LED package can include multiple LEDs mounted to a com continuation of application No. 13/ 109,490, ?led on mon substrate. The LED package can be coupled to a heat May 17, 2011, now Pat. No. 8,348,479, which is a sink for dissipating heat from the LEDs. The heat sink can continuation of application No. 12/235,116, ?led on include a core member from which ?ns extend. Each ?n can Sep. 22, 2008, now Pat. No. 7,959,332. include one or more straight and/ or curved portions. A re?ec (60) Provisional application No. 61/065,914, ?led on Feb. tor h-OHSlng may be coupled to the heat smk and con?gured to 1 5 2008 . . 1 1. . N 61/090 391 rece1ve a re?ector. The re?ector can have any geometry, such , s Provmona app 19m?“ 0' _ _ ’ ’ as a bell-shaped geometry including two radii of curvature ?led on Aug 20’ 2008> PrOVISIOnal appllcanQQ NO- that join together at an in?ection point. An optic coupler can 61010,?49, ?led on Jan 9, 2008, MOI/151011211 be coupled to the re?ector housing and con?gured to cover apphcatlon NO- 60/994,792, ?led on seP~ 21, 2007- electrical connections at the substrate and to guide light emit ted by the LED package. (51) Int. Cl. F21 V29/00 (2006.01) 20 Claims, 12 Drawing Sheets US 8,789,978 B2 Page2

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(56) References Cited Mini Lights; http://WWW.lightinng.com/cat--Minilights--9; Jan. 25, 2006. OTHER PUBLICATIONS Recessed lighting; http://WWW.bedaZZled.uk.com/LightiFittings. htm; Dec. 19,2006. Downlights; http://WWW.vibelighting.com.au/images/Vibe-Cata http://WWW.Wfsenate.co.uldmedia/uploads/ logue-2009-10.pdf; Nov. 1, 2009. 7edd239942f3c6982c76c44c3656757f42964a58.pdf; Apr. 27, 2008. Nora Lighting; http://wwwnoralighting.com/Category. Form Lighting; AUDREY MR 16,; http://wwwformlightingcom. ast?cid:465; Sep. 27, 2008. au/Brands’Banhtm; Aug. 31, 2009. Famco; Luminaires; http://WWWfamco.com.au/search.php?q:lamp; Rexel Lighting Catalogue; http://WWW.-lighting.co.nz/ pdfdownloads/RexelLightingCatalogueiJunl2.pdf; Mar. 5, 2000. Sep. 27, 2008. Steller® , http://WWW.pierlite.com/au/l0660/stellar; Jul. 1, 2002. Prolite; Speci?cation Sheet; Light Adder; http://WWW.prolite.com. WAC HR-88: http://WWW.ipnlighting.com/hr-88-Wt/; Mar. 25, 2009. au/Default.ast?SiteSearchID:l&ID:/searchiresults; Sep. 30, Linear ceiling mounted LED luminaire by Ettore Sottsass; http:// 2009. WWW.archiexpo.com/prod/2umtobel/linear-ceiling-mounted-led-lu WAC Lighting 3" Low Voltage Recessed Downlighting; http://WWW. minaires-ettore-sottsass-9003-1027891.htrnl; Feb. 7, 2007. brandlighting.com/wacirecessedidownlighting-3.htrn; Jan. 27, Specialty Lighting, JJIiLovo Series Downlighting; http://WWW. 2007. lightingresource.com/products/ */ */ 1673: Feb. 1, 2001. Gotham Lighting; Vandal-Resistant CFL Low-pro?le Downlight: Amelec; Interior Lighting 2004; http://WWW.amelec.com.au/pdfs/ http://gothamlighting.acuitybrands.com/products/detail/l02168/ Giorno%20Luce%20Catalogue.pdf; Jul. 15, 2004. gotham-lighting/vrafv/vandal-resistant-c?-vertical-downlight; Jul. Surface mounted 7W GX53imetal ?nish, http://wwwef?cientlight. 1, 2009. co.uldLight-Fittings/Surface-mounted-7W-GX53-metal-?nish Weka Electronics; Weka LED Lights; http://www.wekaelectronics. SURFACE7WGX53ast; Feb. 9, 2010. com/01.html; May 28, 2007. “Cooper Lighting, LLC’s First Amended Answer, Af?rmative Lithonia Lighting; http://WWW.lithonia.com/microiwebs/com Defenses and Counterclaims to Lighting Science Group Corpora mericaldownlighting/literature/ tion’s Complaint for Patent Infringement,” dated May 2, 2014, lithonia%20downlighting%20catalog.pdf: Sep. 15, 2006. regarding US. Patent No. 8,348,477. US. Patent Jul. 29, 2014 Sheet 1 0f 12 US 8,789,978 B2

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\\ Ww/ US 8,789,978 B2 1 2 LIGHT EMITTING DIODE RECESSED require complex electrical and thermal management systems. LIGHT FIXTURE Therefore, traditional recessed light ?xtures have not used LED light sources. Accordingly, a need currently exists in the RELATED APPLICATIONS art for a recessed light ?xture that uses an LED light source.

