Thin profile surface mount lighting apparatus

• US 10,663,127 B2
• Filed: 10/15/2019
• Issued: 05/26/2020
• Est. Priority Date: 06/22/2017
• Status: Active Grant

• Current Assignee: DMF Incorporated
• Original Assignee: DMF Incorporated
• Inventors: Danesh, Michael D., Williams, Vincent, Jongewaard, Mark
• Primary Examiner(s): Hines, Anne M
• Application Number:
  US16/653,497
• Publication Number:
  US 20200056752A1
• Time in Patent Office: 224 Days
• CPC Class Codes: F21K 9/68 Details of reflectors forming part of the light source
• CPC Class Codes: F21S 8/026 intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling
• CPC Class Codes: F21S 8/03 of surface-mounted type F21S8/02, F21S8/04 take precedence; details of wall or floor bases F21V21/02
• CPC Class Codes: F21S 8/043 mounted by means of a rigid support, e.g. bracket or arm
• CPC Class Codes: F21S 9/022 Emergency lighting devices
• CPC Class Codes: F21V 21/047 Mounting arrangements with fastening means engaging the inner surface of a hole in a ceiling or wall, e.g. for solid walls or for blind holes
• CPC Class Codes: F21V 21/088 Clips; Clamps
• CPC Class Codes: F21V 23/04 the elements being switches safety devices F21V25/00
• CPC Class Codes: F21V 29/87 Organic material, e.g. filled polymer composites; Thermo-conductive additives or coatings therefor
• CPC Class Codes: F21Y 2105/16 square or rectangular, e.g. for light panels
• CPC Class Codes: F21Y 2105/18 annular; polygonal other than square or rectangular, e.g. for spotlights or for generating an axially symmetrical light beam
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G02B 6/0021 for housing at least a part of the light source, e.g. by forming holes or recesses
• CPC Class Codes: G02B 6/0031 Reflecting element, sheet or layer

Abstract

A thin profile surface mount LED lighting apparatus includes a housing, an LED board including multiple LEDs, and a lens. The lens has a back side facing the LED board and a front side that provides a downward facing surface when the LED lighting apparatus is installed in an opening of a ceiling. The lens is disposed with respect to the LED board such that the LEDs illuminate the back side of the lens. A first spacing of the LEDs causes resulting light from the downward facing surface of the lens to be substantially uniform during operation of the apparatus. In one example, a thin front edge of a sidewall of the housing, forming a perimeter around the lens, is flush with the lens and is appreciably thin (e.g., a thickness of less than three millimeters), and a depth of the sidewall housing is less than one inch.

Claims

1. An LED lighting apparatus, comprising:

a housing including at least one sidewall, wherein a thickness of at least a portion of the at least one sidewall is less than ten millimeters;

an LED board coupled to the housing, the LED board comprising a plurality of LEDs; and

a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens,

wherein the quotient of;

an LED-to-LED spacing of adjacent LEDs of the plurality of LEDs on the LED board; and

a spacing between the LED board and the lens,

is in a range of from 7.5/8 to 8.5/8.

2. The apparatus of claim 1, wherein:

the at least one sidewall has a front facing edge; and

an edge thickness of the front facing edge of the at least one sidewall is less than 2.0 millimeters.

3. The apparatus of claim 1, wherein the lens is substantially flat or flat.

4. The apparatus of claim 3, wherein the at least one sidewall of the housing is substantially perpendicular or perpendicular to the lens.

5. The apparatus of claim 1, wherein:

the LED board has a first dimension in a first plane parallel to the back side of the lens;

the lens has a second dimension in a second plane corresponding to the back side of the lens; and

the first dimension of the LED board and the second dimension of the lens are substantially the same or the same.

6. The apparatus of claim 1, wherein the front side of the lens is essentially flush with the front facing edge of the at least one sidewall of the housing.

