LED-based lighting system for retrofitting fluorescent lighting fixtures in a transit vehicle

• US 9,243,759 B2
• Filed: 10/22/2012
• Issued: 01/26/2016
• Est. Priority Date: 10/08/2009
• Status: Active Grant

• Current Assignee: I/O Controls Corporation
• Original Assignee: I/O Controls Corporation
• Inventors: Lin, Jerry, Wang, Yongchang
• Primary Examiner(s): Lee, Diane
• Assistant Examiner(s): Wolford, Naomi M
• Application Number:
  US13/657,605
• Publication Number:
  US 20140112014A1
• Time in Patent Office: 1,191 Days
• Field of Search: 362/217.01, 362218-219, 362478-480, 362/520, 362/223, 362/227, 362/249.02
• US Class Current: 1/1
• CPC Class Codes: B60Q 2900/10 Retrofit arrangements
• CPC Class Codes: B60Q 3/43 General lighting
• CPC Class Codes: B60Q 3/47 Circuits; Control arrangements
• CPC Class Codes: F21K 9/27 Retrofit light sources for lighting devices with two fittings for each light source, e.g. for substitution of fluorescent tubes
• CPC Class Codes: F21K 9/65 specially adapted for changing the characteristics or the distribution of the light, e.g. by adjustment of parts
• CPC Class Codes: F21K 9/69 Details of refractors forming part of the light source

Abstract

An LED-based lighting unit for retrofitting a fluorescent light fixture in a transit vehicle has a concave frame or structure conforming to the shape of the fluorescent lighting fixture cavity, connector pins on either end of the frame for secure attachment to sockets of the fluorescent fixture, a plurality of LED modules for illuminating an area of a transit vehicle, a power adapter for receiving and converting an input power supply signal, and a diffusive lens cover. The frame may have rear fins or other features for facilitating dissipation of heat generated by the LEDs. A controller adjusts the intensity of the LEDs based on a reading from a temperature sensor and on a manual brightness setting. The change in light output may be accomplished by reducing a duty cycle of a pulse width modulated (PWM) waveform supplying the LEDs.

Claims

1. An LED-based lighting unit for retrofitting a fluorescent light fixture in a transit vehicle, the LED-based lighting unit comprising:

an elongate fixture frame securably attachable within a fluorescent lighting fixture cavity of the transit vehicle, said cavity having outwardly angled opposing elongate walls, said cavity having left and right electrical sockets for supporting and providing power to a fluorescent tube light, wherein the elongate fixture frame substantially conforms to the shape of the cavity so that the elongate fixture frame fits snugly therein, the elongate fixture frame having a transverse member with outwardly angled opposing sidewalls extending from the transverse member and each forming an obtuse internal angle therewith so that the angle of each sidewall generally matches the pitch of the fluorescent lighting fixture cavity'"'"'s outwardly angled opposing elongate walls;

left and right non-conductive pins extending from the elongate fixture frame, said left and right non-conductive pins securably attaching the elongate fixture frame to the left and right sockets within the fluorescent lighting fixture cavity without making electrical connection with the electrical sockets;

a heat conductive mounting surface on the elongate fixture frame;

a plurality of light-emitting diodes (LEDs) disposed along a length of said heat conductive mounting surface, for illuminating an interior area of the transit vehicle; and

a diffusive lens cover removably attachable to an output opening of the fluorescent lighting fixture cavity.