This application is a continuation of and claims priority SUMMARY under 35 U.S.C. §120 to US. patent application Ser. No. 13/431,439, titled “Light Emitting Diode Recessed Light Fix The invention provides a recessed light ?xture with an LED ture,” ?led on Mar. 27, 2012, which was a continuation of and light source. The light ?xture includes a housing or “can” claims priority to US. patent application Ser. No. 13/109, within which an LED module is mounted. The LED module 490, titled “Light Emitting Diode Recessed Light Fixture,” includes a single LED package that generates all or substan ?led on May 17, 2011, which was a continuation of and tially all the light emitted by the recessed light ?xture. For claims priority to US. patent application Ser. No. 12/235, example, the LED package can include one or more LEDs 116, titled “Light Emitting Diode Recessed Light Fixture,” mounted to a common substrate. Each LED is an LED die or ?led on Sep. 22, 2008, which claims priority under 35 U.S.C. LED element that is con?gured to be coupled to the substrate. §119 to US. Provisional Patent Application No. 60/994,792, The LEDs can be arranged in any of a number of different titled “Light Emitting Diode Downlight Can Fixture,” ?led on con?gurations. For example, the LEDs can be arranged in a Sep. 21, 2007, US. Provisional Patent Application No. round-shaped area having a diameter of less than two inches 61/010,549, titled “Diverging Re?ector for Light Emitting or a rectangular-shaped area having a length of less than two Diode or Small Light Source,” ?led on Jan. 9, 2008, US. 20 inches and a width of less than two inches. Provisional Patent Application No. 61/ 065,914, titled “Dim The LED package can be thermally coupled to a heat sink mable LED Driver,” ?led on Feb. 15, 2008, and US. Provi con?gured to transfer heat from the LEDs. The heat sink can sional Patent Application No. 61/090,391, titled “Light Emit have any of a number of different con?gurations. For ting Diode Downlight Can Fixture,” ?led on Aug. 20, 2008. example, the heat sink can include a core member extending The complete disclosure of each of the foregoing priority 25 away from the LED package and ?ns extending from the core applications is hereby fully incorporated herein by reference. member. Each ?n can include a curved, radial portion and/or a straight portion. For example, each ?n can include a radial TECHNICAL FIELD portion that extends from the core member, and a straight portion that further extends out from the radial portion. In this The invention relates generally to recessed luminaires, and 30 con?guration, heat from the LEDs can be transferred along a more particularly, to a light emitting diode downlight can path from the LEDs to the core member, from the core mem ?xture for a recessed luminaire. ber to the radial portions of the ?ns, from the radial portions of the ?ns to their corresponding straight portions, and from BACKGROUND the corresponding straight portions to a surrounding environ 35 ment. Heat also can be transferred by convection directly A luminaire is a system for producing, controlling, and/or from the core member and/or the ?ns to one or more gaps distributing light for illumination. For example, a luminaire between the ?ns. The LED package can be coupled directly to can include a system that outputs or distributes light into an the core member or to another member disposed between the environment, thereby allowing certain items in that environ LED package and the core member. ment to be visible. Luminaires are often referred to as “light 40 A re?ector housing can be mounted substantially around ?xtures”. the LED package. For example, the re?ector housing can be A recessed light ?xture is a light ?xture that is installed in coupled to the heat sink and/ or the can. The re?ector housing a hollow opening in a ceiling or other surface. A typical can be con?gured to receive a re?ector and to serve as a recessed light ?xture includes hangerbars fastened to spaced secondary heat sink for the LED module. For example, the apart ceiling supports or joists. A plaster frame extends 45 re?ector housing can be at least partially composed of a between the hanger bars and includes an aperture con?gured conductive material for transmitting heat away from the LED to receive a lamp housing or “can” ?xture. package. The re?ector can be composed of any material for Traditional recessed light ?xtures include a lamp socket re?ecting, refracting, transmitting, or diffusing light from the coupled to the plaster frame and/ or the can ?xture. The lamp LED package. For example, the re?ector can comprise a socket receives an incandescent lamp or compact ?uorescent 50 specular, semi-specular, semi-diffuse, or diffuse ?nish, such lamp (“CFL”) discussed above. As is well known in the