7. The apparatus of claim 6, wherein:

the at least one sidewall further has a back facing edge; and

a depth of the at least one sidewall of the housing, between the front facing edge and the back facing edge, is less than one inch.

8. The apparatus of claim 1, further comprising at least one screwless mechanical coupler to couple the apparatus to a surface.

9. The apparatus of claim 8, wherein the at least one screwless mechanical coupler comprises at least one snap fit coupler.

10. The apparatus of claim 8, wherein the at least one screwless mechanical coupler comprises at least one of a friction fit clip, a spring clip, or a magnet.

11. An assembly, comprising:

the apparatus of claim 8; and

an adapter ring to couple the apparatus to a junction box,

wherein the apparatus is coupled to the adapter ring via the at least one screwless mechanical coupler.

12. The assembly of claim 11, further comprising the junction box.

13. The assembly of claim 12, wherein the junction box is one of a 3½

inch or 4 inch square, octagon, or round junction box.

14. The assembly of claim 12, wherein the adapter ring is coupled to the junction box via one or more screws.

15. The apparatus of claim 1, wherein:

the housing, the LED board and the lens are assembled to provide a luminaire; and

the apparatus further comprises at least one mechanical coupler to couple the luminaire to a surface without using one or more screws.

16. The apparatus of claim 15, wherein:

the surface is a ceiling; and

the at least one mechanical coupler includes at least one of a friction fit clip, a spring clip, or a magnet to snap fit the luminaire to a junction box installed and positioned above the ceiling such that when the luminaire is snap fit to the junction box, the housing appears to be surface mounted to the ceiling.

17. The apparatus of claim 16, wherein:

the at least one sidewall of the housing is perpendicular to the ceiling when the luminaire is snap fit to the junction box.

18. An LED lighting apparatus, comprising:

a housing including at least one sidewall, wherein a thickness of at least a portion of the at least one sidewall is less than ten millimeters;

an LED board coupled to the housing, the LED board comprising a plurality of LEDs; and

a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens,

wherein the plurality of LEDs is distributed uniformly on the LED board and spaced apart almost identically or identically; and

wherein an LED-to-LED spacing of adjacent LEDs of the plurality of LEDs on the LED board is in a range of from approximately 7.5 millimeters to 8.5 millimeters.

19. The apparatus of claim 18, wherein the at least one sidewall of the housing is substantially perpendicular or perpendicular to the lens.

20. The apparatus of claim 18, further comprising at least one screwless mechanical coupler to couple the apparatus to a surface.

21. The apparatus of claim 20, wherein the at least one screwless mechanical coupler comprises at least one snap fit coupler.

22. The apparatus of claim 20, wherein the at least one screwless mechanical coupler comprises at least one of a friction fit clip, a spring clip, or a magnet.

23. An assembly, comprising:

the apparatus of claim 20; and

an adapter ring to couple the apparatus to a junction box,

wherein the apparatus is coupled to the adapter ring via the at least one screwless mechanical coupler.

24. The assembly of claim 23, further comprising the junction box.

25. The assembly of claim 24, wherein the junction box is one of a 3½

inch or 4 inch square, octagon, or round junction box.

26. The assembly of claim 24, wherein the adapter ring is coupled to the junction box via one or more screws.

27. The apparatus of claim 18, wherein:

the housing, the LED board and the lens are assembled to provide a luminaire; and

the apparatus further comprises at least one mechanical coupler to couple the luminaire to a surface without using one or more screws.

28. The apparatus of claim 27, wherein:

the surface is a ceiling; and

the at least one mechanical coupler includes at least one of a friction fit clip, a spring clip, or a magnet to snap fit the luminaire to a junction box installed and positioned above the ceiling such that when the luminaire is snap fit to the junction box, the housing appears to be surface mounted to the ceiling.

29. The apparatus of claim 28, wherein:

the at least one sidewall of the housing is perpendicular to the ceiling when the luminaire is snap fit to the junction box.

