Modular LED lighting fixtures

• US 7,726,840 B2
• Filed: 05/30/2008
• Issued: 06/01/2010
• Est. Priority Date: 03/04/2008
• Status: Active Grant

• Current Assignee: Korrus Incorporated (MKD Electric, Inc.)
• Original Assignee: Tempo Industries, Inc.
• Inventors: Pearson, Dennis, Horwitz, Terry, Horvath, Richard
• Primary Examiner(s): TON, ANABEL
• Application Number:
  US12/130,882
• Publication Number:
  US 20090225546A1
• Time in Patent Office: 732 Days
• Field of Search: 362/249.02, 362/800, 362/373, 362/294
• US Class Current: 362/249.06
• CPC Class Codes: F21S 2/005 of modular construction
• CPC Class Codes: F21S 4/28 rigid, e.g. LED bars
• CPC Class Codes: F21V 19/005 by permanent fixing means, e.g. gluing, riveting or embedding in a potting compound
• CPC Class Codes: F21V 21/005 for several lighting devices in an end-to-end arrangement, i.e. light tracks
• CPC Class Codes: F21V 23/002 Arrangements of cables or conductors inside a lighting device, e.g. means for guiding along parts of the housing or in a pivoting arm
• CPC Class Codes: F21V 27/02 Cable inlets
• CPC Class Codes: F21V 29/763 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/767 the planes containing the fins or blades having directions perpendicular to the light emitting axis
• 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]
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

Concatenatable lighting fixtures, each comprising a unitary cover member having a circuit board mounting platform integrally formed with suitable heat sinking and which mounts onto a cooperating base chassis. In one embodiment, the circuit board mounting platform extends farther from one end of the cover member than the other so as to facilitate placement of LEDs in a fashion which enhances lighting uniformity and minimizes dark spots. In one embodiment, first and second guide members may be positioned in respective opposite ends of adjacent fixtures, each guide member having a plurality of extending fingers with a flexible electrical conductor-carrying conduit disposed between the respective opposite ends and retained in position by the fingers.

Claims

1. Apparatus comprising:

a first fixture component and a second fixture component;

a first tongue extending from the first fixture component and having a length;

a second tongue extending from the second fixture component and having a length, the first and second tongues being dimensioned to overlap one another to facilitate interconnection of said first and second components;

a first mounting surface on said first component having parallel edges and terminating in a third tongue having a length;

a second mounting surface on said second component having parallel edges and terminating in a fourth tongue having a length;

first and second circuit boards positioned above said first and second mounting surfaces respectively, said first and second circuit boards each carrying a plurality of LEDs; and

the length of said third tongue being selected to be longer than the length of said fourth tongue so as to enable said first and second fixture components to be mounted at any one of a selected range of angles with respect to one another while positioning said LEDs so as to enhance uniformity of illumination provided thereby.

2. The apparatus of claim 1 further comprising:

first and second guide members positioned in respective opposite ends of said first and second components, each guide member having a plurality of extending fingers; and

a flexible conduit disposed between said respective opposite ends and retained in position by said fingers.

3. The apparatus of claim 1 wherein said first and second fixture components each comprises a unitary cover and an underlying base unit, the unitary cover member adapted to mount onto the underlying base unit.

4. The apparatus of claim 3 wherein said cover member includes an array of heat sink fins.

5. The apparatus of claim 4 wherein said first mounting surface is formed as part of the unitary cover member of said first fixture component and said second mounting surface is formed as part of the unitary cover member of said second fixture component.

6. The apparatus of claim 5 wherein said first tongue is formed as part of the base unit of said first fixture component and said second tongue is formed as part of the base unit of said second fixture component.

7. The apparatus of claim 3 wherein the underlying base unit has a plurality of feet horizontally extending therefrom.

8. The apparatus of claim 1 wherein said first and second circuit boards are attached to said first and second mounting surfaces by thermally conductive tape.

9. The apparatus of claim 6 wherein said cover member has an aperture at an outer edge of said mounting surface providing a passageway for one or more electrical conductors.

29. The light fixture apparatus of claim 1 wherein one of the tongues has a length ½

W and the other tongue has a length 3/2W where “

W”

is a width of said circuit board.

57. The apparatus of claim 1 further comprising:

a plurality of LEDs spaced the same selected distance apart on each respective first and second mounting surface; and

wherein

opposing tongues of said first and second mounting surfaces are dimensioned so as to enable spacing an end most LED on one opposing end of said first mounting surface said selected distance from an end-most LED on the opposing end of said second mounting surface.