art, as gloss white paint or diffuse white paint. The re?ector can the traditional lamp screws into the lamp socket to complete have any of a number of different con?gurations. For an electrical connection between a power source and the example, a cross-sectional pro?le of the re?ector can have a lamp. substantially bell-shaped geometry that includes a smooth Increasingly, lighting manufacturers are being driven to 55 curve comprising an in?ection point. Top and bottom portions produce energy ef?cient alternatives to incandescent lamps. of the curve are disposed on opposite sides of the in?ection One such alternative was the CFL discussed above. CFLs ?t point. To meet a requirement of a top-down ?ash while also in existing incandescent lamp sockets and generally use less creating a smooth, blended light pattern, the bottom portion power to emit the same amount of visible light as incandes of the curve can be more diverging than the top portion of the cent lamps. However, CFLs include mercury, which compli 60 curve. cates disposal of the CFLs and raises environmental con An optic coupler can be mounted to the re?ector housing, cerns. for covering electrical connections at the substrate of the LED Another mercury-free alternative to incandescent lamps is package and/or for guiding or re?ecting light emitted by the the light emitting diode (“LED”). LEDs are solid state light LED package. For example, the optic coupler can include a ing devices that have higher energy ef?ciency and longevity 65 member with a central channel that is aligned with one or than both incandescent lamps and CFLs. However, LEDs do more of the LEDs of the LED package such that the channel not ?t in existing incandescent lamp sockets and generally guides light emitted by the LEDs while portions of the mem US 8,789,978 B2 3 4 ber around the channel cover the electrical connections at the FIG. 10 illustrates a thermal scan of the heat sink of the substrate of the LED package. The optic coupler can have any LED module of FIG. 3, in accordance with certain exemplary of a number of different geometries that may or may not embodiments. correspond to a con?guration of the LED package. For FIG. 11 is a perspective side view of a re?ector housing of example, depending on the sizes and locations of the electri the LED module of FIG. 3, in accordance with certain exem cal connections at the substrate, the portion of the optic cou plary embodiments. pler around the channel can have a substantially square, rect FIG. 12 is a perspective side view of a re?ector being angular, rounded, conical, or frusto-conical shape. inserted in the re?ector housing of FIG. 11, in accordance The LED module can be used in both new construction and with certain exemplary embodiments. retro?t applications. The retro?t applications can include FIG. 13 is a perspective side view of a trim ring aligned for placing the LED module in an existing LED or non-LED installation with the re?ector housing of FIG. 11, in accor dance with certain exemplary embodiments. ?xture. To accommodate installation in a non-LED ?xture, FIG. 14 is a ?ow chart diagram illustrating a method for the LED module can further include a member comprising a installing the LED module of FIG. 3 in an existing, non-LED pro?le that substantially corresponds to an interior pro?le of ?xture, in accordance with certain exemplary embodiments. a can of the non-LED ?xture such that the member creates a FIG. 15 is a perspective side view of the LED module of junction box between the member and a top of the can when FIG. 3 connected to a socket of an existing, non-LED ?xture the LED module is mounted in the can. To install the LED via an Edison base adapter, in accordance with certain exem module, a person can electrically couple an Edison base plary embodiments. adapter to both the existing, non-LED ?xture and the LED 20 FIG. 16 is an elevational side view of the Edison base module. For example, a person can cut at least one wire to adapter of FIG. 15, in accordance with certain exemplary remove an Edison base from the existing ?xture, cut at least embodiments. one other wire to remove an Edison screw-in plug from the FIG. 17 is a perspective top view of an optic coupler of the Edison base adapter, and connect together the cut wires to LED module of FIG. 3, in accordance with certain exemplary electrically couple the Edison base adapter and the existing 25 embodiments. ?xture. Alternatively, a person can release a socket from the FIG. 18 is a perspective bottom view of the optic coupler of existing ?xture and screw the Edison base adapter into the FIG. 17, in accordance with certain exemplary embodiments. socket to electrically couple the Edison base adapter and the FIG. 19 is a perspective top view of an optic coupler of the existing ?xture. The junction box can house the Edison base LED module of FIG. 3, in accordance with certain alternative adapter and at least a portion of the wires coupled thereto. 