LIGHT FIXTURE WITH CO-FORMED PLENUM COMPONENT

• US 20130021803A1
• Filed: 12/28/2011
• Published: 01/24/2013
• Est. Priority Date: 07/24/2011
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Pickard, Paul Kenneth
• Granted Patent: US 8,752,976 B2
• Time in Patent Office: Days
• US Class Current: 362/308
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: F21V 7/0008 providing for indirect lighting
• CPC Class Codes: F21V 7/24 characterised by the material
• CPC Class Codes: F21Y 2113/13 comprising an assembly of point-like light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

A light fixture with co-formed plenum component is disclosed. Embodiments of the invention provide troffer-style recessed solid state fixture using a highly reflective plastic reflector. In at least some embodiments, the plastic reflector can meet the additional requirements placed on mechanical components exposed to the space above the ceiling plane in plenum return ceiling applications. Example embodiments include a light fixture with an LED light source and a reflector that is coextruded from a plenum rated substrate and a reflective material, for example, a plenum rated plastic substrate and a diffuse, white reflective material. In some embodiments, the plenum rated substrate includes polyetherimide, a polyphenylene ether/polystyrene blend, polycarbonate, polycarbonate copolymer, or a combination of the foregoing.

Claims

1. A light fixture comprising:

an LED light source; and

a co-formed reflector to reflect at least some light from the light source.

2. The light fixture of claim 1 wherein the co-formed reflector is coextruded.

3. The light fixture of claim 2 wherein the coextruded reflector comprises plenum rated plastic and a diffuse, white reflective material.

4. The light fixture of claim 2 wherein the LED light source further comprises at least two groups of LEDs, wherein one group, if illuminated, would emit light having a dominant wavelength from 435 to 490 nm, and another group, if illuminated, would emit light having a dominant wavelength from 600 to 640 nm, one group being packaged with a phosphor, which, when excited, emits light having a dominant wavelength from 540 to 585 nm.

5. The light fixture of claim 4 wherein the one group, if illuminated, would emit light having a dominant wavelength from 440 to 480 nm, and the other group, if illuminated, would emit light having a dominant wavelength from 605 to 630 nm, one group being packaged with a lumiphor, which, when excited, emits light having a dominant wavelength from 560 to 580 nm.

6. The light fixture of claim 1 further comprising a lens including at least two lens plates.

7. The light fixture of claim 6 further comprising a pan disposed outside the co-formed reflector.

8. The light fixture of claim 7 wherein the LED light source further comprises at least two groups of LEDs, wherein one group, if illuminated, would emit light having a dominant wavelength from 435 to 490 nm, and another group, if illuminated, would emit light having a dominant wavelength from 600 to 640 nm, one group being packaged with a phosphor, which, when excited, emits light having a dominant wavelength from 540 to 585 nm.

9. The light fixture of claim 8 wherein the one group, if illuminated, would emit light having a dominant wavelength from 440 to 480 nm, and the other group, if illuminated, would emit light having a dominant wavelength from 605 to 630 nm, one group being packaged with a lumiphor, which, when excited, emits light having a dominant wavelength from 560 to 580 nm.

10. The light fixture of claim 9 wherein the co-formed reflector comprises at least two elongated portions adapted to be joined end-to-end.

11. The light fixture of claim 10 wherein the co-formed reflector comprises reinforcing members.

12. A co-formed reflector for a light fixture, the co-formed reflector comprising:

a plenum rated substrate; and

a reflective material co-formed with the plenum rated substrate.

13. The co-formed reflector of claim 12 wherein the plenum rated substrate and the reflective material are coextruded.

14. The co-formed reflector of claim 13 wherein the plenum rated substrate comprises at least one of polyetherimide, a polyphenylene ether/polystyrene blend, polycarbonate and polycarbonate copolymer.

15. The co-formed reflector of claim 13 further comprising at least two elongated portions adapted to be joined end-to-end.

16. The co-formed reflector of claim 14 further comprising reinforcing members.

17. A method of assembling a light fixture, the method comprising:

co-forming a plenum rated reflector;

fixing a plurality of LED devices to a heatsink to serve as a source of light for the light fixture; and

positioning the heatsink with the light source so that at least a portion of the light is reflected from the plenum rated reflector.

18. The method of claim 17 wherein the co-forming of the reflector a further comprises coextruding a plenum rated substrate and reflective material on the substrate.

19. The method of claim 18 wherein the reflector comprises two, complimentary elongated portions and further comprising joining the two, complimentary elongated portions end-to-end.

20. The method of claim 19 further comprising including reinforcing members in the reflector.

21. The method of claim 18 wherein the plenum rated substrate comprises at least one of polyetherimide, a polyphenylene ether/polystyrene blend, a polycarbonate and a polycarbonate copolymer.

22. The method of claim 18 further comprising positioning two lens plates at the sides of the heatsink.

23. The method of claim 22 further comprising installing a pan outside the plenum rated reflector.

24. The method of claim 23 wherein the plurality of LED devices further comprises at least two groups of LEDs, wherein one group, if illuminated, would emit light having a dominant wavelength from 435 to 490 nm, and another group, if illuminated, would emit light having a dominant wavelength from 600 to 640 nm, one group being packaged with a phosphor, which, when excited, emits light having a dominant wavelength from 540 to 585 nm.

25. The method of claim 24 wherein the one group, if illuminated, would emit light having a dominant wavelength from 440 to 480 nm, and the other group, if illuminated, would emit light having a dominant wavelength from 605 to 630 nm, one group being packaged with a lumiphor, which, when excited, emits light having a dominant wavelength from 560 to 580 nm.