LED retrofit method and kit for converting fluorescent luminaries

• US 6,739,734 B1
• Filed: 03/17/2003
• Issued: 05/25/2004
• Est. Priority Date: 03/17/2003
• Status: Expired due to Fees

• Current Assignee: Ultimate Presentation Systems Incorporated
• Original Assignee: Ultimate Presentation Systems Incorporated
• Inventors: Hulgan, Condon “Sparky”
• Primary Examiner(s): O'Shea, Sandra
• Assistant Examiner(s): SAWHNEY, HARGOBIND S
• Application Number:
  US10/389,004
• Time in Patent Office: 435 Days
• Field of Search: 362/217, 362/224, 362/225, 362/227, 362/234, 362/240, 362/241, 362/247, 362/243, 362/253, 362/147, 362/148, 362/800, 362/812, 362/317, 362/347, 362/349
• US Class Current: 362/243
• CPC Class Codes: F21S 4/26 of rope form, e.g. LED lighting ropes, or of tubular form
• CPC Class Codes: F21S 8/02 of recess-mounted type, e.g. downlighters specially adapted for vehicle exteriors F21S41/00-F21S45/00
• CPC Class Codes: F21S 8/026 intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling
• CPC Class Codes: F21V 19/003 Fastening of light source holders, e.g. of circuit boards or substrates holding light sources
• CPC Class Codes: F21V 7/005 with an elongated shape to cooperate with linear light sources
• CPC Class Codes: F21V 7/16 with provision for adjusting the curvature
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

The present invention is a method of converting fluorescent luminaires, or luminaries, into LED luminaires. The most preferred method retrofits a commercial fluorescent light fixture, especially one that uses T12 lamps or T8 lamps, without requiring removal of the fixture housing. The fluorescent luminaire is stripped of its lamps, wireway cover, ballast(s) and tombstones. A novel LED retro-reflector is mounted within the fixture housing to conceal an LED power supply and to provide an ideal surface for mounting LED (Light Emitting Diode) light strips. Any existing diffuser or louver that was part of the fluorescent luminaire may be replaced after the LED retrofit has been completed.

Claims

1. A method for retrofitting a fluorescent luminaire into an LED luminaire that uses LED (light emitting diode) lamps, comprising the steps of:

fabricating an LED retro-reflector using a thin sheet of substantially rigid material that is substantially impervious to fracturing, yet capable of being flexed by an applied hand pressure;

mounting a first multiple LED lamp assembly to a lighted surface of the LED retro-reflector;

substantially removing any louvers or diffusers of the fluorescent luminaire;

stripping the fluorescent luminaire to expose a fixture housing having opposing endplates, the volume inside the fixture housing substantially defining a fixture cavity;

mounting an LED power supply to the fixture housing;

electrically connecting the LED power supply to an A/C power supply;

manipulating the LED retro-reflector so it fits within the fixture cavity;

electrically connecting the first multiple LED lamp assembly to the LED power supply; and

fastening the LED retro-reflector to the fixture housing such that the LED retro-reflector substantially fits inside the fixture cavity and conceals the LED power supply;

replacing any louvers or diffusers.

2. The method of claim 1 further comprising the steps of:

forming apertures in the LED retro-reflector;

mounting at least one additional multiple LED lamp assembly to the lighted surface of the LED retro-reflector; and

electrically connecting the at least one additional multiple LED lamp assembly in series to the first multiple LED lamp assembly with a jumper that passes through the apertures formed in the LED retro-reflector.

3. The method of claim 2 wherein the multiple LED lamp assemblies are LED light strips.

4. The method of claim 3 further comprising the steps of:

fabricating clear plastic tubes that substantially house the LED light strips, the plastic tubes having center guides for aligning the LED light strips within the plastic tubes;

inserting the LED light strips into the plastic tubes; and

wherein the steps of mounting the first and additional multiple LED lamp assemblies are characterized by using tube clamps that mount the plastic tubes to the LED retro-reflector using tube fasteners.

5. The method of claim 3 further comprising the steps of:

fabricating clear plastic tubes that may substantially house the LED light strips, the plastic tubes having center guides for aligning the LED light strips within the plastic tubes;

inserting the LED light strips into the plastic tubes; and

wherein the step of fabricating the LED retro-reflector is characterized by forming sets of raised tabs in the thin sheet that are spaced along lengths of the LED retro-reflector; and

the steps of mounting the first and additional multiple LED lamp assemblies are characterized by using tube clamps that mount the plastic tubes to the LED retro-reflector when part of each tube clamp is inserted between a set of raised tabs and the thin sheet.

6. The method of claim 1 further comprising the step of forming at least two easy-to-bend structures in the LED retro-reflector, the easy-to-bend structures being formed between 1 and 3 inches from opposing edges of the LED retro-reflector such that the LED retro-reflector may be bent to create a large flat area with long flaps that include the opposing edges.

7. The method of claim 1 further comprising the step of bending the LED retro-reflector to create at least three inflections, a middle inflection of the at least three inflections being shallow and farther from the fixture housing than other of the at least three inflections.

8. The method of claim 3 wherein the step of mounting the multiple LED lamp assemblies is characterized by fastening the LED light strips directly to the lighted surface of the LED retro-reflector, and wherein the step of fabricating the LED retro-reflector uses a substantially rigid material that is nonconductive.

9. A retrofit kit, for converting a fluorescent luminaire into an LED luminaire that uses white LED (light emitting diode) lamps, comprising:

a first multiple LED lamp assembly;

an LED retro-reflector made from a thin sheet of substantially rigid material that is substantially impervious to fracturing, yet flexible by an applied hand pressure, the LED retro-reflector having a lighted surface that substantially displays the LED lamps;

an LED power supply;

a means for electrically connecting the LED power supply to an A/C power supply;

a means for electrically connecting the first multiple LED lamp assembly to the LED power supply;

a means for mounting the LED power supply to the fluorescent luminaire being converted; and

a means for mounting the LED retro-reflector to the fluorescent luminaire being converted.

10. The retrofit kit of claim 9 further comprising:

at least one additional multiple LED lamp assembly; and

a jumper for electrically connecting the at least one additional multiple LED lamp assembly in series to the first multiple LED lamp assembly.

11. The retrofit kit of claim 10 wherein the multiple LED lamp assemblies are LED light strips.

12. The retrofit kit of claim 11 further comprising:

clear plastic tubes that substantially house the LED light strips, the plastic tubes having center guides for aligning LED light strips within each of the plastic tubes; and

a means for fastening the plastic tubes to the LED retro-reflector.

13. The retrofit kit of claim 12 wherein the means for fastening the plastic tubes is with tube clamps that attach to the LED retro-reflector using tube fasteners.

14. The retrofit kit of claim 12 wherein the LED retro-reflector further comprises sets of raised tabs formed in the thin sheet that are spaced along lengths of the LED retro-reflector;

and the means for fastening the plastic tubes is with tube clamps that mount to the LED retro-reflector when part of each tube clamp is inserted between a set of raised tabs and the thin sheet.