30. An LED lighting apparatus, comprising:

a housing including at least one sidewall, wherein a thickness of at least a portion of the at least one sidewall is less than ten millimeters;

an LED board coupled to the housing, the LED board comprising a plurality of LEDs; and

a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens,

wherein the plurality of LEDs is distributed uniformly on the LED board and spaced apart almost identically or identically; and

wherein a spacing between the LED board and the lens is approximately or equal to eight millimeters.

31. The apparatus of claim 30, wherein the at least one sidewall of the housing is substantially perpendicular or perpendicular to the lens.

32. The apparatus of claim 30, further comprising at least one screwless mechanical coupler to couple the apparatus to a surface.

33. The apparatus of claim 32, wherein the at least one screwless mechanical coupler comprises at least one snap fit coupler.

34. The apparatus of claim 32, wherein the at least one screwless mechanical coupler comprises at least one of a friction fit clip, a spring clip, or a magnet.

35. An assembly, comprising:

the apparatus of claim 32; and

an adapter ring to couple the apparatus to a junction box,

wherein the apparatus is coupled to the adapter ring via the at least one screwless mechanical coupler.

36. The assembly of claim 35, further comprising the junction box.

37. The assembly of claim 36, wherein the junction box is one of a 3½

inch or 4 inch square, octagon, or round junction box.

38. The assembly of claim 37, wherein the adapter ring is coupled to the junction box via one or more screws.

39. The apparatus of claim 30, wherein:

the housing, the LED board and the lens are assembled to provide a luminaire; and

the apparatus further comprises at least one mechanical coupler to couple the luminaire to a surface without using one or more screws.

40. The apparatus of claim 39, wherein:

the surface is a ceiling; and

the at least one mechanical coupler includes at least one of a friction fit clip, a spring clip, or a magnet to snap fit the luminaire to a junction box installed and positioned above the ceiling such that when the luminaire is snap fit to the junction box, the housing appears to be surface mounted to the ceiling.

41. The apparatus of claim 40, wherein:

the at least one sidewall of the housing is perpendicular to the ceiling when the luminaire is snap fit to the junction box.

42. An LED lighting apparatus, comprising:

a housing including at least one sidewall, wherein a thickness of at least a portion of the at least one sidewall is less than ten millimeters;

an LED board coupled to the housing, the LED board comprising a plurality of LEDs; and

a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens,

wherein the plurality of LEDs is distributed uniformly on the LED board and spaced apart almost identically or identically; and

wherein;

the LED board is circular; and

the plurality of LEDs is arranged on the LED board as a plurality of concentric rings (804).

43. The apparatus of claim 42, wherein a distance between any two adjacent concentric rings of the plurality of concentric rings is the same or approximately the same.

44. The apparatus of claim 42, wherein:

at least a first ring of the plurality of concentric rings comprises a first group of the plurality of LEDs; and

respective LEDs of the first group are spaced substantially evenly around the first ring of the plurality of concentric rings.

45. The apparatus of claim 44, wherein:

each ring of the plurality of concentric rings comprises a different group of the plurality of LEDs; and

respective LEDs of each different group are spaced substantially evenly around a corresponding ring of the plurality of concentric rings.

46. The apparatus of claim 42, wherein the at least one sidewall of the housing is substantially perpendicular or perpendicular to the lens.

47. The apparatus of claim 42, further comprising at least one screwless mechanical coupler to couple the apparatus to a surface.

48. The apparatus of claim 47, wherein the at least one screwless mechanical coupler comprises at least one snap fit coupler.

49. The apparatus of claim 47, wherein the at least one screwless mechanical coupler comprises at least one of a friction fit clip, a spring clip, or a magnet.

50. An assembly, comprising:

the apparatus of claim 47; and

an adapter ring to couple the apparatus to a junction box,

wherein the apparatus is coupled to the adapter ring via the at least one screwless mechanical coupler.

51. The assembly of claim 50, further comprising the junction box.

52. The assembly of claim 51, wherein the junction box is one of a 3½

inch or 4 inch square, octagon, or round junction box.

