LED luminaire

• US 7,939,837 B2
• Filed: 12/05/2008
• Issued: 05/10/2011
• Est. Priority Date: 10/09/2003
• Status: Expired due to Fees

• Current Assignee: Permlight Products Inc
• Original Assignee: Permlight Products Inc
• Inventors: Lynch, Manuel, Fraitag, Leonard
• Primary Examiner(s): HO, TU TU V
• Application Number:
  US12/315,766
• Publication Number:
  US 20090086488A1
• Time in Patent Office: 886 Days
• Field of Search: 257/88, 257/E33.054, 257/E33.057, 257/E33.075, 362/612, 362/218, 362/219, 362/249
• US Class Current: 257/88
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21S 4/10 with light sources attached to loose electric cables, e.g. Christmas tree lights
• CPC Class Codes: F21S 8/024 intended to be recessed in a wall or like vertical structure, e.g. building facade
• CPC Class Codes: F21S 8/035 by means of plugging into a wall outlet, e.g. night light
• CPC Class Codes: F21V 11/00 Screens not covered by groups F21V1/00, F21V3/00, F21V7/00 or F21V9/00 characterised by cooling arrangements F21V29/502
• CPC Class Codes: F21V 19/001 the light sources being semiconductors devices, e.g. LEDs
• CPC Class Codes: F21V 23/007 enclosed in a casing
• CPC Class Codes: F21V 23/0442 activated by means of a sensor, e.g. motion or photodetectors
• CPC Class Codes: F21V 23/0471 the sensor detecting the proximity, the presence or the movement of an object or a person
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 33/006 General building constructions or finishing work for buildings, e.g. roofs, gutters, stairs or floors; Garden equipment; Sunshades or parasols
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/3025 Electromagnetic shielding
• CPC Class Codes: H02G 3/20 Ceiling roses or other lighting sets

Abstract

A modular light emitting diode (LED) mounting configuration is provided including a light source module having a plurality of pre-packaged LEDs arranged in a serial array. The module is connected to a heat dissipating plate configured to mount to an electrical junction box. Thus, heat from the LEDs is conducted to the heat dissipating plate and to the junction box. A sensor is configured to detect environmental parameters and a driver is configured to illuminate the LEDs in response to the environmental parameters, thereby selectively configuring the LEDs to function in a wide variety of useful applications.

Claims

1. A lighting apparatus, comprising:

a light emitting diode (LED) module having;

at least one LED;

a heat conductive base having opposing first and second sides, and having first and second apertures formed therethrough;

a dielectric member disposed on the first side of the base; and

a plurality of electrically conductive contacts disposed on the dielectric member, the contacts configured to mount the at least one LED so that an electrical current path is defined between a first contact and a second contact, and the at least one LED is disposed along the current path;

a heat conductive member having a first side and a second side, the heat conductive member having first, second and third apertures formed therethrough and having a mount surface defined on the first side;

a power driver adapted to receive an electrical input power, condition the power to a desired power configuration, and output conditioned power between first and second nodes;

wherein the LED module is attached to the mount surface on the first side of the heat conductive member so that the second side of the heat conductive base enagages the mount surface and the power driver is disposed on or adjacent the second side of the heat conductive member so that the heat conductive member is sandwiched between the LED module and the power driver, the base arranged on the heat conductive member so that the first and second apertures of the base are aligned with the first and second a apertures, respectively, of the heat conductive member, and the third aperture of the heat conductive member is spaced from the LED module;

a first elongate conductive member extending from the first node through the aligned first apertures of the base and heat conductive member and being electrically connected to the first contact of the LED module; and

a second elongate conductive member extending from the second node through the aligned second apertures of the base and heat conductive member and being electrically connected to the second contact of the LED module;

wherein the driver is electrically connected to the LED module so that conditioned power is supplied across the first and second contacts.

2. The lighting apparatus of claim 1 additionally comprising a heat sink having a mount aperture, the heat conductive member third aperture being aligned with the heat sink mount aperture, and a fastener engaging the apertures to secure the heat conductive member to the heat sink.

3. The lighting apparatus of claim 2, wherein the heat sink comprises a plurality of side walls, and the heat conductive member and heat sink side walls together define a cavity, and wherein the driver is disposed in the cavity.

4. The lighting apparatus of claim 3, wherein the heat sink additionally comprises a back wall configured to enclose the cavity.

5. The lighting apparatus of claim 3 additionally comprising an opening formed through at least on of the heat sink side walls, and a power supply wire extends through the opening and connects to the driver so as to supply electric power to the driver.

6. The lighting apparatus of claim 3, wherein the heat sink side walls define a front periphery, and the heat sink front periphery abuts the second side of the heat conductive member.

7. The lighting apparatus of claim 6, wherein the heat sink comprises a secondary mount member configured to attach the heat sink to a structure.

8. The lighting apparatus of claim 6 additionally comprising a second heat sink connected to the heat conductive member so as to abut the first side of the heat conductive member.

9. The lighting apparatus of claim 8, wherein the second heat sink comprises a hood generally aligned with the LED module and adapted to direct light from the LED module in a desired direction.

10. A lighting apparatus, comprising:

a light emitting diode (LED) module having;

at least one LED;

a heat conductive base

a dielectric member disposed on a first side of the base; and

a plurality of electrically conductive contacts disposed on the dielectric member, the contacts configured to mount the at least one LED so that an electrical current path is defined between a first contact and a second contact, and the at least one LED is disposed along the current path;

a first heat sink having opposing first and second sides, the first heat sink having first and second spaced apart apertures formed therethrough and having a mount surface defined on the first side;

a power driver adapted to receive an electrical input power, condition the power to a desired power configuration, and output conditioned power between first and second nodes;

wherein the LED module is attached to the mount surface on the first side of the first heat sink so that a second side of the LED module heat conductive base engages the mount surface, and the power driver is disposed on or adjacent the second side of the first heat sink;

a second heat sink attached to the first heat sink, the first and second heat sinks cooperating to define a cavity having front and side surfaces, the power driver being disposed in the cavity;

a first elongate conductive member extending from the first node through the first aperture in the first heat sink and being electrically connected to the first contact of the LED module; and

a second elongate conductive member extending from the second node through the second aperture in the first heat sink and being electrically connected to the second contact of the LED module;

wherein the driver is electrically connected to the LED module so that conditioned power is supplied across the first and second contacts.

11. The lighting apparatus of claim 10, wherein the heat conductive base has first and second spaced apart apertures that are aligned with the first and second apertures, respectively, of the first heat sink, and wherein first and second elongate fasteners extend through respective first and second apertures to secure the LED module to the first heat sink, the first and second fasteners engaging respective first and second contacts of the LED module and being electrically spaced from the first heat sink.

12. The lighting apparatus of claim 10, wherein the second heat sink comprises at least one opening formed through a wall thereof so as to provide access to the cavity, and a power supply wire extends through the opening.

13. The lighting apparatus of claim 10 additionally comprising a third heat sink attached to the first side of the first heat sink about the periphery of the LED module, the third heat sink comprising a hood configured to direct light from the LED module in a desired direction.