LIGHTING FIXTURE WITH REFLECTOR AND TEMPLATE PCB

• US 20140268750A1
• Filed: 12/31/2013
• Published: 09/18/2014
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Lui, Nelson Man Hoi, Mung, Felix Chi Hoi, So, Guass Ho Ching, Ng, Alan Hoi Leung
• Granted Patent: US 10,788,177 B2
• Time in Patent Office: Days
• US Class Current: 362/235
• CPC Class Codes: F21S 8/061 with a non-rigid pendant, i.e. a cable, wire or chain
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 7/09 with a combination of different curvatures
• CPC Class Codes: F21W 2131/40 Lighting for industrial, commercial, recreational or military use
• 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: H05K 1/0203 Cooling of mounted components H05K1/0272 takes precedence
• CPC Class Codes: H05K 1/182 associated with components mounted in the printed circuit board, e.g. insert mounted components [IMC]
• CPC Class Codes: H05K 2201/0397 Tab forming integral conductive tabs H05K3/4092
• CPC Class Codes: H05K 2201/09072 Hole or recess under component or special relationship between hole and component
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 2201/10409 Screws
• CPC Class Codes: H05K 2201/10477 Inverted
• CPC Class Codes: H05K 3/0061 onto a metallic substrate, e.g. a heat sink heat sinks for electric apparatus H05K7/20
• CPC Class Codes: H05K 3/341 Surface mounted components
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

The present invention relates to different embodiments of lighting fixtures, such as high bay lighting fixtures, comprising one or more improved features. Some of these features include the direct mounting of emitters on a heat sink and/or the use of a template-like board for providing an electrical connection between emitters. These features can improve heat dissipation from the emitters and simplify fabrication. In other embodiments, expensive lens optics of prior art SSL fixtures can be replaced with a flat lens and reflector in order to produce a fixture having a satisfactory spacing criterion.

Claims

1. A lighting fixture, comprising:

a heat sink;

one or more emitters on said heat sink; and

a circuit board interconnecting said emitters and having a top surface;

wherein a bottom surface of said one or more emitters is below said circuit board top surface.

2. The fixture of claim 1, wherein said one or more emitters are directly on said heat sink.

3. The fixture of claim 1, further comprising a thermally conductive adhesive between each of said one or more emitters and said heat sink.

4. The fixture of claim 1, wherein said circuit board at least partially surrounds each of said emitters.

5. The fixture of claim 1, wherein said circuit board is shaped to define one or more cut-outs;

and

wherein each of said emitters is at least partially within one of said cut-outs.

6. The fixture of claim 1, wherein said circuit board is shaped to define one or more cut-outs;

wherein each of said emitters comprises an emission portion; and

wherein each of said emission portions is within one of said cut-outs.

7. The fixture of claim 1, further comprising an electrically conductive material connecting each of said emitters to said circuit board.

8. The fixture of claim 6, wherein said conductive material is solder.

9. The fixture of claim 1, wherein said circuit board is approximately 1 mm thick or less.

10. The fixture of claim 1, wherein said heat sink comprises one or more mount pads;

and

wherein each of said one or more emitters is mounted on one of said mount pads.

11. The fixture of claim 10, wherein said mount pads are integral to said heat sink.

12. The fixture of claim 1, comprising a plurality of emitters;

wherein the bottom of said plurality of emitters defines a plane below said circuit board top surface.

13. The fixture of claim 1, wherein the top of said one or more emitters defines a plane below said circuit board top surface.

14. The fixture of claim 13, wherein said emitters are configured to emit light at a viewing angle such that said light is not incident on said circuit board.

15. The fixture of claim 1, wherein each of said one or more emitters comprises an emission portion;

and

wherein said circuit board at least partially surrounds the perimeters of said emission portions.

16. The fixture of claim 1, wherein each of said emitters comprises an emission portion and one or more contact portions;

wherein said circuit board surrounds the perimeters of said emission portions; and

wherein said circuit board is on said contact portions.

17. The fixture of claim 16, wherein said circuit board comprises fingers;

and

wherein said fingers are on said contact portions.

18. The lighting fixture of claim 1, wherein said circuit board is on said one or more emitters.

19. A lighting fixture, comprising:

a heat sink;

an array of emitters on said heat sink; and

a circuit board interconnecting at least some of said emitters and comprising one or more cut-outs;

wherein each of said emitters is at least partially within one of said cut-outs.

