LED Light Engine Apparatus

• US 20110068708A1
• Filed: 09/23/2009
• Published: 03/24/2011
• Est. Priority Date: 09/23/2009
• Status: Active Grant

• Current Assignee: EcoFit Lighting LLC
• Original Assignee: EcoFit Lighting LLC
• Inventors: Coplin, Barry Cason, Wilson, Clifford Earl, Householder, John Robert
• Granted Patent: US 8,310,158 B2
• Time in Patent Office: Days
• US Class Current: 315/294
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21V 11/00 Screens not covered by groups F21V1/00, F21V3/00, F21V7/00 or F21V9/00 characterised by cooling arrangements F21V29/502
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 25/10 coming into action when lighting device is overloaded, e.g. thermal switch
• CPC Class Codes: F21V 29/507 of means for protecting lighting devices from damage, e.g. housings
• CPC Class Codes: F21V 29/75 with fins or blades having different shapes, thicknesses or spacing
• CPC Class Codes: F21V 29/763 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21W 2131/103 of streets or roads
• CPC Class Codes: F21W 2131/107 of the exterior of buildings
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/24 using electrical feedback from LEDs or from LED modules
• CPC Class Codes: H05B 45/325 Pulse-width modulation [PWM]
• CPC Class Codes: H05B 45/37 Converter circuits
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]

Abstract

A light emitting diode (LED) light engine is provided for use in a light fixture to enable improved and efficient dissipation of heat generated in the light fixture. The light engine includes a circuit board that includes multiple LEDs for emitting light. The light engine includes a chassis that has a plurality of upper fins that extend upward from a central flanged portion to dissipate heat generated by the LEDs into the lighting fixture. The circuit board is mounted to a mounting surface on the chassis that is surrounded by a fin wall that depends from the central flanged portion. The chassis also has a plurality of lower fins that extend outward from an outer surface of the fin wall to dissipate heat out of the fixture and into the ambient air environment.

Claims

1. A light engine comprising:

at least one power connector to connect to a power source to convey alternating current (AC) power;

an AC to direct current (DC) power converter to;

receive the AC power via the at least one power connector; and

convert the AC power to DC power at a DC power level;

a circuit board comprising;

a plurality of light emitting diodes (LEDs) to receive the DC power and to emit light; and

lighting optics to distribute the light emitted from the LEDs; and

a chassis comprising;

a first side comprising a plurality of first fins extending upward to dissipate heat in a first direction; and

a second side comprising;

a mounting surface for the circuit board;

a fin wall surrounding the mounting surface; and

a plurality of second fins extending outward from an outer surface of the fin wall to dissipate heat in a second direction.

2. The light engine of claim 1 wherein the chassis comprises a monolithic cast aluminum heat sink.

3. The light engine of claim 1 wherein each of the plurality of LEDs emitting light generates the heat.

4. The light engine of claim 3 wherein a heating conducting pad is positioned between the circuit board and the mounting surface to transmit at least some of the heat generated by the plurality of LEDs to the chassis.

5. The light engine of claim 1 wherein the AC to DC power converter converts the AC power to the DC power at an adjustable DC power level.

6. The light engine of claim 1 wherein the at least one power connector comprises a pair of lead wires configured to connect to existing AC power supply lines in the luminaire.

7. The light engine of claim 1 wherein the light engine is located within a housing of a luminaire, and wherein the plurality of first fins dissipate the heat into an interior of the housing.

8. The light engine of claim 7 wherein the plurality of second fins dissipate heat directly into ambient air outside of the housing.

9. The light engine of claim 7 wherein the luminaire has an opening that is a different shape or different size than a shape or a size of the chassis and the light engine further comprises an adaptor plate to enable mounting the chassis to the luminaire having the different shape or the different size.

10. The light engine of claim 1 wherein:

the luminaire comprises a lid comprising an opening, a retention clip, and at least one retention bracket; and

the chassis comprises a central portion that comprises a mounting interface, wherein an end of the mounting interface is positioned beneath the at least one retention bracket such that the plurality of second fins pass through the opening, and wherein an opposite end of the mounting interface is secured to the lid by the retention clip.

11. The light engine of claim 1 wherein the first side of the chassis further comprises a cavity for housing the AC to DC power converter.

12. The light engine of claim 1 further comprising a cover for covering the circuit board and the lighting optics.

13. The light engine of claim 1 wherein an inner surface of the fin wall comprises a baffle to prevent at least a portion of the light from being emitted from the luminaire.

14. The light engine of claim 13 wherein a height of the fin wall is dimensioned to prevent the light from being emitted from the luminaire in a direction from less than a five degree angle below a horizontal plane intersecting a bottom surface of the chassis.

15. The light engine of claim 13 wherein a height of the fin wall is dimensioned to prevent the light from being emitted from the luminaire in a direction from less than a ten degree angle below a horizontal plane intersecting a bottom surface of the chassis.

