LED replacement lamp and a method of replacing preexisting luminaires with LED lighting assemblies

• US 8,256,919 B2
• Filed: 12/02/2009
• Issued: 09/04/2012
• Est. Priority Date: 12/03/2008
• Status: Active Grant

• Current Assignee: Signify Holding B.V. (Signify N.V.)
• Original Assignee: Illumination Management Solutions Incorporated (Eaton Corporation PLC.)
• Inventors: Holder, Ronald, Rhoads, Greg
• Primary Examiner(s): Philogene, Haiss
• Application Number:
  US12/629,461
• Publication Number:
  US 20100134046A1
• Time in Patent Office: 1,007 Days
• Field of Search: 362/217.02, 362/227, 362/240, 362/249.02, 362/289, 362/311.02, 362/335, 362543-545, 362/640, 362/800, 315/149, 315/291, 315/297, 315/294, 315/312, 315/169.1, 257/79, 257/82, 372/98, 372/99
• US Class Current: 362/227
• 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: F21V 19/001 the light sources being semiconductors devices, e.g. LEDs
• 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 23/00 Arrangement of electric circuit elements in or on lighting devices characterised by cooling arrangements F21V29/508
• 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 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/763 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21W 2131/103 of streets or roads
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2113/00 Combination of light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/357 specially adapted for retrofit LED light sources
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

A lighting apparatus for retrofitting an existing luminaire includes a plurality of light emitting diodes (LED) of similar or differing wavelengths arranged and configured in at least one light bar array, a heat sink module thermally coupled to the at least one light bar array, an electronic power module electrically coupled to the at least one light bar array, and a plate coupled to the at least one light bar array, electronic power module and the heat sink module, the plate arranged and configured for coupling to the luminaire to provide quick and easy installation and replacement of the at least one light bar array, heat sink module and electronic power module into and from the luminaire.

Claims

1. A lighting apparatus capable of retrofitting an existing luminaire comprising:

a plurality of light emitting diodes (LED) arranged and configured in at least one light bar array;

an electronic power module electrically coupled to the at least one light bar array; and

a plate coupled to the at least one light bar array, the plate arranged and configured to couple to the luminaire

wherein the luminaire has a preexisting opening through which light is provided;

wherein the plate comprises a shaped plate that fits in the preexisting opening of the luminaire, the plate including a recessed cavity to accommodate the at least one light bar array; and

wherein the recessed cavity reduces light pollution from the light emitted by the at least one light bar array.

2. The lighting apparatus of claim 1 further comprising at least one heat sink thermally coupled to the at least one light bar array.

3. The lighting apparatus of claim 2 further comprising a plurality of heat sinks and a plurality of light bars coupled to the plate.

4. The lighting apparatus of claim 1 where the at least one light bar array is thermally coupled to the luminaire, which serves as a heat sink for the at least one light bar array.

5. The lighting apparatus of claim 1 where the existing luminaire comprises a Cobra Head luminaire.

6. The lighting apparatus of claim 1 where the existing luminaire is originally provided with a conventional non-LED light source, which is removed from the luminaire and replaced in situ by the at least one light bar array, at least one heat sink module thermally coupled to at least one of the at least one light bar array, electronic power module and plate without mechanical or electrical redesign or modification of the luminaire.

7. The lighting apparatus of claim 1, wherein the reduced light pollution satisfies the Dark Sky Initiative.

8. The lighting apparatus of claim 1 where the recessed cavity in the plate comprises a recess formed in plate selected from the group consisting of a stamped shaped plate and a die cast plate.

9. The lighting apparatus of claim 1 where the luminaire includes existing mounting features, where the plate includes a perimeter and where the perimeter of the plate is formed and cut to fit the existing mounting features of the luminaire.

10. The lighting apparatus of claim 2 where the plate has a backside, the luminaire has an interior cavity, and the heat sink module comprises a heat sink coupled to the backside of the plate to transfer heat generated from the LEDs into the interior cavity of the luminaire.

11. The lighting apparatus of claim 3 where the plate is thermally coupled to the luminaire and where heat is transferred from the light bars through the plate into the luminaire.

12. The lighting apparatus of claim 1 further comprising one or more controls selected from the group consisting of dimming controls, color controls, and outdoor lighting controls.

13. The lighting apparatus of claim 1, wherein the plate further comprises a bordering peripheral shield, wherein the bordering peripheral shield is defined by the recessed cavity.

14. The lighting apparatus of claim 13, wherein light emitted by the plurality of light emitting diodes in a direction above a horizon are blocked by the bordering peripheral shield.

15. A method of retrofitting an existing luminaire comprising:

providing a plurality of light emitting diodes (LED) arranged and configured in at least one light bar array, a heat sink module thermally coupled to the at least one light bar array, an electronic power module electrically coupled to the at least one light bar array, and a plate coupled to the at least one light bar array and the heat sink module, the plate arranged and configured for coupling to the luminaire, the at least one light bar array, heat sink, and plate being combined into an LED assembly configured to be coupled to the luminaire and electrically coupled thereto wherein the luminaire has a preexisting opening through which light is provided and wherein the plate comprises a shaped plate that fits in the preexisting opening of the luminaire, the plate including a recessed cavity to accommodate the at least one light bar array and wherein the recessed cavity reduces light pollution from the light emitted by the plurality of LEDs;

removing a preexisting light source from the luminaire including any protective glass coverings and lenses; and

coupling the LED assembly to the luminaire without any other modification of the luminaire.

16. The method of claim 15 where removing the preexisting light source and installing the LED assembly is performed in situ without mechanical or electrical redesign or modification of the luminaire.

17. The method of claim 15 where the luminaire includes preexisting mounting features, where the plate includes a perimeter, and where installing the LED assembly in or on the luminaire without any other modification of the luminaire comprises forming and cutting the perimeter of the plate to fit the preexisting mounting features of the luminaire.

18. The method of claim 15 where the plate has a backside, the luminaire has an interior cavity, and the heat sink module comprises a heat sink extrusion coupled to the backside of the plate, further comprising generating heat from the LEDs and transferring heat generated from the LEDs into the interior cavity of the luminaire through the heat sink extrusion.

19. The method of claim 15 further comprising removing any protective covering from the luminaire.

20. The method of claim 15, wherein the reduced light pollution from the LED assembly complies with the Dark Sky Initiative.

21. A lighting module capable of retrofitting an existing luminaire comprising:

a first plurality of light emitting diodes (LED) arranged into planar array of LEDs; and

a plate coupled to the planar array of LEDs, the plate configured to couple to the luminaire, the plate comprising a recessed cavity to accommodate the planar array of LEDs and a bordering peripheral shield comprising an inner perimeter defined by the cavity, wherein the bordering peripheral shield blocks a portion of the light emitted by the first plurality of LEDs to reduce light pollution from the light emitted by the first plurality of LEDs.