30 exemplary embodiments. These and other aspects, features and embodiments of the FIG. 20 is an exaggerated depiction of a pro?le of the invention will become apparent to a person of ordinary skill in re?ector, in accordance with certain exemplary embodi the art upon consideration of the following detailed descrip ments. tion of illustrated embodiments exemplifying the best mode 35 DETAILED DESCRIPTION OF EXEMPLARY for carrying out the invention as presently perceived. EMBODIMENTS BRIEF DESCRIPTION OF THE DRAWINGS The following description of exemplary embodiments refers to the attached drawings, in which like numerals indi For a more complete understanding of the present inven 40 cate like elements throughout the several ?gures. FIG. 1 is an tion and the advantages thereof, reference is now made to the elevational top view of hanger bars 105, a plaster frame 110, following description, in conjunction with the accompanying a can-shaped receptacle for housing a light source (a “can” ?gures brie?y described as follows. 115, and a junction box 120 of a recessed lighting ?xture 100, FIG. 1 is an elevational top view of hanger bars, a plaster according to certain exemplary embodiments. FIG. 2 is an frame, a can, and a junction box of a recessed lighting ?xture, 45 elevational cross-sectional side view of the hanger bars 105, in accordance with certain exemplary embodiments. plaster frame 110, can 115, and junction box 120 of the FIG. 2 is an elevational cross-sectional side view of the recessed lighting ?xture 100 of FIG. 1, in accordance with recessed lighting ?xture of FIG. 1, in accordance with certain certain exemplary embodiments. With reference to FIGS. 1 exemplary embodiments. and 2, the hanger bars 105 are con?gured to be mounted FIG. 3 is an elevational side view of an LED module of a 50 between spaced supports or j oists (not shown) within a ceiling recessed lighting ?xture, in accordance with certain exem (not shown). For example, ends of the hanger bars 105 can be plary embodiments. fastened to vertical faces of the supports or joists by nailing or FIG. 4 is an elevational top view of the LED module of FIG. other means. In certain exemplary embodiments, the hanger 3, in accordance with certain exemplary embodiments. bars 105 can include integral fasteners for attaching the FIG. 5 is an elevational cross-sectional side view of the 55 hanger bars 105 to the supports or joists, substantially as LED module of FIG. 3, in accordance with certain exemplary described in co-pending US. patent application Ser. No. embodiments. l 0/ 090,654, titled “Hanger Bar for Recessed Luminaires with FIG. 6 is a perspective side view of the LED module of Integral Nail,” and US. patent application Ser. No. 12/122, FIG. 3, in accordance with certain exemplary embodiments. 945, titled “Hanger Bar for Recessed Luminaires with Inte FIG. 7 is an elevational bottom view of the LED module of 60 gral Nail,” the complete disclosures of which are hereby fully FIG. 3, in accordance with certain exemplary embodiments. incorporated herein by reference. FIG. 8 is a perspective exploded side view of the LED The distance between the supports or joists can vary to a module of FIG. 3, in accordance with certain exemplary considerable degree. Therefore, in certain exemplary embodiments. embodiments, the hanger bars 105 can have adjustable FIG. 9 is an elevational cross-sectional top view of a heat 65 lengths. Each hanger bar 105 includes two inter-?tting mem sink of the LED module of FIG. 3, in accordance with certain bers 105a and 10519 that are con?gured to slide in a telescop exemplary embodiments. ing manner to provide a desired length of the hanger bar 105. US 8,789,978 B2 5 6 A person of ordinary skill in the art having the bene?t of the orange, or some other color or tint. In certain exemplary present disclosure will recognize that many other suitable embodiments, the light emitted from the LEDs in the LED means exist for providing adjustable length hanger bars 105. package 305 has a color temperature between 2500 and 5000 For example, in certain alternative exemplary embodiments, degrees Kelvin. one or more of the hanger bars described in Us. Pat. No. In certain exemplary embodiments, an optically transmis 6,105,918, titled “Single Piece Adjustable Hanger Bar for sive or clear material (not shown) encapsulates at least a Lighting Fixtures,” the complete disclosure of which is portion of the LED package 305 and/or each LED therein. hereby fully incorporated herein, may be utilized in the light This encapsulating material provides environmental protec ing ?xture 100 ofFIG. 