Recessed can downlight retrofit illumination device

• US 9,447,935 B2
• Filed: 01/08/2015
• Issued: 09/20/2016
• Est. Priority Date: 11/10/2010
• Status: Active Grant

• Current Assignee: LEDVANCE LLC (MLS Co. Ltd.)
• Original Assignee: TerraLUX Incorporated
• Inventors: Catalano, Anthony W.
• Primary Examiner(s): Husar, Stephen F
• Application Number:
  US14/592,422
• Publication Number:
  US 20150143773A1
• Time in Patent Office: 621 Days
• US Class Current: 1/1
• 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 19/004 by deformation of parts or snap action mountings, e.g. using clips
• CPC Class Codes: F21V 21/04 Recessed bases
• 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 23/001 the elements being electrical wires or cables
• CPC Class Codes: F21V 23/006 the substrate being distinct from the light source holder
• CPC Class Codes: F21V 23/0442 activated by means of a sensor, e.g. motion or photodetectors
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 29/503 of light sources cooling arrangements structurally associated with gas-discharge or vapour-discharge lamps H01J61/52; cooling arrangements structurally associated with electric incandescent lamps H01K1/58; cooling arrangements structurally associated with light-emitting diodes H01L33/64
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 47/105 in response to determined parameters
• CPC Class Codes: H05B 47/115 by determining the presence or movement of objects or living beings
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

In various embodiments, an illumination device includes driver and LED lighting modules collectively sized to fit within a recessed-can lighting fixture constructed for use with incandescent or halogen bulbs, thereby facilitating LED changeover without removal and replacement of the fixture.

Claims

1. A method of upgrading an illumination device disposed at least partially within a recessed-can lighting fixture, the fixture being associated with an outlet electrically connected to a source of power, the method comprising:

connecting to the outlet a discrete driver module comprising (i) circuitry for supplying power to and controlling at least one light-emitting diode and (ii) a connector compatible with the outlet; and

after connecting the driver module to the outlet, mounting within the recessed-can fixture a discrete lighting module configured to operatively couple the driver module to at least one light-emitting diode; and

electrically connecting the lighting module to the driver module such that the lighting module is electrically connected to and otherwise physically separate from the driver module.

2. The method of claim 1, wherein the lighting module comprises a temperature sensor for measuring a temperature of the at least one light-emitting diode.

3. The method of claim 2, wherein the driver module comprises circuitry for controlling current flow to the at least one light-emitting diode based on the measured temperature.

4. The method of claim 1, wherein the outlet comprises a socket for an incandescent or halogen light bulb.

5. The method of claim 1, wherein the source power comprises power mains of a building.

6. The method of claim 5, wherein the power mains operate at a voltage selected from the range of 120 volts to 277 volts.

7. The method of claim 1, wherein at least one of the outlet or the source of power comprises at least one of an electrical conduit or an electrical junction box.

8. The method of claim 1, wherein the recessed-can lighting fixture comprises at least one of a reflector or an electrical junction box therewithin.

9. The method of claim 1, wherein the lighting module comprises at least one of a heat sink or an active cooling element.

10. The method of claim 1, wherein an electrical cable electrically connects the driver module and the lighting module.

11. The method of claim 10, wherein the electrical cable is the only physical connection between the driver module and the lighting module.

12. The method of claim 10, wherein the electrical cable provides substantially no physical support to the lighting module.

13. The method of claim 10, wherein the electrical cable is detachable from the driver module and the lighting module, thereby enabling replacement of the electrical cable with a different electrical cable.

14. The method of claim 10, wherein the lighting module is detachable from the electrical cable, thereby enabling replacement of the lighting module with a second lighting module different from the lighting module.

15. The method of claim 1, wherein, after the lighting module is mounted, the driver module is not in contact with a heat sink.

16. The method of claim 1, wherein at least one of the lighting module or the driver module comprises an ambient temperature sensor.

17. The method of claim 16, wherein at least one of the lighting module or the driver module comprises thermal control circuitry configured to provide over-temperature protection to the at least one light-emitting diode based at least in part on the ambient temperature.

18. The method of claim 17, wherein the thermal control circuitry is configured to reduce power supplied to the at least one light-emitting diode based at least in part on the ambient temperature.

19. The method of claim 17, wherein (i) the lighting module comprises an active cooling element, and (ii) the thermal control circuitry is configured to control the active cooling element based at least in part on the ambient temperature.

20. The method of claim 1, wherein the lighting module lacks circuitry for supplying power to and controlling the at least one light-emitting diode.

21. The method of claim 1, wherein the driver module and the lighting module collectively fit within the recessed-can lighting fixture.

22. An illumination device comprising:

a discrete driver module comprising (i) circuitry for supplying power to and controlling at least one light-emitting diode, and (ii) a connector for connecting to a source of power;

a discrete lighting module configured for electrical connection to but otherwise physically separate from the driver module, the lighting module comprising (i) a mechanism for mounting the lighting module within a recessed-can lighting fixture; and

(ii) an electrical cable electrically connecting the driver module and the lighting module, the lighting module configured to operatively couple the driver module to at least one light emitting diode;

wherein (i) the driver module and the lighting module are collectively sized to fit within the recessed-can lighting fixture and (ii) the electrical cable is the only physical connection between the driver module and the lighting module.

23. A method of upgrading an illumination device disposed at least partially within a recessed-can lighting fixture comprising an outlet electrically connected to a source of power, the method comprising:

connecting to the outlet a discrete driver module comprising (i) circuitry for supplying power to and controlling at least one light-emitting diode and (ii) a connector compatible with the outlet; and

mounting within the recessed-can fixture a discrete lighting module (i) electrically connected to and otherwise physically separate from the driver module and (ii) configured to operatively couple the driver module to at least one light-emitting diode;

wherein (i) the driver module and the lighting module collectively fit within the recessed-can lighting fixture, (ii) an electrical cable electrically connects the driver module and the lighting module, and (iii) the electrical cable is the only physical connection between the driver module and the lighting module.