2. An LED-based lighting unit for retrofitting a fluorescent light fixture in a transit vehicle having a fluorescent light compartment with left and right walls, said left and right walls having left and right electrical sockets capable of supporting and providing power to a fluorescent tube light, the LED-based lighting unit comprising:

a transverse frame member securably attachable within the fluorescent light compartment, wherein said transverse frame member substantially conforms to the shape of the fluorescent light compartment so that the transverse frame member fits snugly therein;

wherein said transverse frame member has a backwall portion with a top edge and a bottom edge, the transverse frame member further comprising opposing metallic sidewalls extending and outwardly angled from the top and bottom edges respectively of the backwall, each of the opposing metallic sidewalls forming an obtuse internal angle with the backwall so as to conform to the angle of the fluorescent lighting fixture cavity'"'"'s outwardly angled opposing elongate walls;

left and right endpieces disposed at either end of the transverse frame member and adapted to be placed in the left and right electrical sockets of the fluorescent light compartment without making electrical connection therewith; and

a plurality of light-emitting diodes (LEDs) mounted to the backwall portion of the transverse frame member and disposed between the outwardly angled sidewalls of the transverse frame member.

3. The LED-based lighting unit of claim 2, wherein the fluorescent light compartment has outwardly flared walls creating a concave opening generally parabolic in cross-sectional shape, and wherein the opposing metallic sidewalls of the transverse frame member are outwardly angled to substantially flushly align with the flared walls of the fluorescent light compartment.

4. The LED-based lighting unit of claim 3, further comprising at least one LED strip containing the plurality of LEDs.

5. The LED-based lighting unit of claim 3, further comprising a series of LED strips containing the plurality of LEDS, wherein the series of LED strips are aligned end-to-end along a linear axis of the transverse frame member.

6. The LED-based lighting unit of claim 2, wherein the opposing metallic sidewalls extending from the top and bottom edges respectively of the backwall are of a vertical height greater than the vertical height of the LEDs, as measured perpendicularly from a front surface of the backwall portion of the transverse frame member.

7. The LED-based lighting unit of claim 6, further comprising at least one LED strip containing the plurality of LEDs.

8. The LED-based lighting unit of claim 6, further comprising a series of LED strips containing the plurality of LEDS, wherein the series of LED strips are aligned end-to-end along a linear axis of the transverse frame member.

9. The LED-based lighting unit of claim 2, wherein said left and right endpieces are semi-elliptical in shape so as to substantially conform to the shape of the fluorescent light compartment.

10. The LED-based lighting unit of claim 9, further comprising at least one LED strip containing the plurality of LEDs.

11. The LED-based lighting unit of claim 9, further comprising a series of LED strips containing the plurality of LEDS, wherein the series of LED strips are aligned end-to-end along a linear axis of the transverse frame member.

12. The LED-based lighting unit of claim 2, further comprising a power cable for providing power to the LEDs.

13. The LED-based lighting unit of claim 2, further comprising control electronics providing a plurality of driving signals to the LEDs, said control electronics comprising:

a power converter for generating a lower power level from an incoming power signal from a power bus of the transit vehicle; and

a microcontroller in communication with a brightness control driver.

14. The LED-based lighting unit of claim 13, further comprising a temperature sensor, wherein the temperature sensor measures ambient temperature and provides a temperature output signal to the microcontroller.

15. The LED-based lighting system of claim 14, wherein the temperature output signal is based on a comparison of the ambient temperature to at least one temperature threshold.

16. The LED-based lighting system of claim 15, wherein the temperature output signal varies in discrete steps based on a comparison of the ambient temperature to a plurality of temperature thresholds.

17. The LED-based lighting unit of claim 13, wherein the microcontroller outputs a brightness command signal to the brightness control driver.

18. The LED-based lighting unit of claim 13, wherein the control electronics comprise a manual brightness control interface, said manual brightness control interface providing a brightness level signal to the brightness control driver.

19. The LED-based lighting unit of claim 18, wherein the manual brightness control has several discrete settings, each discrete setting corresponding to a selected brightness level.

20. The LED-based lighting unit of claim 18, wherein the manual brightness control has four discrete settings, each discrete setting corresponding to a selected brightness level.

21. The LED-based lighting unit of claim 20, wherein the four discrete settings correspond to 100%, 70%, 50% and 30% of maximum LED brightness, respectively.

22. The LED-based lighting unit of claim 2, further comprising:

a plurality of heat-dissipating fins integrally formed with the backwall portion of the transverse frame member.