16. The light engine of claim 1 wherein the lighting optics comprise:

a plurality of optical lenses to disperse the light, wherein each of the plurality of optical lenses is positioned over a different one of the plurality of LEDs; and

a plurality of optical reflectors each positioned over at least one of the optical lenses to reflect the light dispersed by the at least one of the optical lenses.

17. The light engine of claim 1 further comprises a processor to:

generate a control signal to control the AC to DC power converter to convert the AC power to the DC power at the DC power level;

track a total operation time for the plurality of LEDs; and

store the total operation time in a memory.

18. The light engine of claim 17 wherein the processor is further configured to:

modify the control signal via pulse width modulation in response to user input;

transmit the modified control signal to the AC to DC power converter to modify the DC power to a modified DC power level to modify an amount of light being emitted by the plurality of LEDs.

19. The light engine of claim 17 further comprises:

a heat sensor to sense a temperature in the luminaire; and

wherein the processor is further configured to;

generate a power off control signal when the temperature exceeds a threshold value stored in the memory; and

transmit the power off control signal to the AC to DC power converter to convert the AC power to the DC power at the DC power level equal to zero.

20. A lighting fixture comprising:

a housing;

a terminal block for supplying alternating current (AC) power; and

a light engine comprising;

at least one power connector to connect to the terminal block to convey the AC power;

an AC to direct current (DC) power converter to;

receive the AC power via the at least one power connector; and

convert the AC power to DC power at a DC power level;

a circuit board comprising;

a plurality of light emitting diodes (LEDs) to receive the DC power and to emit light; and

lighting optics to distribute the light emitted from the LEDs from the lighting fixture in a desired light pattern; and

a chassis to mountably fit within the lighting fixture, the chassis comprising;

a central portion;

a first side comprising a plurality of first fins extending vertically upward from the central portion to dissipate heat in a first direction; and

a second side comprising;

a mounting surface for the circuit board;

a fin wall depending from the central portion and surrounding the mounting surface; and

a plurality of second fins extending horizontally outward from an outer surface of the fin wall to dissipate heat in a second direction.

21. The lighting fixture of claim 20 wherein the chassis comprises a monolithic cast aluminum heat sink.

22. The lighting fixture of claim 20 wherein the plurality of first fins dissipate the heat into an interior of the housing.

23. The lighting fixture of claim 20 wherein the plurality of second fins dissipate the heat directly into ambient air outside of the housing.

24. The lighting fixture of claim 20 wherein each of the plurality of LEDs emitting light generates the heat.

25. The lighting fixture of claim 24 wherein a heating conducting pad is positioned between the circuit board and the mounting surface to transmit at least some of the heat generated by the plurality of LEDs to the chassis.

26. The lighting fixture of claim 20 wherein the AC to DC power converter comprises a current driver to convert the AC power to the DC power at an adjustable DC current level.

27. The lighting fixture of claim 20 wherein the at least one power connector comprises a pair of lead wires configured to connect to AC power supply lines of the lighting fixture.

28. The lighting fixture of claim 20 further comprising:

a lid comprising an opening, a retention clip, and a retention bracket; and

wherein the central portion further comprises a mounting interface, wherein an end of the mounting interface is positioned beneath the retention bracket such that the plurality of second fins pass through the opening, and wherein an opposite end of the mounting interface is secured to the lid by the retention clip.

29. The lighting fixture of claim 20 wherein the first side of the chassis further comprises a cavity for housing the AC to DC power converter.

30. The lighting fixture of claim 20 wherein an inner surface of the fin wall comprises a baffle to prevent at least a portion of the light from being emitted from the lighting fixture.

31. The lighting fixture of claim 30 wherein a height of the fin wall is dimensioned to prevent the light from being emitted from the lighting fixture in a direction from less than a five degree angle below a horizontal plane intersecting a bottom surface of the chassis.

32. The lighting fixture of claim 20 wherein the lighting optics comprise:

a plurality of optical lenses to disperse the light, wherein each of the plurality of optical lenses is positioned over a different one of the plurality of LEDs; and

a plurality of optical reflectors each positioned over at least one of the optical lenses to reflect the light dispersed by the at least one of the optical lenses to create the desired light pattern.

33. The lighting fixture of claim 20 further comprises a processor to:

generate a control signal to control the driver to convert the AC power to the DC power at the DC power level;

track a total operation time for the plurality of LEDs; and

store the total operation time in a memory.

34. The lighting fixture of claim 33 wherein the processor is further configured to:

modify the control signal via pulse width modulation in response to user input; and

transmit the modified control signal to the driver to modify the DC power to a modified DC power level to modify an amount of light being emitted by the plurality of LEDs.

35. The lighting fixture of claim 33 further comprises:

a heat sensor to sense a temperature in the lighting fixture; and

wherein the processor is further configured to;

generate a power off control signal when the temperature exceeds a threshold value stored in the memory; and

transmit the power off control signal to the AC to DC power converter to convert the AC power to the DC power at the DC power level equal to zero.

