LIGHTING APPARATUS WITH REFLECTOR AND OUTER LENS

• US 20150292714A1
• Filed: 06/24/2015
• Published: 10/15/2015
• 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: Castillo, Mario A., Wilcox, Kurt S., Dungan, William L., Schultz, Russell S., Kinnune, Brian
• Granted Patent: US 10,323,828 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: F21S 8/063 with a rigid pendant, i.e. a pipe or rod
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 15/01 Housings, e.g. material or assembling of housing parts F21V15/02 takes precedence housings forming signs or letters G09F13/04
• CPC Class Codes: F21V 23/003 the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array
• CPC Class Codes: F21V 23/0464 the sensor sensing the level of ambient illumination, e.g. dawn or dusk sensors
• CPC Class Codes: F21V 23/0471 the sensor detecting the proximity, the presence or the movement of an object or a person
• 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 29/85 characterised by the material liquid coolants F21V29/56
• CPC Class Codes: F21V 5/02 of prismatic shape F21V5/04 takes precedence
• CPC Class Codes: F21V 7/0008 providing for indirect lighting
• CPC Class Codes: F21V 7/0041 for avoiding direct view of the light source or to prevent dazzling
• 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]

Abstract

A lighting apparatus is provided with a first housing assembly formed from a thermally conductive material and a second housing assembly formed of a thermally conductive material. At least one electrical component is positioned within the first housing assembly and the at least one electrical component is in thermally conductive contact with the first housing assembly. At least one light source is in thermally conductive contact with the second housing assembly. The second housing assembly is not in thermally conductive contact with the first housing assembly, such that thermal energy from the first housing assembly does not directly transfer to the second housing assembly.

Claims

1. A lighting apparatus, comprising:

a first housing assembly formed from a thermally conductive material, wherein at least one electrical component is positioned within the first housing assembly and the at least one electrical component is in thermally conductive contact with the first housing assembly;

a second housing assembly formed of a thermally conductive material, wherein at least one light source is in thermally conductive contact with the second housing assembly; and

wherein the second housing assembly is not in thermally conductive contact with the first housing assembly, such that thermal energy from the first housing assembly does not directly transfer to the second housing assembly.

2. The lighting apparatus of claim 1, wherein the first housing assembly and the second housing assembly are separated by a material that is non-metallic.

3. The lighting apparatus of claim 2, wherein the material separating the first housing assembly and the second housing assembly is foam.

4. The lighting apparatus of claim 2, wherein the first housing assembly and the second housing assembly are separated by a middle housing assembly comprising an acrylic lens such that the acrylic lens is positioned below the first housing assembly and above the second housing assembly, and wherein the acrylic lens is connected to the first housing assembly and the second housing assembly.

5. The lighting apparatus of claim 4, wherein the at least one electrical component positioned within the first housing assembly comprises a driver for the at least one LED, and wherein the at least one light source includes at least one LED in thermally conductive contact with the second housing assembly.

6. The lighting apparatus of claim 5, wherein the at least one LED further comprises a plurality of LEDs configured to emit between 2600 lumens and 5700 lumens.

7. The lighting apparatus of claim 2, further comprising a plurality of elongate ribs positioned within an interior of the first housing assembly such that thermal energy from the at least one electrical component is transferred along the elongate ribs to an outer surface of the first housing assembly, and another plurality of elongate ribs positioned within an interior of the second housing assembly such that thermal energy from the at least one light source is transferred along the plurality of elongate ribs to an outer surface of the second housing portion.

8. The lighting apparatus of claim 6, wherein an outer surface of the first housing assembly and an outer surface of the second housing assembly both include a plurality of raised fins.

9. A lighting apparatus, comprising:

a housing assembly having a lower assembly and at least one other assembly;

at least one light source contained within the housing assembly; and

at least one sensor, wherein the light source is configured to react to changes in light detected by the sensor, and wherein the sensor is recessed within the lower housing assembly.

10. The lighting apparatus of claim 9, wherein the lower housing assembly includes an aperture positioned at a bottom region of the lower housing assembly, wherein the sensor is positioned adjacent to the aperture and analyzes light patterns sensed through the aperture.

11. The lighting apparatus of claim 10, further comprising a wedge shaped bezel formed of a light transmissive material, wherein the wedge shaped bezel covers the aperture.

12. The lighting apparatus of claim 10, wherein an outer surface of the lower housing assembly includes a plurality of raised fins spaced radially around the lower housing assembly and wherein the raised fins extend towards the bottom region of the lower housing assembly.

13. The lighting apparatus of claim 9, wherein the at least one light source includes at least one LED, and the sensor comprises a motion sensor, and wherein the at least one other housing assembly includes an upper housing assembly spaced apart from the lower housing assembly, the upper housing assembly housing an LED driver circuit in electrical communication with the motion sensor and the at least one LED.

14. The lighting apparatus of claim 13, further comprising a middle housing assembly having an outer lens positioned between and connected to the upper housing assembly and the lower housing assembly, the middle housing assembly houses a reflector extending above the at least one LED such that light is emitted in an upward direction from the at least one LED for reflection off the reflector and through the outer lens.

15. The lighting apparatus of claim 14, wherein the upper housing assembly and the lower housing assembly are formed of a thermally conductive material.

16. The lighting apparatus of claim 14, further comprising a plurality of LEDs, wherein the plurality of LEDs emit between 2600 and 5700 lumens.