53. The assembly of claim 51, wherein the adapter ring is coupled to the junction box via one or more screws.

54. The apparatus of claim 42, wherein:

the housing, the LED board and the lens are assembled to provide a luminaire; and

the apparatus further comprises at least one mechanical coupler to couple the luminaire to a surface without using one or more screws.

55. The apparatus of claim 54, wherein:

the surface is a ceiling; and

the at least one mechanical coupler includes at least one of a friction fit clip, a spring clip, or a magnet to snap fit the luminaire to a junction box installed and positioned above the ceiling such that when the luminaire is snap fit to the junction box, the housing appears to be surface mounted to the ceiling.

56. The apparatus of claim 55, wherein:

the at least one sidewall of the housing is perpendicular to the ceiling when the luminaire is snap fit to the junction box.

57. An LED lighting apparatus, comprising:

a housing including at least one sidewall, wherein a thickness of at least a portion of the at least one sidewall is less than ten millimeters;

an LED board coupled to the housing, the LED board comprising a plurality of LEDs; and

a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens,

wherein the plurality of LEDs is distributed uniformly on the LED board and spaced apart almost identically or identically;

wherein;

the LED board is rectangular; and

the plurality of LEDs is arranged substantially uniformly across an entire surface or substantially the entire surface of the LED board; and

wherein an LED-to-LED distance between neighboring LEDs of the plurality of LEDs is in a range of from approximately 7.5 millimeters to 8.5 millimeters.

58. An LED lighting apparatus, comprising:

a housing;

an LED board coupled to the housing, the LED board comprising a plurality of LEDs distributed uniformly on the LED board; and

a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens,

wherein;

the lens is flat;

the LED board has a first dimension in a first plane parallel to the back side of the lens;

the lens has a second dimension in a second plane corresponding to the back side of the lens; and

the first dimension of the LED board and the second dimension of the lens are the same.

59. The apparatus of claim 58, wherein the plurality of LEDs are spaced apart almost identically or identically on the LED board.

60. The apparatus of claim 58, wherein an LED-to-LED spacing of adjacent LEDs of the plurality of LEDs on the LED board is in a range of from approximately 7.5 millimeters to 8.5 millimeters.

61. The apparatus of claim 60, wherein a spacing between the LED board and the lens is approximately or equal to eight millimeters.

62. The apparatus of claim 58, wherein:

the housing includes at least one sidewall having a front facing edge;

the front side of the lens is essentially flush with the front facing edge of the at least one sidewall of the housing; and

an edge thickness of the front facing edge of the at least one sidewall is less than two millimeters.

63. The apparatus of claim 62, wherein:

the at least one sidewall further has a back facing edge; and

a depth of the at least one sidewall of the housing, between the front facing edge and the back facing edge, is less than one inch.

64. The apparatus of claim 58, wherein:

the housing includes at least one sidewall; and

the at least one sidewall of the housing is substantially perpendicular or perpendicular to the lens.

65. The apparatus of claim 58, further comprising at least one screwless mechanical coupler to couple the apparatus to a surface.

66. The apparatus of claim 65, wherein the at least one screwless mechanical coupler comprises at least one snap fit coupler.

67. The apparatus of claim 65, wherein the at least one screwless mechanical coupler comprises at least one of a friction fit clip, a spring clip, or a magnet.

68. An assembly, comprising:

the apparatus of claim 65; and

an adapter ring to couple the apparatus to a junction box,

wherein the apparatus is coupled to the adapter ring via the at least one screwless mechanical coupler.

69. The assembly of claim 68, further comprising the junction box.

70. The assembly of claim 69, wherein the junction box is one of a 3½

inch or 4 inch square, octagon, or round junction box.

