Method and apparatus for light square assembly

• US 9,719,672 B1
• Filed: 12/01/2014
• Issued: 08/01/2017
• Est. Priority Date: 05/04/2012
• Status: Active Grant

• Current Assignee: Signify Holding B.V. (Signify N.V.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Nimma, Sridhar Reddy, Moghal, Khurram Zeshan, Winters, Philip Dean
• Primary Examiner(s): Sawhney, Hargobind S
• Application Number:
  US14/556,949
• Time in Patent Office: 974 Days
• CPC Class Codes: F21K 9/20 Light sources comprising attachment means
• CPC Class Codes: F21K 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21V 5/007 Array of lenses or refractors for a cluster of light sources, e.g. for arrangement of multiple light sources in one plane combination of two or more refractors F21V5/008
• 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

A light module includes a cover, a circuit board, a gasket, a bottom covering, and an optional optic assembly. The cover includes an inner and an outer wall extending outwardly from the cover, where the outer wall surrounds the inner wall and forms a groove therebetween. The circuit board is positioned within the inner wall'"'"'s profile and includes a plurality of LEDs. The gasket is disposed within the groove. The bottom covering is positioned adjacent to the circuit board and is coupled to the cover. The gasket provides a seal between the cover and the bottom covering. The optic assembly is disposed within the inner wall'"'"'s profile and between the cover and the circuit board. The optic assembly includes one or more apertures and one or more optics disposed around at least some of the apertures. Each optic is aligned with one or more LEDs.

Claims

1. A light module, comprising:

a cover plate comprising;

a first surface;

an opposing second surface;

two parallel protrusions extending orthogonally from the opposing second surface of the cover plate and defining a groove there between to house a gasket material, wherein the two parallel protrusions comprise an inner wall and an outer wall surrounding the inner wall;

circuitry comprising a plurality of light emitting diodes (LEDs) coupled thereon, the circuitry being disposed within a profile of the inner wall, the plurality of LEDs being oriented to emit light towards the cover plate;

the gasket material disposed within the groove; and

a bottom covering disposed adjacent to the circuitry and coupled to the cover plate, wherein the bottom covering comprises a channel extending therethrough allowing one or more electrical wires to be inserted therethrough,

wherein the gasket material provides a seal between the cover plate and the bottom covering.

2. The light module of claim 1, wherein the cover plate further comprises one or more first openings formed therein and positioned outside the profile of the outer wall, and

wherein the bottom covering comprises one or more second openings formed therein, the second openings being vertically aligned with the first openings when the bottom covering is coupled to the cover plate, the first and second openings configured to receive a coupling device to couple the bottom covering to the cover plate.

3. The light module of claim 1, wherein the cover plate and the bottom covering are substantially square and the inner wall and the circuit board are substantially square shaped with one or more chamfered corners.

4. The light module of claim 1, wherein the bottom covering is fabricated using at least one of an aluminum material, a metal alloy material, or another metal material.

5. The light module of claim 1, wherein the plurality of LEDs comprise an array of LED die packages.

6. The light module of claim 1, wherein the cover plate further comprises one or more lenses integrally formed therein, each lens being vertically aligned with at least one LED of the plurality of LEDs.

7. A light module, comprising:

a cover plate comprising;

a first surface;

a second opposing surface,

two parallel protrusions extending orthogonally from the second opposing surface of the cover plate and defining a groove disposed there between to house a gasket material, wherein the two parallel protrusions comprise an inner wall and an outer wall surrounding the inner wall; and

at least one first opening extending through the cover plate;

an optic assembly disposed within the profile of the inner wall and comprising;

one or more second openings formed therethrough; and

at least one lens coupled to the optic assembly, each lens disposed over at least one of the second openings and extending through at least a portion of the respective first opening,

circuitry comprising a plurality of light emitting diodes (LEDs) coupled thereto, the circuitry disposed within a profile of the inner wall and adjacent to the optic assembly such that the inner wall separates the circuitry from the gasket material, the LEDs being oriented to emit light into the respective lens;

the gasket material disposed within the groove; and

a bottom covering being positioned adjacent to the circuitry and coupled to the cover plate through apertures disposed outside of a perimeter of the groove,

wherein the gasket material provides an environmental seal between the cover plate and the bottom covering.

8. The light module of claim 7, wherein the optic assembly comprises:

an adhesive layer comprising;

a gas-permeable layer comprising one or more first apertures extending therethrough;

a first adhesive material coupled to one surface of the gas-permeable layer; and

a second adhesive material coupled to an opposite surface of the gas-permeable layer;

a second material layer coupled to the first adhesive material, the second material layer comprising one or more second apertures formed therethrough, the second apertures being vertically aligned with the respective first apertures and surrounding the perimeter of the respective first apertures when the second material is coupled to the adhesive layer, a portion of the adhesive layer being exposed within the perimeter of the second apertures; and

at least one lens coupled to the adhesive layer, a portion of each lens being disposed on the adhesive layer through the respective second aperture.

9. The light module of claim 8, wherein the circuitry comprises a driver, and

wherein the optic assembly further comprises one or more caps being coupled to the adhesive layer through one or more second apertures, the caps being disposed over the driver when the optic assembly is positioned adjacent to the circuitry.

10. The light module of claim 7, wherein the plurality of LEDs comprise an array of LED die packages.

11. The light module of claim 7, wherein the optic assembly comprises an adhesive layer and a second material layer.

12. The light module of claim 11, wherein the adhesive layer comprises:

a gas-permeable layer;

a first adhesive material coupled to one surface of the gas-permeable layer; and

a second adhesive material coupled to an opposite surface of the gas-permeable layer.

13. A light module, comprising:

a cover plate comprising;

an outer surface;

an inner surface;

a groove disposed in the inner surface and comprising an inner wall; and

a first plurality of coupling apertures;

a bottom covering disposed adjacent to circuitry and comprising a second plurality of coupling apertures, wherein the bottom covering comprises a first channel extending therethrough;

an optic assembly disposed between the cover plate and the bottom covering, the optic assembly comprising;

one or more openings formed therethrough; and

at least one lens coupled to the optic assembly, each lens disposed over at least one of the one or more openings;

the circuitry being disposed between the cover plate and the bottom covering and within the profile of the cover plate, wherein the circuitry comprises a driver and a plurality of LEDs, and wherein the optic assembly further comprises one or more caps being coupled to an adhesive layer of the optic assembly, the one or more caps being disposed over the driver when the optic assembly is positioned adjacent to the circuitry;

a gasket material disposed in the groove, wherein the gasket material provides an environmental seal between the cover plate and the bottom covering; and

a plurality of fastening devices, each fastening device extending at least partially through one of the first plurality of coupling apertures and one of the second plurality of coupling apertures to couple the bottom covering to the cover plate.

14. The light module of claim 13, wherein the optic assembly comprises the adhesive layer and a second material layer.

15. The light module of claim 14, wherein the adhesive layer comprises:

a gas-permeable layer;

a first adhesive material coupled to one surface of the gas-permeable layer; and

a second adhesive material coupled to an opposite surface of the gas-permeable layer.