Prismatic LED module for luminaire

• US 8,888,320 B2
• Filed: 01/22/2013
• Issued: 11/18/2014
• Est. Priority Date: 01/27/2012
• Status: Active Grant

• Current Assignee: Hubbell Lighting Incorporated (Hubbell, Inc.)
• Original Assignee: Hubbell, Inc.
• Inventors: Lueken, Thomas Carl, Neuer, Michael Scott, Chen, Zhijie, Butteris, Jamey, Hill, Ezekial Thomas
• Primary Examiner(s): Husar, Stephen F
• Assistant Examiner(s): CRANSON JR, JAMES W
• Application Number:
  US13/747,033
• Publication Number:
  US 20130208471A1
• Time in Patent Office: 665 Days
• Field of Search: 362/235, 362/294, 362/329
• US Class Current: 362/235
• 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: F21K 9/20 Light sources comprising attachment means
• CPC Class Codes: F21V 17/04 the fastening being onto or by the light source
• CPC Class Codes: F21V 29/763 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21V 5/02 of prismatic shape F21V5/04 takes precedence
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

An LED module for a luminaire has a downwardly directed heat sink comprising cooling fins that extend rearward from the module'"'"'s front end and downward from its top wall, which has a top face that abuts the underside of a luminaire carrier plate. A circuit board carrying at least one LED is mounted on the front face, and a prism is mounted to the heat sink over the LED(s). The front (light-emitting) face of the catadioptric prism has several prominent side-by-side sections which emit beam patterns that diverge laterally and overlap in a central region. A prominent full-width upper section on the front face emits a primarily downwardly directed beam pattern to help fill in dark spots.

Claims

1. An LED lighting module for installation on the underside of a luminaire carrier plate comprising:

a metallic heat sink including;

a front end having a front face,

a top wall extending rearward from said front end and having a top face for abutting the underside of the carrier plate, and

a plurality of cooling fins extending rearward from said front end and downward from said top wall;

a circuit board mounted on said front face and carrying at least one LED; and

a prism mounted to said heat sink over said at least one LED.

2. The lighting module of claim 1, wherein said heat sink is integrally formed as one piece.

3. The lighting module of claim 2, wherein said top face is disposed at an acute angle to said front face.

4. The lighting module of claim 2, wherein said top wall has at least one opening for accommodating a fastener for securing the module to a carrier plate.

5. The lighting module of claim 4, further comprising an upwardly projecting locating stud integral with said top wall for engaging a hole or a recess in the carrier plate.

6. The lighting module of claim 2, further comprising a sealing gasket between said prism and said front face and surrounding said circuit board.

7. The lighting module of claim 6, wherein said prism comprises a hollow mounting base having a flange surrounding said circuit board.

8. The lighting module of claim 2, wherein said cooling fins taper in height from said front end rearward.

9. The lighting module of claim 2, wherein said top wall is devoid of cooling fins above said top face.

10. The lighting module of claim 2, wherein said at least one LED comprises four aligned LEDs arranged in two laterally spaced pairs.

11. The lighting module of claim 10, wherein said prism comprises a rear face having four aligned pockets arranged in two laterally spaced pairs, each pocket cradling a respective LED.

12. A luminaire comprising a carrier plate and a plurality of lighting modules according to claim 2 mounted against the underside of the carrier plate.

13. A catadioptric prism for shaping and directing light emitted by an even number of aligned, laterally spaced LEDs having a transparent body with a fore-and-aft medial vertical plane and comprising:

a rear light-receiving face;

a front light-emitting face;

a top face;

a bottom face; and

two side faces,

said front face including;

a prominent lower section on each side of said medial vertical plane, each lower section having a substantially vertical front and substantially vertical curved sides and that merge with said front;

a prominent middle section above each lower section, the width of each middle section being greater than its height, each middle section having a substantially horizontal rounded face and rounded ends that merge with said rounded face; and

a prominent upper section above both of said middle sections, said upper section having a downwardly and forwardly slanted surface, and

said rear face including a convex cradle section on each side of said medial vertical plane, each cradle section having at least one pocket behind said middle section of said front face for cradling an LED, said pockets being symmetrically disposed on opposite sides of said medial vertical plane.

14. The catadioptric prism of claim 13, wherein the prism is bilaterally symmetrical about said medial vertical plane.

15. The catadioptric prism of claim 14, wherein said lower sections and said middle sections have substantially the same width.

16. The catadioptric prism of claim 15, wherein said lower sections meet at said medial vertical plane and extend laterally to their respective adjacent side faces, said middle sections meet at said medial vertical plane and extend laterally to their respective adjacent side faces, and said upper section extends completely to both of said side faces.

17. The catadioptric prism of claim 16, wherein the front of each of said lower sections is substantially flat.

18. The catadioptric prism of claim 17, wherein the radius of curvature of the rounded face of each of said middle sections diminishes toward the most prominent part thereof.

19. The catadioptric prism of claim 18, wherein said slanted surface of said upper section of said front face comprises a brow portion that is more steeply sloped than the portion above it.

20. The catadioptric prism of claim 19, wherein said at least one pocket comprises two laterally aligned pockets in each cradle section.

21. The catadioptric prism of claim 20, wherein said top face, said bottom face and said side faces are substantially flat.

22. The catadioptric prism of claim 21, further comprising an integral, substantially rectangular base having a rearwardly projecting peripheral flange for surrounding a printed circuit board on which the LEDs are mounted.

23. The catadioptric prism of claim 14, wherein said at least one pocket comprises two laterally aligned pockets in each cradle section.

24. The catadioptric prism of claim 23, wherein said slanted surface of said upper section of said front face comprises a brow portion that is more steeply sloped than the portion above it.

25. The catadioptric prism of claim 24, wherein during use said lower sections and said middle sections emit beam patterns that diverge laterally and overlap in a central region, and said upper section emits a primarily downwardly directed beam pattern.