LED array wafer lighting fixture

• US 7,744,256 B2
• Filed: 05/22/2006
• Issued: 06/29/2010
• Est. Priority Date: 05/22/2006
• Status: Expired due to Fees

• Current Assignee: Edison Price Lighting, Inc.
• Original Assignee: Edison Price Lighting, Inc.
• Inventors: Smester, Paul
• Primary Examiner(s): O'Shea; Sandra L
• Assistant Examiner(s): DZIERZYNSKI, EVAN P
• Application Number:
  US11/439,482
• Publication Number:
  US 20070268707A1
• Time in Patent Office: 1,499 Days
• Field of Search: 362/362, 362/357, 362/382, 362/373, 362/294
• US Class Current: 362/362
• CPC Class Codes: F21S 6/00 Lighting devices intended to be free-standing F21S9/00, F21S10/00, F21S13/12 take precedence lighting devices specially adapted to be transported from place to place, e.g. lighting devices carried on wheeled supports F21L; details of supports for lighting devices F21V21/00
• 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 8/022 intended to be recessed in a floor or like ground surface, e.g. pavement or false floor
• CPC Class Codes: F21S 8/033 the surface being a wall or like vertical structure, e.g. building facade
• CPC Class Codes: F21S 8/04 intended only for mounting on a ceiling or the like overhead structures F21S8/02 takes precedence; details of ceiling bases F21V21/03
• CPC Class Codes: F21V 19/001 the light sources being semiconductors devices, e.g. LEDs
• CPC Class Codes: F21V 19/004 by deformation of parts or snap action mountings, e.g. using clips
• CPC Class Codes: F21V 19/04 with provision for changing light source, e.g. turret auxiliary devices for cleaning, placing, or removing incandescent lamps H01K3/32, fluorescent lamps H01J9/006
• 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 7/10 Construction
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

Presented is a lighting fixture that incorporates a LED wafer, having an array of a plurality of light-emitting LEDs, as a light source. The fixture includes a holding plate having an aperture surrounded by a flange. A heat sink includes a lamp support surface facing the holding plate and positioned opposite to the aperture. The LED wafer is mounted to the lamp support surface in a manner to assure maintenance of a thermal communication. A mounting assembly secures the LED wafer to the lamp support surface and includes a mounting clip having a spring element extending from a main portion, a lamp holder block, and an insulative isolation member.

Claims

1. A lighting fixture comprising:

a holding plate including a flange defining an aperture in the holding plate;

a heat sink including a lamp support surface;

at least one mounting bracket interconnecting the heat sink to the holding plate, wherein the lamp support surface is positioned opposed to the holding plate aperture; and

an LED wafer, which includes a first surface having a plurality of light emitting LEDs, in thermal communication with the lamp support surface; and

a reflector, having a proximal end defining a first opening and a distal end defining a second opening, mechanically coupled to the holding plate flange such that a longitudinal axis between the proximal end and distal end intersects a plane containing the holding plate;

wherein the reflector has a shielding angle θ

measured with respect to a central longitudinal axis of the reflector, wherein the shielding angle is configured to produce a reflector efficiency approaching 90 percent and a visual comfort probability index approaching 100 percent.

2. The lighting fixture of claim 1, further comprising a LED wafer mounting assembly operable to secure the LED wafer to the lamp support surface, the LED wafer mounting assembly comprising:

a mounting clip having a main portion with though holes, and a spring element extending from the main portion;

a lamp holder block having through holes; and

an insulative isolation member with through holes;

wherein the mounting clip main portion secures a first edge of the LED wafer to the lamp support surface, the spring element is configured to apply pressure against the LED wafer in a direction towards the heat sink, and

wherein the lamp holder block, with the isolation member positioned between the block and the LED wafer, secures a second edge of the LED wafer to the lamp support surface.

3. The lighting fixture of claim 2, wherein the isolation member further includes a notch dimensioned so as to accept the second edge of the LED wafer.

4. The lighting fixture of claim 1, wherein the LED wafer further includes a pair of conductive contact pads, and the isolation member further includes a wiring channel, the lighting fixture further comprising:

a lamp cord including a pair of contact wires therein, each wire having a distal end coupled to a source of electrical energy, and a proximal end in electrical communication with the contact pads;

wherein a portion of the lamp cord close to the proximal end passes though the isolation member wiring channel.

