Modular architecture for sealed LED light engines

• US 8,593,044 B2
• Filed: 01/23/2011
• Issued: 11/26/2013
• Est. Priority Date: 01/26/2010
• Status: Active Grant

• Current Assignee: Signify North America Corporation (Signify N.V.)
• Original Assignee: Once Innovations Inc. (Signify N.V.)
• Inventors: Grajcar, Zdenko
• Primary Examiner(s): RALEIGH, DONALD L
• Application Number:
  US13/011,927
• Publication Number:
  US 20110193467A1
• Time in Patent Office: 1,038 Days
• Field of Search: 362/345, 36224901-24903, 362/217.01, 362/217.1, 313/113
• US Class Current: 313/113
• CPC Class Codes: F21K 9/23 Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21S 2/005 of modular construction
• CPC Class Codes: F21S 4/28 rigid, e.g. LED bars
• CPC Class Codes: F21V 17/14 Bayonet-type fastening
• CPC Class Codes: F21V 19/003 Fastening of light source holders, e.g. of circuit boards or substrates holding light sources
• CPC Class Codes: F21V 19/0055 by screwing
• CPC Class Codes: F21V 29/505 of reflectors
• 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 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 29/85 characterised by the material liquid coolants F21V29/56
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/40 Details of LED load circuits
• CPC Class Codes: H05B 45/48 having LEDs organised in strings and incorporating parallel shunting devices
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

Apparatus and associated methods involve an assembly of multiple LED light engines in which a desired number of LED lamps are mounted to a plate that forms a wall of an enclosure. In an illustrative example, three LED light engines may be mounted to a plate that may be slidably installed as a wall of an extruded housing that contains electrical connections from an AC power inlet to each light engine. In various examples, the number and layout arrangement of the LED light engines may be custom selected for a particular application.

Claims

1. A method of fabricating a light source, the method comprising:

providing a predetermined number of sealed light engine modules (SLEMs), each SLEM comprising;

a) a lamp including a lens and a body shell where the body shell is seated on a distal end of a base member and a socket cup is fitted to a proximal end of the base member and the lamp is sealed with a sealing ring that mates with the lens and body shell to substantially resist the ingress of contaminants;

b) a light emitting diode (LED) module housed within the light chamber, wherein the LED module receives electrical excitation to convert the electrical excitation into light output;

mounting the SLEMs to a support plate of a light assembly;

slidably installing the light assembly into a base; and

installing end caps onto the base to substantially contain an electrical interface of each of the mounted SLEMs.

2. The method of claim 1, further comprising making electrical connection to a pluggable socket for making connection to an excitation source.

3. The method of claim 2, further comprising performing the step of making electrical connection to the pluggable socket before performing the step of slidably installing the light assembly into the base.

4. The method of claim 1, further comprising selecting the predetermined number of SLEMs to meet a specified light output level.

5. The method of claim 1, further comprising modulating a color temperature of at least one of the SLEMs to provide a substantially smooth and continuous function of an amplitude of the electrical excitation.

6. The method of claim 1, further comprising modulating a color temperature of at least one of the SLEMs to provide a substantially smooth and continuous function of a phase modulation of the electrical excitation.

7. A light source comprising:

a predetermined number of sealed light engine modules (SLEMs), each SLEM comprising;

a) a lamp including a thermal spreader having a distally extended pocket formed in a central portion thereof that receives a LED module;

b) a lens and body shell where the lamp is sealed with a sealing ring that retains the lens against a reflector that is in thermal communication with the thermal spreader to substantially resist the ingress of contaminants; and

c) a light emitting diode (LED) module housed within the light chamber, wherein the LED module is configured to receive electrical excitation from an electrical interface and to supply conditioned electrical excitation to provide light output;

a light assembly having a support plate configured to have the SLEMs mounted thereon;

a base configured to slidably receive the light assembly; and

end caps configured to be installed onto the base to form an enclosed volume that substantially contains the electrical interface of each of the mounted SLEMs.

8. The light source of claim 7, wherein the lens is translucent.

9. The light source of claim 8, wherein the lens comprises an optical diffusive material.

10. The light source of claim 7, wherein the SLEM comprises a parabolic reflector.