71. The assembly of claim 69, wherein the adapter ring is coupled to the junction box via one or more screws.

72. The apparatus of claim 58, wherein:

the housing, the LED board and the lens are assembled to provide a luminaire; and

the apparatus further comprises at least one mechanical coupler to couple the luminaire to a surface without using one or more screws.

73. The apparatus of claim 72, wherein:

the surface is a ceiling; and

the at least one mechanical coupler includes at least one of a friction fit clip, a spring clip, or a magnet to snap fit the luminaire to a junction box installed and positioned above the ceiling such that when the luminaire is snap fit to the junction box, the housing appears to be surface mounted to the ceiling.

74. The apparatus of claim 73, wherein:

the housing includes at least one sidewall; and

the at least one sidewall of the housing is perpendicular to the ceiling when the luminaire is snap fit to the junction box.

75. A thin profile surface mount LED lighting apparatus, comprising:

a housing comprising at least one sidewall having a front facing edge and a back facing edge positioned adjacent to a ceiling when the LED lighting apparatus is installed in an opening of the ceiling, wherein a depth of the at least one sidewall of the housing, between the front facing edge and the back facing edge, is less than one inch;

an LED board coupled to the housing, the LED board comprising a plurality of LEDs; and

a lens coupled to the housing, the lens having a back side facing the LED board, a front side opposite to the back side, and an outer edge, wherein the front side of the lens provides a downward facing surface when the LED lighting apparatus is installed in the opening of the ceiling, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens,

wherein;

the front facing edge of the at least one sidewall forms a perimeter around the outer edge of the lens;

the front side of the lens, providing the downward facing surface when the LED lighting apparatus is installed in the opening in the ceiling, is flush with the front facing edge of the at least one sidewall of the housing forming the perimeter around the outer edge of the lens; and

the perimeter around the outer edge of the lens is significantly thin so as not to extend significantly beyond the outer edge of the lens.

76. The apparatus of claim 75, wherein a perimeter thickness of the perimeter is less than two millimeters.

77. The apparatus of claim 75, wherein a perimeter thickness of the perimeter is less than 1.5 millimeters.

78. The apparatus of claim 75, wherein:

a first spacing of adjacent LEDs of the plurality of the LEDs on the LED board causes resulting light from the downward facing surface of the lens to be substantially uniform during operation of the apparatus; and

a second spacing between the LED board and the lens further causes the resulting light from the downward facing surface of the lens to be substantially uniform during operation of the apparatus.

79. The apparatus of claim 78, wherein:

the first spacing of the adjacent LEDs of the plurality of LEDs on the LED board includes an LED-to-LED spacing in a range of from approximately 7.5 millimeters to 8.5 millimeters;

the second spacing is approximately or equal to eight millimeters; and

a perimeter thickness of the perimeter is less than 1.5 millimeters.

80. The apparatus of claim 75, wherein:

the at least one sidewall of the housing is substantially perpendicular or perpendicular to the lens.

81. The apparatus of claim 75, further comprising at least one screwless mechanical coupler to couple the apparatus to the ceiling.

82. The apparatus of claim 81, wherein the at least one screwless mechanical coupler comprises at least one snap fit coupler.

83. The apparatus of claim 81, wherein the at least one screwless mechanical coupler comprises at least one of a friction fit clip, a spring clip, or a magnet.

84. An assembly, comprising:

the apparatus of claim 81; and

an adapter ring to couple the apparatus to a junction box installed and positioned above the ceiling,

wherein the apparatus is coupled to the adapter ring via the at least one screwless mechanical coupler.

85. The assembly of claim 84, further comprising the junction box.

86. The assembly of claim 85, wherein the junction box is one of a 3½

inch or 4 inch square, octagon, or round junction box.

87. The assembly of claim 85, wherein the adapter ring is coupled to the junction box via one or more screws.

88. The apparatus of claim 75, wherein:

the housing, the LED board and the lens are assembled to provide a luminaire; and

the apparatus further comprises at least one mechanical coupler to couple the luminaire to the ceiling without using one or more screws.

