Lighting apparatus

• US 7,329,024 B2
• Filed: 09/20/2004
• Issued: 02/12/2008
• Est. Priority Date: 09/22/2003
• Status: Expired due to Fees

• Current Assignee: Permlight Products Inc
• Original Assignee: Permlight Products Inc
• Inventors: Wijesinghe, Rehana, Fraitag, Lenny, Lynch, Manuel
• Primary Examiner(s): O'Shea; Sandra
• Assistant Examiner(s): ZETTL, MARY E
• Application Number:
  US10/945,069
• Publication Number:
  US 20050190553A1
• Time in Patent Office: 1,240 Days
• Field of Search: 362/240, 362/231, 362/249, 362/365, 362/800, 257/99, 200/314
• US Class Current: 362/240
• CPC Class Codes: F21S 2/005 of modular construction
• CPC Class Codes: F21S 4/10 with light sources attached to loose electric cables, e.g. Christmas tree lights
• CPC Class Codes: F21S 4/28 rigid, e.g. LED bars
• 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 17/12 by screwing
• CPC Class Codes: F21V 21/02 Wall, ceiling, or floor bases; Fixing pendants or arms to the bases F21V21/08 takes precedence; bases for movable standing lamps F21V21/06
• CPC Class Codes: F21V 23/00 Arrangement of electric circuit elements in or on lighting devices characterised by cooling arrangements F21V29/508
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 25/04 breaking the electric circuit
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/745 the fins or blades being planar and inclined with respect to the joining surface from which the fins or blades extend
• CPC Class Codes: F21V 29/76 with essentially identical parallel planar fins or blades, e.g. with comb-like cross-section
• CPC Class Codes: F21V 3/04 characterised by materials, surface treatments or coatings
• CPC Class Codes: F21V 31/04 Provision of filling media
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A lighting apparatus is provided including an array of light emitting diodes (LEDs) disposed on a base. The base is configured to move heat away from the array of LEDs to other portions of the base and further to the atmosphere or an adjacent housing. In one embodiment, a native oxide on the base electrically insulates the base from the LEDs. In another embodiment, a cover is removably disposed over the array of LEDs, and removal of the cover prevents electrical energization of the LEDs.

Claims

1. A lighting apparatus, comprising:

a base comprised of an electrically conductive material and a layer of oxide on said material, the base comprising a cavity;

electrically conductive traces mounted on the base, at least a portion of the conductive traces being disposed in the cavity

an array of LEDs electrically connected to the conductive traces, at least a portion of the array of LEDs disposed in the cavity;

said LEDs electrically insulated from the conductive material by said oxide; and

a selectively removable cover configured to fit over the array of LEDs and to at least partially cover the cavity when in an installed position, the cover comprising an electrically conductive portion;

wherein the electrically conductive portion of the cover is configured to electrically communicate with the conductive traces so that electrical current flows between the cover and the traces when the cover is in the installed position, and electrical current flow is interrupted when the cover is removed from the cavity.

2. The lighting apparatus of claim 1, wherein at least a portion of the cavity is filled with a light transmissive material.

3. The lighting apparatus of claim 1, wherein the base has a substantially flat mounting surface, and additionally comprising a power supply having a substantially flat mounting surface, and the base is mounted flush onto the mounting surface of the power supply.

4. The lighting apparatus of claim 3, wherein the power supply has an electrical supply node, and the electrically conductive portion of the cover is selectively electrically engageable with the power supply node so that electrical current from the power supply flows through the cover to the traces.

5. The lighting apparatus of claim 4 additionally comprising a fastener adapted to selectively and simultaneously engage the electrical supply node of the power supply and the electrically conductive portion of the cover, wherein the fastener is electrically conductive so that electrical current from the power supply flows through the fastener to the conductive portion of the cover.

6. The lighting apparatus of claim 5, wherein the fastener comprises a threaded fastener, and the electrical supply node comprises a threaded portion.