1. tion while transmitting light from the LEDs. For example, the The plaster frame 1 10 extends between the hanger bars 1 05 encapsulating material can include a conformal coating, a and includes a generally rectangular, ?at plate 11011 with upturned edges 11019. For example, the ?at plate 110a can rest silicone gel, a cured/curable polymer, an adhesive, or some on a top surface of the ceiling. The junction box 120 is other material known to a person of ordinary skill in the art mounted to a top surface 1101111 of the ?at plate 11011. The having the bene?t of the present disclosure. In certain exem junction box 120 is a box-shaped metallic container that plary embodiments, phosphors are coated onto or dispersed in typically includes insulated wiring terminals and knock-outs the encapsulating material for creating white light. In certain for connecting external wiring (not shown) to an LED driver exemplary embodiments, the white light has a color tempera (not shown) disposed within the can 115 of the light ?xture ture between 2500 and 5000 degrees Kelvin. 100 or elsewhere within the light ?xture 100. In certain exemplary embodiments, the LED package 305 In certain exemplary embodiments, the plaster frame 110 20 includes one or more arrays of LEDs that are collectively includes a generally circular-shaped aperture 1100 sized for con?gured to produce a lumen output from 1 lumen to 5000 receiving at least a portion of the can 115 therethrough. The lumens in an area having less than two inches in diameter or can 115 typically includes a substantially dome-shaped mem in an area having less than two inches in length and less than ber con?gured to receive an LED module (not shown) that two inches in width. In certain exemplary embodiments, the includes at least one LED light source (not shown). The 25 LED package 305 is a CL-L220 package, CL-L230 package, aperture 1100 provides an illumination pathway for the LED CL-L240 package, CL-L102 package, or CL-L190 package light source. A person of ordinary skill in the art having the manufactured by Citizen Electronics Co., Ltd. By using a bene?t of the present disclosure will recognize that, in certain single, relatively compact LED package 305, the LED mod alternative exemplary embodiments, the aperture 1100 can ule 300 has one light source that produces a lumen output that have another, non-circular shape that corresponds to an outer 30 is equivalent to a variety of lamp types, such as incandescent pro?le of the can 115. lamps, in a source that takes up a smaller volume within the FIGS. 3-8 illustrate an exemplary LED module 300 of the ?xture. Although illustrated in FIGS. 7 and 8 as including recessed lighting ?xture 100 of FIG. 1. The exemplary LED LEDs arranged in a substantially square geometry, a person of module 300 can be con?gured for installation within the can ordinary skill in the art having the bene?t of the present 115 ofthe lighting ?xture 100 ofFIG. 1. The LED module 300 35 disclosure will recognize that the LEDs can be arranged in includes an LED package 305 mounted to a heat sink 310. The any geometry. For example, the LEDs can be arranged in LED package 305 may be mounted directly to the heat sink circular or rectangular geometries in certain alternative exem 310 or with one or more other components mounted in-be plary embodiments. tween the LED package 305 and the heat sink 310. The LEDs in the LED package 305 are attached to the The LED package 305 includes one or more LEDs 40 substrate 306 by one or more solder joints, plugs, epoxy or mounted to a common substrate 306. The substrate 306 bonding lines, and/or other means for mounting an electrical/ includes one or more sheets of ceramic, metal, laminate, optical device on a surface. Similarly, the substrate 306 is circuit board, mylar, or another material. Each LED includes mounted to a bottom surface 31011 of the heat sink 310 by one a chip of semi-conductive material that is treated to create a or more solder joints, plugs, epoxy or bonding lines, and/or positive-negative (“p-n”) junction. When the LED package 45 other means for mounting an electrical/optical device on a 305 is electrically coupled to a power source, such as a driver surface. For example, the substrate 306 can be mounted to the 315, current ?ows from the positive side to the negative side heat sink 310 by a two-part arctic silver epoxy. of each junction, causing charge carriers to release energy in The substrate 306 is electrically connected to support cir the form of incoherent light. cuitry (not shown) and/or the driver 315 for supplying elec The wavelength or color of the emitted light depends on the 50 trical power and control to the LED package 305. For materials used to make the LED package 305. For example, a example, one or more wires (not shown) can couple opposite blue or ultraviolet LED can include