Plastic heat sink for luminaires
First Claim
Patent Images
1. A luminaire comprising:
- a plastic heat sink body that defines a first end, and a second end opposite the first end along a central axis,a first driver cover that at least substantially closes the first end;
a driver configured to receive input electrical power from an electrical power source, and output electrical power;
a second driver cover attached to the heat sink body, such that the driver is contained between the first driver cover and the second driver cover; and
an LED panel including a substrate supported by the heat sink body at a location such that the first driver cover is disposed between the LED panel and the driver, and at least one LED carried by the substrate, wherein the at least one LED is in electrical communication with the driver so as to receive the output electrical power and, in response, produce illumination; and
a lens assembly supported by the heat sink body at the second end so as to at least substantially close the second end, such that at least a portion of the illumination passes through the lens assembly and out the luminaire,wherein one of the first driver cover and the lens assembly is monolithic with the heat sink body at a respective one of the first and second ends, such that the LED panel is configured for insertion into the heat sink body at the other of the first and second ends,wherein the lens assembly further comprises a diffuser and a bezel that is supported by the heat sink body at the second end, wherein an outer periphery of the diffuser is supported by bezel, and the diffuser is monolithic with the bezel.
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Accused Products
Abstract
Luminaires are disclosed that are configured to emit LED illumination. Certain components of the luminaire can be assembled without the use of fasteners. Further, the luminaires can include a plastic heat sink that can be molded with other components of the luminaire.
29 Citations
19 Claims
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1. A luminaire comprising:
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a plastic heat sink body that defines a first end, and a second end opposite the first end along a central axis, a first driver cover that at least substantially closes the first end; a driver configured to receive input electrical power from an electrical power source, and output electrical power; a second driver cover attached to the heat sink body, such that the driver is contained between the first driver cover and the second driver cover; and an LED panel including a substrate supported by the heat sink body at a location such that the first driver cover is disposed between the LED panel and the driver, and at least one LED carried by the substrate, wherein the at least one LED is in electrical communication with the driver so as to receive the output electrical power and, in response, produce illumination; and a lens assembly supported by the heat sink body at the second end so as to at least substantially close the second end, such that at least a portion of the illumination passes through the lens assembly and out the luminaire, wherein one of the first driver cover and the lens assembly is monolithic with the heat sink body at a respective one of the first and second ends, such that the LED panel is configured for insertion into the heat sink body at the other of the first and second ends, wherein the lens assembly further comprises a diffuser and a bezel that is supported by the heat sink body at the second end, wherein an outer periphery of the diffuser is supported by bezel, and the diffuser is monolithic with the bezel. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A method of fabricating a luminaire, the method comprising the steps of:
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placing a driver adjacent a driver cover that closes the first end of a plastic heat sink body and is monolithic with the plastic heat sink body; attaching a second driver cover to the heat sink body such that the driver is contained between the first driver cover and the second driver cover; and inserting an LED panel through a second end of the plastic heat sink body that is opposite the first end, the LED panel including a substrate and at least one LED supported by the substrate; placing the at least one LED in electrical communication with the driver; and after the inserting step, mounting the substrate to the heat sink body such that the substrate is supported by the heat sink body at a location such that the first driver cover is disposed between the LED panel and the driver, further comprising the step of fabricating a lens assembly including a bezel and a lens supported at its outer periphery by the bezel and monolithic with the bezel, and mounting the lens assembly to the second end of the heat sink body.
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8. A luminaire comprising:
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a heat sink that defines a first end and an open second end opposite the first end along a central axis; a driver configured to receive input electrical power from an electrical power source, and output electrical power; an LED panel including a substrate supported by the heat sink, and at least one LED carried by the substrate, wherein the at least one LED is in electrical communication with the driver so as to receive the output electrical power and, in response, produce illumination; and a lens assembly that closes the open second end of the heat sink, the lens assembly including a bezel that is supported by the second end of the heat sink, and a lens that is supported at its periphery by the bezel and monolithic with the bezel, wherein an entirety of the lens assembly comprises a plastic configured to emit at least a portion of the illumination produced by the at least one LED. - View Dependent Claims (9, 10, 11, 12)
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13. A method of fabricating a luminaire, the method comprising the steps of:
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inserting an LED panel through an open end of a heat sink, the LED panel including a substrate and at least one LED supported by the substrate; placing the at least one LED in electrical communication with a driver; and after the inserting step, mounting the substrate to the heat sink; and attaching a bezel of a lens assembly to the open end of the heat sink, such that a lens that is monolithic with the bezel closes the open end of the heat sink and is positioned to allow illumination produced by the at least one LED to pass through and out the luminaire. - View Dependent Claims (14, 15)
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16. A luminaire comprising:
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a heat sink body that defines a first end, a second end opposite the first end along a central axis; a first driver cover supported at the first end of the heat sink body, wherein the first driver cover substantially closes the first end; a driver configured to receive input electrical power from an electrical power source, and output electrical power; a second driver cover attached to the heat sink body, such that the driver is contained between the first driver cover and the second driver cover; an LED panel including a substrate supported by the heat sink body at a location such that the first driver cover is disposed between the LED panel and the driver, and at least one LED carried by the substrate, wherein the at least one LED is in electrical communication with the driver so as to receive the output electrical power and, in response, produce illumination; and a lens assembly supported by the heat sink body at the second end, such that at least a portion of the illumination passes through the lens assembly and out the luminaire, wherein each of the second driver cover and the lens assembly is configured to be fit to the heat sink body so as to attach
1) the second driver cover to the first end of the heat sink body, and
2) the lens assembly to the second end of the heat sink body, andwherein the lens assembly comprises a bezel and a lens monolithic with the bezel, and the bezel is attached to the heat sink body. - View Dependent Claims (17)
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18. A method for assembling a luminaire, the method comprising the steps of:
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placing a driver adjacent a first driver cover that is supported by a heat sink body at a first end of the heat sink body; fitting a second driver cover to the first end of the heat sink body so as to contain the driver between the first driver cover and the second driver cover; inserting an LED panel through an open second end of the heat sink body opposite the first end, the LED panel including a substrate and at least one LED supported by the substrate; supporting the substrate in the heat sink body at a location such that the first driver cover separates the LED panel from the driver; placing the at least one LED in electrical communication with the driver; and fitting a lens assembly to the second end of the heat sink body, such that illumination produced by the at least one LED passes through and out the luminaire further comprising the step of fabricating a lens assembly including a bezel and a lens supported at its outer periphery by the bezel and monolithic with the bezel, and mounting the lens assembly to the second end of the heat sink body.
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19. A lens assembly configured to close an end heat sink of a luminaire, the lens assembly comprising 1) a plastic bezel configured to attach to an open end of the luminaire, wherein the plastic bezel encloses an interior, and 2) a plastic diffuser monolithic with the plastic bezel so as to extend along an entirety of the interior, such that when the lens assembly closes the end of the heat sink, the plastic diffuser is configured to allow illumination from the luminaire to pass through.
Specification