7. The lighting apparatus of claim 1, wherein the oxide is a native oxide of the electrically conductive material.

8. The lighting apparatus of claim 7, wherein a thickness of the oxide layer is about 2 mil or less.

9. The lighting apparatus of claim 7, wherein the oxide layer is produced by anodization.

10. A lighting apparatus, comprising:

a base comprised of an electrically conductive material and a layer of oxide on said material, the base further comprising a cavity and a substantially flat mounting surface;

electrically conductive traces disposed on the oxide, at least a portion of the conductive traces being disposed in the cavity;

an array of LEDs mounted on the base and being electrically connected to the conductive traces so that at least a portion of the array of LEDs is disposed in the cavity, said LEDs electrically insulated from the conductive material by said oxide;

a cover configured to fit over the array of LEDs and to at least partially cover the cavity, the cover comprising an electrically conductive portion that is configured to electrically communicate with the conductive traces so that electrical current flows from the cover to the traces, the cover being selectively removable to interrupt the electrical current flow; and

a power supply having a substantially flat mounting surface, the base being mounted on the mounting surface of the power supply;

wherein the power supply has a positive electrical supply node and a negative electrical supply node, and the cover has two electrically conductive portions that are selectively electrically engageable with respective power supply nodes, and each cover portion is selectively electrically engageable with the conductive traces so as to selectively create an electrical pathway between the nodes through the cover portions, the traces and the array of LEDs.

11. A lighting apparatus, comprising:

a base;

an array of LEDs mounted to the base;

a circuit trace disposed on the base and configured to deliver electrical power to the array of LEDs;

a selectively removable cover configured to cover the array, the cover having an electrically conductive portion; and

an electrical supply path having an end spaced from the circuit trace;

wherein the cover is mechanically coupled to the base such that the electrically conductive portion communicates with the circuit trace and with the electrical supply path so as to complete an electrical pathway to permit power to flow to the LEDs, and removal of the cover opens the electrical pathway to prevent flow of power.

12. The lighting apparatus of claim 11 additionally comprising a cover contact configured to electrically connect the circuit trace to the cover when the cover is coupled to the base.

13. The lighting apparatus of claim 12, wherein the cover contact is permanently in contact with the circuit trace, and extends from the circuit trace.

14. The lighting apparatus of claim 13, wherein the circuit trace comprises a terminus portion, and the cover contact is affixed to the terminus portion.

15. The lighting apparatus of claim 12, wherein the base is electrically conductive, and the base is coated with a non-electrically-conductive electroless metal, wherein the circuit trace is insulated from the base by the coating.

16. The lighting apparatus of claim 11 additionally comprising a fastener adapted to couple the cover to the base, wherein the electrical supply path comprises the fastener.

17. The lighting apparatus of claim 16 additionally comprising a power supply having an energized mounting node, wherein the fastener is adapted to selectively engage the energized mounting node.

18. A lighting apparatus, comprising:

a base;

an array of LEDs mounted to the base so that the LEDs are electrically connected to one another;

a cover configured to cover the array, the cover comprising a first conductive portion and a second conductive portion; and

a first cover contact and a second cover contact electrically connected to the array of LEDs;

wherein power is supplied to the LEDs via an electrical pathway, and the cover is mechanically coupled to the base such that the first and second cover portions are electrically engageable with respective cover contacts when the cover is in place so that attachment of the cover completes an electrical pathway to permit power to flow via an electrical pathway through the first cover portion to the array of LEDs and to the second cover portion, and wherein removal of the cover interrupts the electrical pathway to prevent flow of power.

19. The lighting apparatus of claim 18 additionally comprising a power supply having first and second power supply nodes, and the base and cover are attachable to the power supply so that the first and second nodes electrically communicate with the first and second cover conductive portions.

20. The lighting apparatus of claim 19, wherein the base has a substantially flat mounting surface and the power supply has a substantially complementary mounting surface.

21. An ultraviolet lighting device, comprising a lighting apparatus as in claim 20, wherein the base comprises a cavity, the array of LEDs is arranged in the cavity and comprises LEDs configured to emit ultraviolet light, and the cover is configured to completely enclose the cavity when the cover is in place so that substantially no light emitted by the LEDs exits the cavity without first contacting the cover.