10. Light fixture apparatus comprising:

a unitary cover member having first and second ends and an elongated platform located on an exterior top surface of said cover member, said platform providing a mounting surface;

first and second tongues extending from opposite ends of said elongated platform and beyond the respective first and second ends of said cover member,

a circuit board having a top surface carrying an array of LEDs and a bottom surface positioned above said mounting surface, respective ends of said circuit board lying above said first and second tongues; and

the length of said first and second tongues being different and selected to assist in disposing said LEDs so as to enhance the uniformity of illumination provided thereby.

11. The apparatus fixture of claim 10 further comprising a unitary base member having first and second vertical support members extending upwardly therefrom, said unitary cover member shaped and dimensioned to fit down and over said support members so as to form an enclosure wherein electrical leads are disposed.

12. The apparatus of claim 11 wherein said cover member snap-fittingly engages said base member.

13. The apparatus of claim 11 wherein said cover member is fastened to said base member by one or more mechanical fastening devices.

14. The apparatus of claim 10 wherein one of the tongues has a length ½

W and the other tongue has a length 3/2W where “

W”

is a width of said circuit board.

15. Apparatus comprising:

a first lighting fixture component having a top surface and first and second downwardly depending side surfaces, the top and side surfaces enclosing electrical leads passing through an interior of said first fixture component;

a second lighting fixture component having a top surface and first and second downwardly depending side surfaces, the top and side surfaces enclosing electrical leads passing through an interior of said second lighting fixture component;

a first tongue extending from a first end of the first lighting fixture component and having a length;

a second tongue extending from a second end of the second lighting fixture component disposed opposite the first end of said first lighting fixture component and having a length, the first and second tongues being dimensioned to overlap one another, said first and second tongues being pivotally connected together such that said first lighting fixture component may pivot with respect to said second lighting fixture component;

a first mounting surface located on the top surface of said first lighting fixture component, the first mounting surface terminating in a third tongue having a length;

a second mounting surface located on the top surface of said second lighting fixture component, the second mounting surface terminating in a fourth tongue having a length;

a first plurality of LEDs each mounted spaced apart from the other above and along a length of said first mounting surface;

a second plurality of LEDs each mounted spaced apart from the other above and along a length of said second mounting surface; and

the length of said third tongue being selected to be longer than the length of said fourth tongue such that said LEDs are positioned to achieve enhanced uniformity of illumination when said first and second lighting fixture components are pivotally interconnected at any one of a selected range of angles with respect to one another.

16. The apparatus of claim 15 further comprising:

a flexible conduit disposed between the first end of said first lighting fixture component and the first end of said second lighting fixture component, the flexible conduit conducting electrical leads between said first lighting fixture component and the second lighting fixture component.

17. The apparatus of claim 15 wherein said first and second lighting fixture components each comprises a unitary cover member adapted to mount onto an underlying base unit.

18. The apparatus of claim 17 wherein the unitary cover members of each of said first and second lighting fixture component includes an array of heat sink fins.

19. The apparatus of claim 18 wherein said first mounting surface is formed as part of the unitary cover member of said first lighting fixture component and said second mounting surface is formed as part of the unitary cover member of said second lighting fixture component.

20. The apparatus of claim 19 wherein said first tongue is formed as part of the base unit of said first lighting fixture component and said second tongue is formed as part of the base unit of said second lighting fixture component.

21. The apparatus of claim 17 wherein the underlying base unit has a plurality of feet horizontally extending from a side thereof.

22. The apparatus of claim 15 wherein said first and second plurality of LEDs are mounted on first and second circuit boards respectively attached to said first and second mounting surfaces.

23. The apparatus of claim 17 wherein said first and second plurality of LEDs are mounted on first and second circuit boards respectively attached to said first and second mounting surfaces.

24. The apparatus of claim 17 wherein each unitary cover member has an aperture at an outer edge of said mounting surface providing a passageway for one or more electrical conductors.

58. The apparatus of claim 15 further comprising:

a plurality of LEDs spaced the same selected distance apart on each respective first and second mounting surface; and

wherein opposing tongues of said first and second mounting surfaces are dimensioned so as to enable spacing an end most LED on one opposing end of said first mounting surface said selected distance from an end-most LED on the opposing end of said second mounting surface.

25. Light fixture apparatus comprising:

a unitary elongated, generally box-shaped cover member having opposite ends;

an elongated platform on an exterior top surface of said cover member, said platform comprising an elongated mounting surface above which are mounted a plurality of LEDs; and

said elongated platform having first and second tongues, each tongue extending beyond a respective one of the opposite ends of said cover member, at least one of the tongues having an LED disposed above its top surface, the length of said first and second tongues being different and selected to position said LEDs so as to enhance the uniformity of illumination provided thereby.

26. The light fixture apparatus of claim 25 further comprising a unitary base member having first and second vertical support members extending upwardly therefrom, said unitary cover member fitting down and over said support members to form an enclosure, a plurality of electrical leads being positioned in said enclosure.

