Integrated linear light engine

• US 9,482,396 B2
• Filed: 03/01/2013
• Issued: 11/01/2016
• Est. Priority Date: 11/08/2012
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Dixon, Mark Edward, Durkee, John, Medendorp, Nicholas W. Jr., Pickard, Paul Kenneth, Van De Ven, Antony
• Primary Examiner(s): Hines, Annie
• Application Number:
  US13/782,820
• Publication Number:
  US 20140126196A1
• Time in Patent Office: 1,341 Days
• Field of Search: 362/218
• US Class Current: 1/1
• CPC Class Codes: F21L 4/00 Electric lighting devices with self-contained electric batteries or cells
• CPC Class Codes: F21S 8/063 with a rigid pendant, i.e. a pipe or rod
• CPC Class Codes: F21V 21/00 Supporting, suspending, or attaching arrangements for lighting devices F21V17/00, F21V19/00 take precedence; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q, stands for supporting apparatus or articles in general F16M11/00; Hand grips
• CPC Class Codes: F21V 21/112 Fixing lighting devices to pendants F21V21/002 takes precedence
• CPC Class Codes: F21V 23/023 Power supplies in a casing F21V23/003 takes precedence
• CPC Class Codes: F21V 3/02 characterised by the shape
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 7/00 Reflectors for light sources characterised by cooling arrangements F21V29/505
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

This disclosure relates to light engines for use in lighting fixtures, such as troffer-style lighting fixtures. Light engines according to the present disclosure have integrated features that eliminate the need for additional components such as a Printed Circuit Board (PCB), a heat sink, a cover portion, a lens and/or a reflective element. Devices according to this disclosure can comprise a rigid body, conductive elements arranged into electrical pathways and light sources such as light emitting diodes (LEDs). Devices according to this disclosure can further comprise integrated cover, lens and/or reflective element features. Methods for the manufacture of such devices are also disclosed.

Claims

1. A light engine, comprising:

an elongated body;

light sources on said body; and

conductive elements embedded into said body such that at least a portion of said conductive elements are within said body and in communication with said light sources, said conductive elements comprising electrical pathways between said light sources.

2. The light engine of claim 1, wherein said light sources comprise LED packages with heat dissipating features.

3. The light engine of claim 1, wherein said light sources are staggered.

4. The light engine of claim 1, wherein said conductive elements are configured to dissipate heat generated during operation of said light source.

5. The light engine of claim 1, wherein said conductive elements comprise barbed portions.

6. The light engine of claim 1, wherein said conductive elements comprises magnetic wire.

7. The light engine of claim 1, wherein said conductive elements comprise flex circuits.

8. The light engine of claim 1, wherein said conductive elements comprise flattened braided wire.

9. The light engine of claim 1, wherein said conductive elements comprise nonconductive rails that have been coated with a conductive material at locations in communication with said light sources.

10. The light engine of claim 1, further comprising a reflective element.

11. The light engine of claim 10, wherein said reflective element is integrated into said body.

12. The light engine of claim 10, wherein said reflective element is coextruded with said body.

13. The light engine of claim 10, wherein said reflective element is held in place through a snap-fit connection.

14. The light engine of claim 1, further comprising a lens.

15. The light engine of claim 14, wherein said lens is integrated into said body.

16. The light engine of claim 14, wherein said lens is coextruded with said body.

17. The light engine of claim 14, wherein said lens is connected to said body through a living hinge.

18. The light engine of claim 1, wherein said body further comprises a connecting portion to allow for attachment of said light engine to other objects.

19. The light engine of claim 1, wherein said light sources are connected to said at least one light conductive element via a conductive adhesive.

20. The light engine of claim 1, further comprising at least one endcap providing an external power connection to said light engine.

21. A light engine, comprising:

a rigid body;

at least one light source on said body; and

at least one conductive element embedded into said rigid body such that at least a potion of said at least one conductive element is within said rigid body and in communication with said light source, said at least one conductive element configured to conduct heat generated during operation of said at least one light source.

22. The light engine of claim 21, wherein said at least one light source comprises at least one LED package with heat dissipating features.

23. The light engine of claim 21, wherein said light sources are staggered.

24. The light engine of claim 21, wherein said at least one conductive element comprises a barbed portion.

25. The light engine of claim 21, wherein said at least one conductive element comprises copper wire.

26. The light engine of claim 21, wherein said at least one conductive element comprises a flex circuit.

27. The light engine of claim 21, wherein said at least one conductive element comprises flattened braided wire.

28. The light engine of claim 21, wherein said at least one conductive element comprises nonconductive rails that have been coated with a conductive material at locations in communication with said at least one light source.

29. The light engine of claim 21, further comprising a reflective element.

30. The light engine of claim 29, wherein said reflective element is integrated into said body.

31. The light engine of claim 29, wherein said reflective element is coextruded with said body.

32. The light engine of claim 29, wherein said reflective element is held in place through a snap-fit connection.

33. The light engine of claim 21, further comprising a lens.

34. The light engine of claim 33, wherein said lens is integrated into said body.

35. The light engine of claim 33, wherein said lens is coextruded with said body.

36. The light engine of claim 33, wherein said lens is connected to said body through a living hinge.

37. The light engine of claim 21, wherein said body further comprises a connecting portion to allow for attachment of said light engine to other objects.

38. The light engine of claim 21, wherein said at least one light source is connected to said at least one conductive element via a conductive adhesive.

39. The light engine of claim 21, further comprising at least one endcap providing an external power connection to said light engine.

40. A light engine, comprising:

a body;

at least one conductive element embedded into said body;

at least one light source in communication with said at least one conductive element; and

a lens integrated into said body.

41. The light engine of claim 40, wherein said lens is coextruded with said body.

42. The light engine of claim 40, wherein said lens is connected to said body through a living hinge.

43. The light engine of claim 42, wherein said lens and body further comprises a snap-fit structure and said lens comprises open and closed positions.

46. The light engine of claim 40, wherein said at least one conductive element comprise at least one interrupted portion.

44. A light engine, comprising:

a body;

at least one conductive element on said body, wherein said at least one conductive elements is help in place by one or more features of said body;

at least one light source in communication with said at least one conductive element; and

a reflective element integrated into said body.

45. The light engine of claim 44, wherein the reflective element is white.