20. The lighting fixture of claim 19, further comprising electrically conductive traces on said circuit board;

wherein said circuit board consists of an electrically insulating material.

21. The lighting fixture of claim 19, wherein said emitters comprise one or more contact portions;

and

wherein said circuit board comprises fingers on said one or more contact portions.

22. The lighting fixture of claim 21, wherein said contact portions and said fingers are connected by an electrically conductive material.

23. The lighting fixture of claim 19, further comprising a thermally conductive adhesive between said emitters and said heat sink.

24. A method of fabricating a lighting fixture, comprising:

providing a heat sink;

mounting one or more emitters on said heat sink; and

mounting a circuit board having cut-outs on said heat sink such that each of said emitters is at least partially within said cut-outs.

25. The method of claim 24, wherein said one or more emitters are mounted on said heat sink before said circuit board.

26. The method of claim 24, wherein said circuit board is mounted such that it at least partially surrounds the perimeters of an emission portion of each of said emitters.

27. The method of claim 24, wherein said mounting comprises mounting said one or more emitters to said heat sink using a thermally conductive adhesive.

28. The method of claim 24, wherein said circuit board comprises fingers and said emitters comprise one or more top contacts;

wherein said circuit board is mounted such that said fingers are on said top contacts.

29. The method of claim 28, further comprising connecting said fingers to said top contacts.

30. The method of claim 29, wherein said connecting comprises soldering said fingers to said top contacts.

31. The method of claim 24, wherein said emitters suffer damage at 260°

C. or above.

32. A lighting fixture, comprising:

an array of solid state emitters on a heat sink;

a planar lens over said emitters; and

a reflector configured to redirect at least some light emitted by said one or more solid state emitters;

wherein said fixture has a spacing criterion of approximately 1.5 or higher.

33. The fixture of claim 32, wherein said array of emitters comprises an inner group and an outer group.

34. The fixture of claim 32, wherein said emitters are arranged in an inner ring and an outer ring.

35. The fixture of claim 32, wherein said reflector has a cross-section at least partially defined by a lower arc and an upper arc;

wherein said lower arc has a radius greater than that of said upper arc.

36. The fixture of claim 35, wherein said lower arc has a radius about 3.5 times or greater the radius of the upper arc.

37. The fixture of claim 35, wherein said lower arc has a radius of about 10 times or greater the radius of the upper arc.

38. The fixture of claim 32, wherein said reflector has a cross-section at least partially defined by a lower portion and an upper portion of different shapes;

and

wherein a transition point between said lower and upper portions is in the upper half of said reflector.

39. The fixture of claim 32, wherein said reflector has a cross-section at least partially defined by a lower portion and an upper portion of different shapes;

and

wherein a transition point between said lower and upper portions is about 60% or more up the height of said reflector.

40. The fixture of claim 32, wherein said reflector has a cross-section at least partially defined by a lower portion and an upper portion of different shapes;

and

wherein a transition point between said lower and upper portions is about 80% or more up the height of said reflector.

41. The fixture of claim 32, wherein said reflector comprises a specular material.

42. The fixture of claim 32, wherein said reflector is textured.

43. The fixture of claim 32, wherein said fixture is configured to emit about 18,000 lumens or more at an efficacy of about 90 lm/W or more.

44. The fixture of claim 32, wherein said fixture is configured to emit about 23,000 lumens or more at an efficacy of about 100 lm/W or more.

45. A reflector for use in a bay lighting fixture, said comprising:

an upper portion with a cross-section defined by a first arc having a first radius;

a lower portion with a cross-section defined by a second arc having a second radius;

wherein said second radius is larger than said first radius; and

wherein said upper portion and said lower portion meet at a transition point;

wherein said transition point is in the top half of said reflector.

46. The reflector of claim 45, wherein said transition point is in the top 40% of said reflector.

47. The reflector of claim 45, wherein said transition point is in the top 15% of said reflector.

48. The reflector of claim 45, wherein said second radius is at least about three times larger than said first radius.

49. The reflector of claim 45, wherein said second radius is about four times larger than said first radius.

50. The reflector of claim 45, wherein said second radius is at least about ten times larger than said first radius.

51. The reflector of claim 45, wherein said second radius is about fifteen times larger than said first radius.