23. The LED-based lighting unit of claim 22, wherein the plurality of heat-dissipating fins form a groove for placement of a power cable.

24. An LED-based lighting unit for retrofitting a fluorescent light fixture in a transit vehicle having a concave fluorescent light compartment with a generally parabolic cross section, the concave fluorescent light compartment having left and right walls with respective left and right electrical sockets capable of supporting and providing power to a fluorescent tube light, the LED-based lighting unit comprising:

a transverse frame member securably attachable within the concave fluorescent light compartment, wherein said transverse frame member substantially conforms to the cross-sectional shape of the fluorescent light compartment to fit snugly therein, said transverse frame member having a backwall portion with a top edge and a bottom edge running along a lengthwise axis thereof, the transverse frame member further comprising opposing metallic sidewalls extending and outwardly angled from the top and bottom edges respectively of the backwall to lie substantially flush within the concave fluorescent light compartment to form a seal therewith;

a plurality of light-emitting diodes (LEDs) disposed along the backwall portion of the transverse frame member and between the outwardly angled sidewalls of the transverse frame member; and

a diffusive lens cover removably attachable to an opening of the fluorescent light compartment, wherein the diffusive lens cover is positioned such that light from the LEDs passes through the diffusive lens cover.

25. The LED-based lighting unit of claim 24, wherein the fluorescent light compartment has flared sidewalls creating a cavity that is generally parabolic in cross-sectional shape, and wherein the opposing metallic sidewalls of the transverse frame member are outwardly angled to substantially flushly align with the flared walls of the fluorescent light compartment.

26. The LED-based lighting unit of claim 25, wherein the diffusive lens cover is positioned between 1.5 to 2.0 inches from the LEDs.

27. The LED-based lighting unit of claim 26, further comprising at least one LED strip containing the plurality of LEDs, said at least one LED strip being mounted to said backwall portion of the transverse frame member.

28. The LED-based lighting unit of claim 26, further comprising a series of LED strips containing the plurality of LEDS, wherein the series of LED strips are aligned end-to-end on said backwall portion along the lengthwise axis of the transverse frame member.

29. The LED-based lighting unit of claim 24, wherein the opposing metallic sidewalls extending from the top and bottom edges respectively of the backwall are of a vertical height greater than the vertical height of the LEDs, as measured perpendicularly from a front mounting surface of the backwall portion of the transverse frame member.

30. The LED-based lighting unit of claim 29, wherein the diffusive lens cover is positioned 1.5 to 2.0 inches from the LEDs.

31. The LED-based lighting unit of claim 30, further comprising at least one LED strip containing the plurality of LEDs, said at least one LED strip being mounted to said backwall portion of the transverse frame member.

32. The LED-based lighting unit of claim 30, further comprising a series of LED strips containing the plurality of LEDS, wherein the series of LED strips are aligned end-to-end on said backwall portion along the lengthwise axis of the transverse frame member.

33. The LED-based lighting unit of claim 24, further comprising left and right endpieces connected to either end of the transverse frame member and adapted to connect to the left and right sockets respectively of the right and left walls of the fluorescent light compartment, the left and right endpieces being generally parabolic in shape so as to substantially conform to the cross-sectional shape of the concave fluorescent light compartment.

34. The LED-based lighting unit of claim 33, further comprising a series of LED strips containing the plurality of LEDS, wherein the series of LED strips are aligned end-to-end on said backwall portion along the lengthwise axis of the transverse frame member.

35. The LED-based lighting unit of claim 33, further comprising a foam sealant around the outer edges of the left and right endpieces forming a seal between the concave fluorescent light compartment and each of the left and right endpieces.

36. The LED-based lighting unit of claim 24, wherein the diffusive lens cover bows outwardly from the opening of the concave fluorescent light compartment, and comprises integral tab portions adapted to interlock with mating slots running along either side of the opening the concave fluorescent light compartment.