17. A lighting apparatus, comprising:

an upper housing assembly, wherein at least one electrical component is at least partially housed by the upper housing assembly;

a lower housing assembly, wherein at least one other electrical component is at least partially housed by the lower housing assembly; and

a reflector positioned between the upper housing assembly and the lower housing assembly, the reflector having a hollow portion such that electrical wiring is adapted to extend from the lower housing assembly through the hollow portion of the reflector to the upper housing assembly.

18. The lighting apparatus of claim 17, wherein the reflector has a top opening positioned adjacent the upper housing assembly and a bottom opening positioned adjacent the lower housing assembly, and wherein the hollow portion extends between the top opening and the bottom opening of the reflector.

19. The lighting apparatus of claim 18, wherein the bottom opening of the reflector is positioned proximate a longitudinal center axis of the lighting apparatus.

20. The lighting apparatus of claim 18, further comprising a middle housing assembly positioned between the upper housing assembly and the lower housing assembly, wherein the middle housing assembly further comprises an outer lens, and wherein the reflector is disposed within the outer lens between the upper housing assembly and lower housing assembly.

21. The lighting apparatus of claim 18, wherein the at least one electrical component of the upper housing assembly includes an LED driver circuit, and wherein the at least one electrical component of the lower housing assembly includes at least one lighting module having a plurality of LEDs.

22. The lighting apparatus of claim 21, wherein the at least one electrical component of the lower housing assembly includes a sensor configured to analyze light patterns, wherein the sensor is electrically coupled to the LED driver circuit of the upper housing assembly via electrical wiring extending through the hollow portion of the reflector.

23. The lighting apparatus of claim 22, wherein the LED driver circuit is electrically coupled to the lighting module via electrical wiring extending through the hollow portion of the reflector.

24. The lighting apparatus of claim 21, wherein the plurality of LEDs are held on an LED plate of the LED module, and further comprising a collimator plate positioned atop the LED plate, wherein the collimator plate and the LED plate each have central openings to permit electrical wiring to extend therethrough.

25. The lighting apparatus of claim 17, wherein the electrical wiring includes power wiring and communication wiring for the electrical components of the upper housing assembly and the lower housing assembly.

26. The lighting apparatus of claim 25, wherein the lighting apparatus is configured to emit between 2600 and 5700 lumens.

27. A lighting apparatus, comprising:

an upper housing assembly;

at least one electrical component housed within the upper housing assembly, wherein thermal energy emitted by the at least one electrical component is conducted along a first thermal path away from the at least one electrical component;

a middle housing assembly positioned below and attached to the upper housing assembly, wherein the middle housing assembly is substantially non-conductive of thermal energy relative to the upper housing assembly;

a lower housing assembly positioned below and attached to the middle housing assembly such that the upper housing assembly is vertically spaced apart from the lower housing assembly; and

at least one light source housed within the lower housing assembly, wherein thermal energy emitted by the at least one light source is conducted along a second thermal path away from the at least one light source, and wherein the second thermal path is decoupled from the first thermal path.

28. The lighting apparatus of claim 27, wherein the first thermal path includes thermally conductive ribs within the upper housing assembly, wherein the second thermal path includes thermally conductive ribs within the lower housing assembly.

29. The lighting apparatus of claim 28, wherein the ribs within the upper housing assembly are in thermally conductive communication with the outside surface of the upper housing assembly such that thermal energy from the at least one electrical component is conducted from the ribs within the upper housing assembly to the outer surface of the upper housing assembly.

30. The lighting apparatus of claim 29, wherein the upper housing assembly is configured to be mounted below a ceiling.

31. The lighting apparatus of claim 27, wherein the at least one light source is electrically coupled to the at least one electrical component of the upper housing assembly.

32. The lighting apparatus of claim 31, wherein the at least one electrical component includes a driver circuit for the light source, and wherein the at least one light source is an LED.

33. The lighting apparatus of claim 32, wherein the at least one driver circuit and the at least one LED light source are electrically coupled by electrical wiring, and wherein the electrical wiring extends through the middle housing assembly.

34. The lighting apparatus of claim 33, further comprising a reflector positioned within the middle housing assembly, wherein the reflector has a hollow portion extending through the reflector, and wherein the electrical wiring extends through the hollow portion of the reflector.

35. The lighting apparatus of claim 33, wherein the at least one LED comprises a plurality of LEDs configured to emit between 2,600 and 5,700 lumens.

36. A lighting apparatus, comprising:

a housing, including an outer lens;

at least one light source positioned within the housing; and

a reflector positioned within the housing, wherein at least a portion of the reflector is asymmetrical about a plane defined by a longitudinal axis of the reflector and a vector perpendicular to the longitudinal axis of the reflector, wherein the at least one light source is configured to emit light towards the reflector, and wherein the reflector is configured to reflect light emitted by the light source out through the outer lens.

37. The lighting apparatus of claim 36, wherein the reflector has a plurality of formations asymmetrically distributed around a longitudinal axis of the reflector.

38. The lighting apparatus of claim 37, wherein the slope of the reflector at a given point along the longitudinal axis changes between formations.

39. The lighting apparatus of claim 38, wherein each formation is configured to reflect light in a different pattern.

40. The lighting apparatus of claim 39, wherein the formations are equally distributed among a surface area of the reflector.

41. The lighting apparatus of claim 39, wherein the formations are not equally distributed among a surface area of the reflector.

42. The lighting apparatus of claim 41, wherein there are at least three formations, and wherein at least two of the formations are equally distributed among a surface area of the reflector.

43. The lighting apparatus of claim 39, wherein no one formation covers the same amount of surface area as any other formation.

44. The lighting apparatus of claim 36, wherein the at least one light source further comprises a plurality of LEDs such that the lighting apparatus is configured to emit between 2,600 lumens and 5,700 lumens.