27. The light fixture apparatus of claim 26 wherein said cover member snap-fittingly engages said base member.

28. The light fixture apparatus of claim 26 wherein said cover member is fastened to said base member by one or more mechanical fastening devices.

30. The light fixture apparatus of claim 25 wherein one of the tongues has a length ½

W and the other tongue has a length 3/2W where “

W”

is a width of said mounting surface.

31. Apparatus comprising:

a first lighting fixture component carrying a first plurality of LEDs;

a second lighting fixture component carrying a second plurality of LEDs;

a first tongue extending from a lower end of the first fixture component and having a length;

a second tongue extending from a lower end of the second fixture component and having a length, the first and second tongues being positioned and dimensioned to overlap one another to facilitate interconnection of said first and second fixture components;

a first mounting surface on a top side of said first fixture component terminating in a third tongue having a length;

a second mounting surface on a top side of said second fixture component terminating in a fourth tongue having a length;

first and second circuit boards positioned above said first and second mounting surfaces respectively, said first and second circuit boards respectively mounting said first and second plurality of LEDs; and

the length of said third tongue being selected to be longer than the length of said fourth tongue so as to enable said first and second fixture components to be mounted at any one of a selected range of angles with respect to one another while positioning said LEDs so as to enhance uniformity of illumination provided thereby.

59. The apparatus of claim 31 further comprising:

a plurality of LEDs spaced the same selected distance apart on each respective first and second mounting surface; and

wherein

opposing tongues of said first and second mounting surfaces are dimensioned so as to enable spacing an end most LED on one opposing end of said first mounting surface said selected distance from an end-most LED on the opposing end of said second mounting surface.

32. Lighting fixture apparatus comprising:

a single piece cover member having a horizontally disposed mounting platform;

said single piece cover member further having respective first and second side surfaces depending downwardly on opposite sides of said platform, said first and second side surfaces each further including a heat sink structure; and

wherein the mounting platform is recessed beneath respective top edges of said first and second side surfaces and has first and second ends, each of the first and second ends extending beyond a respective end of said cover member.

33. The lighting fixture apparatus of claim 32 further comprising:

a single piece base member having first and second elongated side rails and first and second upwardly extending end posts at respective opposite ends of said first and second elongated side rails,

wherein the unitary base member is shaped and dimensioned such that said unitary cover member is installable downwardly over said mounting posts to form an enclosure for electrical componentry of said fixture.

34. The lighting fixture apparatus of claim 33 further including a plurality of horizontally projecting feet disposed along a bottom edge of said base member and shaped and dimensioned to space the lighting fixture apparatus a selected distance from a surface adjacent thereto.

35. The lighting fixture apparatus of claim 34 further including one or more holes in a top surface of said cover member and one or more fastening devices insertable through said one or more holes to removably fasten said cover member to said base member.

36. The lighting fixture apparatus of claim 33 further including an aluminum circuit board carrying a plurality of LEDs and mounted on said platform within said recess.

37. The apparatus of claim 36 wherein one of the tongues has a length ½

W and the other tongue has a length 3/2W where “

W”

is a width of said circuit board.

38. The lighting fixture apparatus of claim 37 wherein said circuit board mounts 12 LED lamps equally spaced apart from one another with a first of the end-most LEDs spaced ½

inch from a first end of the circuit board and the opposite end-most LED spaced ½

inch from a second end of the circuit board.

39. The lighting fixture apparatus of claim 37 wherein said circuit board mounts 6 LEDs each spaced two inches from the other with one end-most LED being spaced ½

inch from one end of the circuit board and the opposite end-most LED being spaced 1½

inches from the opposite end of the circuit board.

40. Lighting fixture apparatus comprising:

a single piece cover member having a first mounting platform and respective first and second side surfaces depending downwardly on opposite sides of said first platform, said first and second side surfaces each further including a heat sink structure;

wherein the first platform has first and second ends, each extending beyond a respective end of said cover member;

a plurality of LEDs positioned above said first mounting platform; and

a unitary base member having first and second elongated side rails and first and second upwardly extending end posts at respective opposite ends of said first and second elongated side rails;

wherein the unitary base member is shaped and dimensioned such that said unitary cover member is installable downwardly over said mounting posts and attachable to said mounting posts to form an enclosure for electrical componentry of said apparatus.

41. The lighting fixture apparatus of claim 40 further including a plurality of horizontally projecting feet disposed along a bottom edge of said base member and shaped and dimensioned to space the lighting fixture apparatus a selected distance from a surface adjacent thereto.

42. The lighting fixture apparatus of claim 40 further including one or more holes in a top surface of said cover member and one or more fastening devices insertable through said one or more holes to removably fasten said cover member to said base member.