gallium nitride (“GaN”) ends of the substrate 306 to the driver 315, thereby complet or indium gallium nitride (“InGaN”), a red LED can include ing a circuit between the driver 315, substrate 306, and LEDs. aluminum gallium arsenide (“AlGaAs”), and a green LED In certain exemplary embodiments, the driver 315 is con?g can include aluminum gallium phosphide (“AlGaP”). Each of 55 ured to separately control one or more portions of the LEDs to the LEDs in the LED package 305 can produce the same or a adjust light color or intensity. distinct color of light. For example, the LED package 305 can As a byproduct of converting electricity into light, LEDs include one or more white LED’s and one or more non-white generate a substantial amount of heat that raises the operating LEDs, such as red, yellow, amber, or blue LEDs, for adjusting temperature of the LEDs if allowed to accumulate. This can the color temperature output of the light emitted from the 60 result in ef?ciency degradation and premature failure of the ?xture 100. A yellow or multi-chromatic phosphor may coat LEDs. The heat sink 310 is con?gured to manage heat output or otherwise be used in a blue or ultraviolet LED to create blue by the LEDs in the LED package 305. In particular, the heat and red-shifted light that essentially matches blackbody sink 310 is con?gured to conduct heat away from the LEDs radiation. The emitted light approximates or emulates even when the lighting ?xture 100 is installed in an insulated “white,” incandescent light to a human observer. In certain 65 ceiling environment. The heat sink 310 is composed of any exemplary embodiments, the emitted light includes substan material con?gured to conduct and/or connect heat, such as tially white light that seems slightly blue, green, red, yellow, die cast metal. US 8,789,978 B2 7 8 FIG. 9 is an elevational cross-sectional top view of the re?ector housing 320 can be coupled to another portion of the exemplary heat sink 310. FIG. 10 illustrates a thermal scan of LED module 300 or the lighting ?xture 100 in certain alter the exemplary heat sink 310 in operation. With reference to native exemplary embodiments. FIG. 11 illustrates the exem FIGS. 3-10, the bottom surface 31011 of the heat sink 310 plary re?ector housing 320. With reference to FIGS. 3-8 and includes a substantially round member 31019 with a protrud 11, the re?ector housing 320 includes a substantially round ing center member 3100 on which the LED package 305 is member 32011 having a top end 3201) and a bottom end 3200. mounted. In certain exemplary embodiments, the center Each end 3201) and 3200 includes an aperture 3201911 and member 3100 includes two notches 310d that provide a path 3200a, respectively. A channel 320d extends through the way for wires (not shown) that extend between the driver 315 re?ector housing 320 and connects the apertures 3201911 and and the ends of the substrate 306. In certain alternative exem 320011. plary embodiments, three or more notches 310d may be The top end 3201) includes a substantially round top surface included to provide pathways for wires. In certain alternative 320bb disposed aron at least a portion of the channel 320d. exemplary embodiments, the bottom surface 310a may The top surface 3201)!) includes one or more holes 320b0 include only a single, relatively ?at member without any capable of receiving fasteners that secure the re?ector hous protruding center member 3100. ing 320 to the heat sink 310. Each fastener includes a screw, Fins 311 extend substantially perpendicular from the bot nail, snap, clip, pin, or other fastening device known to a tom surface 310a, towards a top end 3100 of the heat sink 310. person of ordinary skill in the art having the bene?t of the The ?ns 311 are spaced around a substantially central core present disclosure. In certain alternative exemplary embodi 905 ofthe heat sink 310. The core 905 is a member that is at ments, the re?ector housing 320 does not include the holes least partially composed of a conductive material. The core 20 320190. In those embodiments, the re?ector housing 320 is 905 can have any of a number of different shapes and con formed integrally with the heat sink 310 or is secured to the ?gurations. For example, the core 905 can be a solid or heat sink 310 via means, such as glue or adhesive, that do not non-solid member having a substantially cylindrical or other require holes for fastening. In certain exemplary embodi shape. Each ?n 311 includes a curved, radial portion 311a and ments, the re?ector housing 320 is con?gured to act as a a substantially straight portion 31119. In certain exemplary 25 secondary heat sink for conducting heat away from the LEDs. embodiments, the radial portions 31111 are substantially sym For example, the re?ector housing 320 can assist with