89. The apparatus of claim 88, wherein:

the at least one mechanical coupler includes at least one of a friction fit clip, a spring clip, or a magnet to snap fit the luminaire to a junction box installed and positioned above the ceiling such that when the luminaire is snap fit to the junction box, the housing appears to be surface mounted to the ceiling.

90. The apparatus of claim 89, wherein:

the at least one sidewall of the housing is perpendicular to the ceiling when the luminaire is snap fit to the junction box.

91. A thin profile surface mount LED lighting apparatus, comprising:

a housing comprising at least one sidewall having a front facing edge and a back facing edge positioned adjacent to a ceiling when the LED lighting apparatus is installed in an opening of the ceiling;

an LED board coupled to the housing, the LED board comprising a plurality of LEDs; and

a lens coupled to the housing, the lens having a back side facing the LED board, a front side opposite to the back side, and an outer edge, wherein the front side of the lens provides a downward facing surface when the LED lighting apparatus is installed in the opening of the ceiling, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens,

wherein;

the front facing edge of the at least one sidewall forms a perimeter around the outer edge of the lens;

the front side of the lens, providing the downward facing surface when the LED lighting apparatus is installed in the opening in the ceiling, is essentially flush or flush with the front facing edge of the at least one sidewall of the housing forming the perimeter around the outer edge of the lens;

the perimeter around the outer edge of the lens is significantly thin so as not to extend significantly beyond the outer edge of the lens;

the lens is substantially flat or flat;

the LED board has a first dimension in a first plane parallel to the back side of the lens;

the lens has a second dimension in a second plane corresponding to the back side of the lens;

the first dimension of the LED board and the second dimension of the lens are substantially the same or the same; and

a perimeter thickness of the perimeter is less than two millimeters.

92. The apparatus of claim 91, wherein:

a first spacing of adjacent LEDs of the plurality of the LEDs on the LED board causes resulting light from the downward facing surface of the lens to be substantially uniform during operation of the apparatus; and

a second spacing between the LED board and the lens further causes the resulting light from the downward facing surface of the lens to be substantially uniform during operation of the apparatus.

93. The apparatus of claim 92, wherein the quotient of the first spacing and the second spacing is in a range of from 7.5/8 to 8.5/8.

94. The apparatus of claim 91, wherein:

the at least one sidewall of the housing is substantially perpendicular or perpendicular to the lens.

95. The apparatus of claim 91, further comprising at least one screwless mechanical coupler to couple the apparatus to the ceiling.

96. The apparatus of claim 95, wherein the at least one screwless mechanical coupler comprises at least one snap fit coupler.

97. The apparatus of claim 95, wherein the at least one screwless mechanical coupler comprises at least one of a friction fit clip, a spring clip, or a magnet.

98. An assembly, comprising:

the apparatus of claim 95; and

an adapter ring to couple the apparatus to a junction box installed and positioned above the ceiling,

wherein the apparatus is coupled to the adapter ring via the at least one screwless mechanical coupler.

99. The assembly of claim 98, further comprising the junction box.

100. The assembly of claim 99, wherein the junction box is one of a 3½

inch or 4 inch square, octagon, or round junction box.

101. The assembly of claim 99, wherein the adapter ring is coupled to the junction box via one or more screws.

102. The apparatus of claim 91, wherein:

the housing, the LED board and the lens are assembled to provide a luminaire; and

the apparatus further comprises at least one mechanical coupler to couple the luminaire to the ceiling without using one or more screws.

103. The apparatus of claim 102, wherein:

the at least one mechanical coupler includes at least one of a friction fit clip, a spring clip, or a magnet to snap fit the luminaire to a junction box installed and positioned above the ceiling such that when the luminaire is snap fit to the junction box, the housing appears to be surface mounted to the ceiling.

104. The apparatus of claim 103, wherein:

the at least one sidewall of the housing is perpendicular to the ceiling when the luminaire is snap fit to the junction box.