43. The lighting fixture apparatus of claim 40 further including a circuit board carrying a plurality of LEDs and mounted on said mounting platform.

44. The apparatus of claim 43 wherein one of the tongues has a length ½

W and the other tongue has a length 3/2W where “

W”

is a width of said circuit board.

45. The lighting fixture apparatus of claim 43 wherein said circuit board mounts 12 LED lamps equally spaced apart from one another with a first the end-most LEDs spaced ½

inch from a first end of the circuit board and the opposite end most LED spaced ½

inch from a second end of the circuit board.

46. The lighting fixture apparatus of claim 43 wherein said circuit board mounts 6 LEDs each spaced two inches from the other with one end-most LED being spaced ½

inch from one end of the circuit board and the opposite end-most LED being spaced 1½

inches from the opposite end of the circuit board.

47. The lighting fixture apparatus of claim 40 wherein said platform has a horizontal planar surface recessed below adjacent portions of a top surface of said cover member.

48. The lighting fixture apparatus of claim 40 further comprising:

a first tongue extending from said unitary base member; and

a second single piece cover member having a second mounting platform and respective first and second side surfaces depending downwardly on opposite sides of said second platform, said first and second side surfaces of said second cover member each further including a heat sink structure;

wherein the second platform of said second cover member has first and second ends, each extending beyond a respective end of said second cover member;

a plurality of LEDs positioned above the second mounting platform of said second cover member; and

a second unitary base member having first and second elongated side rails, first and second upwardly extending end posts at respective opposite ends of said first and second elongated side rails and a second tongue extending therefrom and dimensioned to overlap said first tongue, said first and second tongues being pivotally interconnectable;

wherein the second unitary base member is shaped and dimensioned such that said second unitary cover member is installable downwardly over the mounting posts of said second cover member and attachable to said mounting posts to form an enclosure for electrical componentry of said apparatus.

49. The lighting fixture apparatus of claim 48 wherein the length of one of the tongues of said first cover member is selected to be longer than the length of an oppositely disposed tongue of said second cover member so as to position said LEDs to achieve uniformity of illumination when said first and second lighting fixture components are pivotally interconnected to one another.

50. The lighting fixture apparatus of claim 49 wherein the heat sink structure on each of said first and second side surfaces comprises a plurality of heat sink fins.

60. The lighting fixture apparatus of claim 48 further comprising:

a plurality of LEDs spaced the same selected distance apart on each respective first and second mounting platform; and

wherein

opposing ends of said first and second mounting platforms are dimensioned so as to enable spacing an end most LED on one opposing end of said first mounting surface said selected distance from an end-most LED on the opposing end of said second mounting surface.

51. Lighting fixture apparatus comprising:

a single piece cover member having a mounting platform and respective first and second side surfaces depending downwardly on opposite sides of said platform;

a plurality of LEDs positioned above said mounting platform; and

a unitary base member having first and second elongated side rails and first and second upwardly extending end posts at respective opposite ends of said first and second elongated side rails;

wherein the unitary based member is shaped and dimensioned such that said unitary cover member is installable downwardly over said end posts.

52. Apparatus comprising:

a first fixture component and a second fixture component;

a first tongue extending from the first fixture component and having a length;

a second tongue extending from the second fixture component and having a length, the first and second tongues being dimensioned to overlap one another to facilitate pivotal interconnection of said first and second components;

a first mounting surface on said first component terminating in a third tongue having a length;

a second mounting surface on said second component;

first and second circuit boards positioned above said first and second mounting surfaces respectively, said first and second circuit boards each carrying a plurality of LEDs; and

means formed at opposing ends of each of said first and second mounting surfaces for enabling spacing said LEDs so as to maintain uniformity of illumination when said first and second fixture components are pivotally interconnected to one another.

53. A method for constructing lighting fixture apparatus comprising:

fabricating first and second light fixtures each having an elongated mounting surface positioned on a top surface thereof; and

dimensioning the length of respective first and second ends of said first and second mounting surfaces to enable spacing LEDs positioned on said first and second mounting surfaces so as to enhance the uniformity of illumination provided by the LEDs.

54. The method of claim 53 further comprising:

spacing a plurality of LEDs the same selected distance apart on each respective first and second mounting surface; and

dimensioning the length of opposing ends of said first and second mounting surfaces so as to enable spacing an end most LED on one opposing end of said first mounting surface said same selected distance from an end-most LED on the opposing end of said second mounting surface.

55. The method of claim 54 wherein said step of fabricating comprises forming first and second unitary covers comprising the respective mounting surfaces of the first and second light fixtures.

56. The method of claim 55 wherein said first and second cover members are formed of die cast aluminum.