heat metrical to one another and extend directly from the core 905. dissipation by connecting cool air from the bottom of the light In certain alternative exemplary embodiments, the radial por ?xture 100 towards the LED package 305 via one or more tions 31111 are not symmetrical to one another. Each straight ridges 321. portion 311!) extends from its corresponding radial portion 30 The re?ector housing 320 is con?gured to receive a re?ec 311a, towards an outer edge 310fof the heat sink 310, sub tor 1205 (FIG. 12) composed of a material for re?ecting, stantially along a tangent of the radial portion 31111. refracting, transmitting, or diffusing light emitted by the LED The radius and length of the radial portion 311a and the package 305. The term “re?ector” is used herein to refer to length of the straight portion 311!) can vary based on the size any material con?gured to serve as an optic in a light ?xture, of the heat sink 310, the size of the LED module 300, and the 35 including any material con?gured to re?ect, refract, transmit, heat dissipation requirements of the LED module 300. By or diffuse light. FIG. 12 is a perspective side view of the way of example only, one exemplary embodiment of the heat exemplary re?ector 1205 being inserted in the channel 320d sink 310 can include ?ns 311 having a radial portion 31111 of the re?ector housing 320, in accordance with certain exem with a radius of 1.25 inches and a length of 2 inches, and a plary embodiments. With reference to FIGS. 3-8, 11, and 12, straight portion 311!) with a length of 1 inch. In certain alter 40 when the re?ector 1205 is installed in the re?ector housing native exemplary embodiments, some or all of the ?ns 311 320, outer side surfaces 1205a of the re?ector 1205 are dis may not include both a radial portion 311a and a straight posed along corresponding interior surfaces 3200 of the portion 31119. For example, the ?ns 311 may be entirely re?ector housing 320. In certain exemplary embodiments, a straight or entirely radial. In certain additional alternative top end 1205b of the re?ector 1205 abuts an edge surface exemplary embodiments, the bottom surface 31011 of the heat 45 33011 of an optic coupler 330, which is mounted to a bottom sink 310 may not include the round member 31019. In these edge 31011 of the top surface 3201919. The re?ector 1205 is embodiments, the LED package 305 is coupled directly to the described in more detail below with reference to FIG. 20. The core 905, rather than to the round member 31019. optic coupler 330 includes a member con?gured to cover the As illustrated in FIG. 10, the heat sink 310 is con?gured to electrical connections at the substrate 306, to allow a geomet dissipate heat from the LED package 305 along a heat-trans 50 ric tolerance between the LED package 305 and the re?ector fer path that extends from the LED package 305, through the 1205, and to guide light emitted by the LED package 305. The bottom surface 31011 of the heat sink, and to the ?ns 311 via optic coupler 330 and/ or a material applied to the optic cou the core 905. The ?ns 311 receive the conducted heat and pler 330 can be optically refractive, re?ective, transmissive, transfer the conducted heat to the surrounding environment specular, semi-specular, or diffuse. The optic coupler 330 is (typically air in the can 115 of the lighting ?xture 100) via 55 described in more detail below with reference to FIGS. 17-19. convection. For example, heat from the LEDs can be trans The bottom end 3200 of the re?ector housing 320 includes ferred along a path from the LED package 305 to the core 905, a bottom surface 3200a that extends away from the channel from the core 905 to the radial portions 31111 of the ?ns 311, 320d, forming a substantially annular ring aron the channel from the radial portions 31111 of the ?ns 311 to their corre 320d. The surface 3200a includes slots 3200b that are each sponding straight portions 311b, and from the corresponding 60 con?gured to receive a corresponding tab 1305a from a trim straight portions 311!) to a surrounding environment. Heat ring 1305 (FIG. 13). FIG. 13 illustrates a portion of the trim also can be transferred by convection directly from the core ring 1305 aligned for installation with the re?ector housing 905 and/ or the ?ns 311 to one or more gaps between the ?ns 320. With reference to FIGS. 3-8 and 11-13, proximate each 311. slot 3200b, the surface 3200a includes a ramped surface In certain exemplary embodiments, a re?ector housing 320 65 32000 that enables installation of the trim ring 1305 on the is coupled to the bottom surface 31011 of the heat sink 310. A re?ector housing 320 via a twisting maneuver. Speci?cally, person of ordinary skill in the art will recognize that the the trim ring 1305 can be installed on the re?ector housing