36. A light engine for retrofitting an existing light fixture comprising:

at least one power connector to connect to a power source of the existing lighting fixture to convey alternating current (AC) power;

a current driver to;

receive the AC power via the at least one power connector; and

convert the AC power to direct current (DC) power at a DC power level;

a circuit board comprising;

a plurality of light emitting diodes (LEDs) to receive the DC power and to emit light;

a plurality of optical lenses to disperse light, wherein each of the plurality of optical lenses is positioned over a different one of the LEDs; and

a plurality of optical reflectors each positioned over at least one of the optical lenses to reflect the light dispersed by the lenses to create the desired light pattern; and

a chassis comprising;

a central portion;

a first side comprising a plurality of first fins extending upward from the central portion to dissipate heat in a first direction; and

a second side comprising;

a mounting surface for the circuit board;

a fin wall depending from the central portion and fully surrounding the mounting surface; and

a plurality of second fins extending outward from an outer surface of the fin wall to dissipate heat in a second direction;

wherein the central portion comprises a mounting interface for mounting the chassis to a lid of the existing light fixture, wherein the lid comprises an opening, a retention clip, and at least one retention bracket, and wherein an end of the mounting interface is positioned beneath the retention bracket such that the plurality of second fins pass through the opening, and wherein an opposite end of the mounting interface is secured to the lid by the retention clip.

37. A light engine comprising:

a driver assembly the comprising;

at least one power connector to connect to a power source to convey alternating current (AC) power;

an AC to direct current (DC) power converter to receive the AC power via the at least one power connector and convert the AC power to DC power at a DC power level; and

a processor to generate a control signal to control the AC to DC power converter to convert the AC power to the DC power at the DC power level;

a circuit board comprising;

a plurality of light emitting diodes (LEDs) to receive the DC power and to emit light; and

lighting optics to distribute the light emitted from the LEDs in a desired light pattern; and

;

a chassis comprising;

a central portion;

a first side comprising a plurality of first fins extending vertically upward from the central portion to dissipate heat in a first direction; and

a second side comprising;

a mounting surface for the circuit board;

a fin wall depending from the central portion and surrounding the mounting surface, wherein an inner surface of the fin wall prevents the light from being emitted from the light engine in a direction from less than a five degree angle below a horizontal plane intersecting a bottom surface of the chassis; and

a plurality of second fins extending horizontally outward from an outer surface of the fin wall to dissipate heat in a second direction.

38. The light engine of claim 37 wherein the processor is further configured to:

track a total operation time for the plurality of LEDs; and

store the total operation time in a memory.

39. The light engine of claim 37 wherein the processor is further configured to:

modify the control signal via pulse width modulation in response to user input; and

transmit the modified control signal to the AC to DC convert to modify the DC power to a modified DC power level to modify an amount of light being emitted by the plurality of LEDs.

40. The light engine of claim 37 wherein the light engine is in a luminaire and the luminaire comprises:

a heat sensor to sense a temperature in the luminaire; and

wherein the processor is further configured to;

generate a power off control signal when the temperature exceeds a threshold value stored in the memory; and

transmit the power off control signal to the AC to DC power converter to convert the AC power to the DC power at the DC power level equal to zero.

41. A light engine for a luminaire, the luminaire comprising a housing and a terminal block for supplying alternating current (AC) power, the light engine comprising:

at least one power connector to connect to the terminal block to convey the AC power;

an AC to direct current (DC) power converter to;

receive the AC power via the at least one power connector; and

convert the AC power to DC power at a DC power level;

a circuit board comprising;

a plurality of light emitting diodes (LEDs) to receive the DC power and to emit light; and

lighting optics to distribute the light emitted from the LEDs from the luminaire in a desired light pattern; and

a chassis comprising;

a central portion;

a first side comprising a plurality of first fins extending vertically upward from the central portion to dissipate heat into an interior of the housing; and

a second side comprising;

a mounting surface for the circuit board;

a fin wall depending from the central portion and surrounding the mounting surface, wherein an inner surface of the fin wall blocks at least a portion of the light in the desired light pattern from being emitted from the luminaire; and

a plurality of second fins extending horizontally outward from an outer surface of the fin wall to dissipate heat directly into ambient air outside of the housing.

42. A luminaire comprising:

a housing;

a terminal block for supplying alternating current (AC) power; and

a light engine comprising;

at least one power connector to connect to the terminal block to convey the AC power;

an AC to direct current (DC) power converter to;

receive the AC power via the at least one power connector; and

convert the AC power to DC power at a DC power level;

a circuit board comprising;

a plurality of light emitting diodes (LEDs) to receive the DC power and to emit light; and

lighting optics to distribute the light emitted from the LEDs from the luminaire

in a desired light pattern; and

a chassis comprising;

a central portion;

a first side comprising a plurality of first fins extending vertically upward from the central portion to dissipate heat into an interior of the housing; and

a second side comprising;

a mounting surface for the circuit board;

a fin wall depending from the central portion and surrounding the mounting surface, wherein an inner surface of the fin wall blocks at least a portion of the light in the desired light pattern from being emitted from the luminaire; and

a plurality of second fins extending horizontally outward from an outer surface of the fin wall to dissipate heat directly into ambient air outside of the housing.