Method and apparatus for thermally effective trim for light fixture

• US 7,670,021 B2
• Filed: 05/20/2008
• Issued: 03/02/2010
• Est. Priority Date: 09/27/2007
• Status: Active Grant

• Current Assignee: Enertron, Inc.
• Original Assignee: Enertron, Inc.
• Inventors: Chou, Der Jeou
• Primary Examiner(s): TSO, LAURA K
• Application Number:
  US12/123,960
• Publication Number:
  US 20090086474A1
• Time in Patent Office: 651 Days
• Field of Search: 362/147, 362/148, 362/149, 362/150, 362/404, 362/294, 362/373, 362/547
• US Class Current: 362/148
• CPC Class Codes: F21K 9/233 specially adapted for generating a spot light distribution, e.g. for substitution of reflector lamps
• CPC Class Codes: F21K 9/90 Methods of manufacture
• 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 21/04 Recessed bases
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21Y 2113/13 comprising an assembly of point-like light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A lighting assembly comprises a light fixture. The light fixture includes a trim formed by a stamping or die casting process. The trim has thermally conductive properties and includes a flange around a perimeter of the trim. The light fixture includes a light source mounted to a central portion of a front surface of the trim, and a heatsink formed by an extrusion or die casting process. The heatsink has thermally conductive properties and is mounted to a back surface of the trim. The light fixture includes an attachment mechanism connected to the light fixture. A recessed can housing mounted to a surface may be provided. The light fixture may be mounted to the recessed can housing by inserting the heatsink into the recessed can housing and engaging the attachment mechanism to an interior portion of the recessed can housing to brace the flange against the surface.

Claims

1. A method of manufacturing a lighting assembly, comprising:

providing a light fixture by,

(a) forming a trim by a stamping or die casting process, the trim having thermally conductive properties and including a flange around a perimeter of the trim,

(b) mounting a light source to a central portion of a front surface of the trim,

(c) forming a heatsink by an extrusion or die casting process, the heatsink having thermally conductive properties,

(d) mounting the heatsink to a back surface of the trim opposite the light source, and

(e) connecting an attachment mechanism to the light fixture;

providing a recessed can housing mounted to a surface; and

mounting the light fixture to the recessed can housing by,

(f) inserting the light fixture into the recessed can housing, and

(g) engaging the attachment mechanism to an interior portion of the recessed can housing to brace the flange against the surface.

2. The method of claim 1, wherein the trim includes a metal, thermally conductive plastic or thermally conductive carbon fiber composite material.

3. The method of claim 1, wherein the light source includes a light engine having a plurality of light emitting diodes (LEDs)

4. The method of claim 3, wherein each of the plurality of LEDs has a color selected to achieve a target correlated color temperature.

5. The method of claim 3, wherein the light engine includes blue LEDs having a phosphor coating.

6. The method of claim 1, including mounting a lens to the trim over the light source, the lens including a clear, frosty or translucent glass or plastic material.

7. A method of manufacturing a light fixture, comprising:

forming a trim, the trim having thermally conductive properties and including a flange around a perimeter of the trim;

mounting a light source to a central portion of a front surface of the trim;

forming a heatsink, the heatsink having thermally conductive properties;

mounting the heatsink to a back surface of the trim opposite the light source; and

connecting an attachment mechanism to the light fixture.

8. The method of claim 7, including:

providing a recessed can housing mounted to a surface; and

mounting the light fixture to the recessed can housing by,

(a) inserting the light fixture into the recessed can housing, and

(b) engaging the attachment mechanism to an interior portion of the recessed can housing to brace the flange against the surface.

9. The method of claim 7, wherein the trim is formed using a stamping or die casting process.

10. The method of claim 7, wherein the heatsink is formed using an extrusion or die casting process.

11. The method of claim 7, wherein the trim includes aluminum, aluminum alloy, copper, copper alloy, thermally conductive plastic, or thermally conductive carbon fiber composite material.

12. The method of claim 7, wherein the light source includes a light engine having a plurality of light emitting diodes (LEDs)

13. The method of claim 12, wherein the light engine includes blue LEDs having a phosphor coating.

14. The method of claim 12, wherein each of the plurality of LEDs has a color selected to achieve a target correlated color temperature.

15. The method of claim 7, including mounting a lens to the trim over the light source, the lens including a clear, frosty or translucent glass or plastic material.

16. A light fixture, comprising:

a trim formed by a stamping or die casting process, the trim having thermally conductive properties and including a flange around a perimeter of the trim;

a light source mounted to a central portion of a front surface of the trim;

a heatsink mounted to a back surface of the trim opposite the light source, the heatsink being formed by an extrusion or die casting process and having thermally conductive properties; and

an attachment mechanism connected to the light fixture.

17. The light fixture of claim 16, wherein the trim includes aluminum, aluminum alloy, copper, copper alloy, thermally conductive plastic, or thermally conductive carbon fiber composite material.

18. The light fixture of claim 16, wherein the light source includes a light engine having a plurality of light emitting diodes (LEDs)

19. The light fixture of claim 16, wherein the light engine includes blue LEDs having a phosphor coating.