Light emitting diode recessed light fixture

• US 7,959,332 B2
• Filed: 09/22/2008
• Issued: 06/14/2011
• Est. Priority Date: 09/21/2007
• Status: Active Grant

• Current Assignee: Signify Holding B.V. (Signify N.V.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Tickner, Jerold, Wegner, Scott David, Thompson, Evans Edward III
• Primary Examiner(s): Sember; Thomas M
• Application Number:
  US12/235,116
• Publication Number:
  US 20090086476A1
• Time in Patent Office: 995 Days
• Field of Search: 362/235, 362/249.02, 362/294, 362/373, 362/347, 362/350, 362364-365, 362/368, 362/345
• US Class Current: 362/373
• 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 8/026 intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling
• 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 21/04 Recessed bases
• CPC Class Codes: F21V 21/048 Mounting arrangements for fastening lighting devices to false ceiling frameworks
• CPC Class Codes: F21V 23/009 the casing being inside the housing of the lighting device
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/75 with fins or blades having different shapes, thicknesses or spacing
• CPC Class Codes: F21V 29/78 with helically or spirally arranged fins or blades
• CPC Class Codes: F21V 7/09 with a combination of different curvatures
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/382 with galvanic isolation between input and output
• CPC Class Codes: H05B 47/185 via power line carrier transmission

Abstract

A recessed light fixture includes an LED module, which includes a single LED package that is configured to generate all light emitted by the recessed light fixture. For example, the LED package can include multiple LEDs mounted to a common substrate. The LED package can be coupled to a heat sink for dissipating heat from the LEDs. The heat sink can include a core member from which fins extend. Each fin can include one or more straight and/or curved portions. A reflector housing may be coupled to the heat sink and configured to receive a reflector. The reflector can have any geometry, such as a bell-shaped geometry including two radii of curvature that join together at an inflection point. An optic coupler can be coupled to the reflector housing and configured to cover electrical connections at the substrate and to guide light emitted by the LED package.

Claims

1. A recessed lighting fixture, comprising:

a substantially can-shaped recess housing defining an opening; and

a light emitting diode (“

LED”

) downlight module mounted within the housing, the LED module comprising;

a single LED package that generates substantially all light emitted by the recessed lighting fixture through the opening, the single LED package comprising a plurality of LEDs mounted to a common substrate;

a heat sink comprising a plurality of fins extending radially around a core to which the LED package is mounted;

a member disposed substantially between a top side of the heat sink and a top interior surface of the housing, the member comprising a profile that substantially corresponds to an interior profile of the housing such that the member and the top interior surface of the housing define an area for wire connections in the housing, between a top side of the member opposite the heat sink and the top interior surface of the housing;

a reflector housing coupled to the heat sink and disposed adjacent a bottom side of the heat sink such that the heat sink is disposed substantially between the reflector housing and the member; and

a reflector disposed substantially within the reflector housing and configured to reflect at least a portion of the light generated by the LED package through the opening.

2. The recessed lighting fixture of claim 1, further comprising a pair of torsion springs coupled to opposite sides of the LED downlight module, each torsion spring comprising an end that extends through an opening of the housing, thereby coupling the torsion spring to the housing.

3. The recessed lighting fixture of claim 1, wherein the LEDs in the LED package are arranged in an area having one of (a) a diameter of less than two inches, and (b) a length of less than two inches and a width of less than two inches.

4. The recessed lighting fixture of claim 1, wherein each fin transfers heat from the LED package along a path from the LED package to the fin and from the fin to a surrounding environment.

5. The recessed lighting fixture of claim 4, wherein at least a portion of the heat from the LED package is dissipated between at least a portion of the fins.

6. The recessed lighting fixture of claim 1, further comprising a bracket coupled to the first side of the member and configured to receive an Edison base adapter and an Edison base socket.

7. The recessed lighting fixture of claim 1, further comprising an optical member positioned around at least a portion of the LED package and configured to:

cover at least one electrical connection at the substrate, and

guide light emitted by the LED package.

8. The recessed lighting fixture of claim 7, wherein the optical member comprises a segment that defines a channel through which light emitted by the LED package is guided.

9. The recessed lighting fixture of claim 1, wherein the interior profile of the housing is substantially circular, and the member comprises a substantially circular plate.

10. The recessed lighting fixture of claim 1, wherein the LED downlight module further comprises a trim member disposed along a bottom edge of the opening.

11. The recessed lighting fixture of claim 1, wherein the LED package is substantially centrally positioned along a horizontal plane within the housing.