5. The lighting fixture of claim 4, wherein the source of electrical energy is a LED driver unit.

6. The lighting fixture of claim 4, further comprising a complementary mating connector pair, wherein a first member of the pair is in electrical connection with the contact pads and a second member of the pair is in electrical connection with the pair of contact wires so as to achieve the electrical communication.

7. The lighting fixture of claim 6, wherein the complementary mating connector pair is formed from one of a telephone connector, a bayonet connector, a sexless connector, and a threaded connector.

8. The lighting fixture of claim 1, further comprising a junction box and a LED driver unit housing mounted on the holding plate.

9. The lighting fixture of claim 1, further comprising a rail support bracket coupled to the holding plate.

10. The lighting fixture of claim 1, further comprising a lens positioned over the LED wafer first surface.

11. The lighting fixture of claim 1, further comprising a housing enclosure attached to the holding plate, wherein the housing enclosure and holding plate form a container.

12. The lighting fixture of claim 1, wherein the lighting fixture is configured to be one of a recessed, free standing, surface mount, floor, and track lighting unit.

13. A lighting fixture comprising:

a holding plate having an outer perimeter edge and an inner perimeter edge, the inner perimeter edge defining an aperture in the holding plate;

a heat sink, which includes a lamp support surface, mechanically coupled to the holding plate, wherein the lamp support surface is positioned opposed to the holding plate aperture; and

a LED wafer, which includes a first surface having a plurality of light emitting LEDs, in thermal communication with the lamp support surface; and

a reflector, having a proximal end defining a first opening and a distal end defining a second opening, mechanically positioned within the holding plate aperture such that a longitudinal axis between the proximal end and distal end intersects a plane containing the holding plate;

wherein the reflector has a shielding angle θ

measured with respect to a central longitudinal axis of the reflector, wherein the shielding angle is configured to produce a reflector efficiency approaching 90 percent and a visual probability index approaching 100 percent.

14. The lighting fixture of claim 13, further comprising a LED wafer mounting assembly operable to secure the LED wafer to the lamp support surface, the LED wafer mounting assembly comprising:

a mounting clip having a main portion and a spring element extending from the main portion;

a lamp holder block; and

an insulative isolation member;

wherein the mounting clip main portion is configured to be mounted to the heat sink so as to secure a first edge of the LED wafer to the lamp support surface, and the spring element is configured to apply pressure against the LED wafer in a direction towards the heat sink, and

wherein the lamp holder block, with the isolation member positioned between the block and the LED wafer, is configured to be mounted to the heat sink so as to secure a second edge of the LED wafer to the lamp support surface.

15. The lighting fixture of claim 14, wherein the isolation member further includes a notch dimensioned so as to accept the second edge of the LED wafer.

16. The lighting fixture of claim 13, wherein the LED wafer further includes a pair of conductive contact pads, and the isolation member further includes a wiring channel, the lighting fixture further comprising:

a lamp cord including a pair of contact wires therein, each wire having a distal end coupled to a source of electrical energy, and a proximal end in electrical contact with the contact pads;

wherein a portion of the lamp cord close to the proximal end passes through the isolation member wiring channel.

17. The lighting fixture of claim 16, wherein the source of electrical energy is a LED driver unit.

18. The lighting fixture of claim 16, further comprising a complementary mating connector pair, wherein a first member of the pair is in electrical connection with the contact pads and a second member of the pair is in electrical connection with the pair of contact wires so as to achieve the electrical communication.

19. The lighting fixture of claim 18, wherein the complementary mating connector pair is formed from one of a telephone connector, a bayonet connector, a sexless connector, and a threaded connector.

20. The lighting fixture of claim 13, further comprising a junction box and a LED driver unit housing mounted on the holding plate.

21. The lighting fixture of claim 13, further comprising a rail support bracket mechanically coupled to the holding plate.

22. The lighting fixture of claim 13, further comprising a lens positioned over the LED wafer first surface.

23. The lighting fixture of claim 13, further comprising a housing enclosure attached to the holding plate, wherein the housing enclosure and holding plate form a container.

24. The lighting fixture of claim 13, wherein the lighting fixture is configured to be one of a recessed, free standing, surface mount, floor, and track lighting unit.