22. The ultraviolet lighting device of claim 21, wherein the cover comprises a phosphor.

23. The lighting apparatus of claim 20, wherein the cover is selectively mechanically coupled to the base and power supply by a first and a second fastener, the first and second fasteners being electrically conductive, and the first and second fasteners communicate electricity from the first and second power supply nodes, respectively, to the first and second cover portions.

24. The lighting apparatus of claim 23, wherein the base is attached to the power supply so that the base mounting surface is fit substantially flush onto the power supply mounting surface.

25. A lighting apparatus, comprising:

a base;

an array of LEDs mounted to the base and electrically communicating with a circuit trace;

a cover configured to cover the array, the cover comprising a fastener and a conductive insert;

wherein power is supplied to the LEDs via an electrical pathway, and the cover is mechanically coupled to the base such that the conductive insert communicates electrical power between the circuit trace and the fastener so that attachment of the cover completes an electrical pathway to permit power to flow to the LEDs, and removal of the cover opens the electrical pathway to prevent flow of power.

26. The lighting apparatus of claim 25, wherein the fastener is a threaded fastener and the insert is threaded so as to mechanically and electrically engage the fastener.

27. The lighting apparatus of claim 25 additionally comprising a housing comprising a heat conductive material, the housing configured so that the base fits therein and in contact with the housing so that heat from the base is communicated to the housing.

28. The lighting apparatus of claim 27, wherein the housing comprises heat dissipating fins.

29. A lighting apparatus comprising:

a base comprising a pair of apertures;

a plurality of contacts on the base, the plurality of contacts comprising a first terminus and a second terminus;

at least one LED disposed on the contacts and arranged so that an electrical pathway is established from the first terminus to the second terminus;

a power module comprising first and second threaded mount portions, the power module configured to supply electric power between the first and second mount portions and comprising a casing that has first and second apertures that enable access to the first and second mount portions, the apertures configured to generally align with the base apertures; and

a first conductive fastener and a second conductive fastener, the fasteners being elongate and adapted to fit through the base apertures and the power module apertures to engage the respective mount portions;

wherein the first and second conductive fasteners are adapted to engage the first and second mount portions, respectively, so as to hold the base in a position relative the power module and to electrically connect the first and second mount portions to a respective one of the first and second terminus so as to supply electrical power across the electrical pathway when the fasteners are in place, and wherein the first and second mount portions are threaded, and the first and second fasteners are threaded so as to engage the mount portion threads.

30. The lighting apparatus of claim 29, wherein the base is thermally conductive.

31. A lighting system comprising a housing and a plurality of the lighting apparatuses of claim 30, wherein the lighting apparatuses are electrically linked together and the housing is configured to hold the plurality of lighting apparatuses so that the bases of the apparatuses contact the housing, and wherein the housing comprises a thermally conductive material adapted to receive heat from the base.

32. The lighting apparatus of claim 29, wherein the base has a substantially flat mounting surface and the power module has a substantially complementary mounting surface, and the base mounting surface is mounted substantially flush onto the power module mounting surface.

33. The lighting apparatus of claim 29, wherein the power module is connected to a source of electrical power, and the power module is adapted to convert the electrical power to a desired condition.

34. A lighting apparatus comprising:

a base having a first aperture and a second aperture;

a plurality of contacts on the base, the plurality of contacts comprising a first terminus and a second terminus, the first base aperture generally adjacent the first terminus and the second base aperture generally adjacent the second terminus;

at least one LED disposed on the contacts and arranged so that an electrical pathway is established from the first terminus to the second terminus;

a power module comprising first and second mount portions, the power module configured to supply electric power between the first and second mount portions; and

a first conductive fastener and a second conductive fastener;

wherein the first and second conductive fasteners are adapted to engage the first and second mount portions, respectively, and extend from the power module mounting portions and through the first and second apertures, respectively, of the base so as to hold the base in a position relative the power module and to electrically connect the first and second mount portions to a respective one of the first and second terminus so as to supply electrical power across the electrical pathway when the fasteners are in place; and

wherein a cover is adapted to fit over the at least one LED, and the fasteners physically connect the cover to the base.

35. The lighting apparatus of claim 34, wherein each terminus comprises an upwardly extending contact member.