LIGHTING ASSEMBLIES, METHODS OF INSTALLING SAME, AND METHODS OF REPLACING LIGHTS

• US 20080084701A1
• Filed: 09/21/2007
• Published: 04/10/2008
• Est. Priority Date: 09/21/2006
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: LED Lighting Fixtures, Inc. (Wolfspeed, Inc.)
• Inventors: VAN DE VEN, Antony, Negley, Gerald
• Granted Patent: US 8,827,507 B2
• Time in Patent Office: Days
• US Class Current: 362/373
• 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: F21V 17/164 the parts being subjected to bending, e.g. snap joints
• CPC Class Codes: F21V 23/026 Fastening of transformers or ballasts
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/80 with pins or wires
• CPC Class Codes: F21V 29/85 characterised by the material liquid coolants F21V29/56
• 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 lighting assembly comprising a light engine housing, a circuit board, a heat transfer material, an electrically conductive leg and a solid state light emitter. The emitter is in contact with a first end of the leg. The leg extends through the circuit board. A second end of the leg extends into the heat transfer material. Also, a lighting assembly as described above, which further comprises a fixture housing, in which the heat transfer material is in contact with the light engine housing and the light engine housing is connected to the fixture housing. In addition, a method of installing a lighting assembly, comprising connecting an electrical conductor and inserting the lighting assembly through a hole in a construction element such that clips attached to a fixture housing engage the construction element. Also, a method of changing a light emitter in a lighting assembly.

Claims

1. A lighting assembly, comprising:

a fixture housing;

a light engine housing;

a circuit board;

a heat transfer material;

at least a first electrically conductive leg; and

at least a first solid state light emitter,

said first solid state light emitter being in contact with a first end of said first electrically conductive leg,

said first electrically conductive leg extending through said circuit board,

a second end of said first electrically conductive leg extending into said heat transfer material,

said heat transfer material being in contact with said light engine housing,

said light engine housing being connected to said fixture housing.

2. A lighting assembly as recited in claim 1, wherein said heat transfer material is positioned within a space defined between said light engine housing and said circuit board.

3. A lighting assembly as recited in claim 1, wherein an axis of symmetry of said fixture housing is substantially co-linear with an axis of symmetry of said light engine housing.

4. A lighting assembly as recited in claim 3, wherein an axis of symmetry of said first leg is substantially parallel to said axis of symmetry of said light engine housing.

5. A lighting assembly as recited in claim 3, wherein an axis of symmetry of said first solid state light emitter is substantially parallel to said axis of symmetry of said light engine housing.

6. A lighting assembly as recited in claim 1, wherein heat sink fins extend from said light engine housing away from said heat transfer material.

7. A lighting assembly as recited in claim 1, wherein said heat transfer material comprises at least one material selected from the group consisting of epoxy and silicon carbide.

8. A lighting assembly as recited in claim 1, further comprising:

at least two clips attached to said fixture housing and extending away from a periphery of said fixture housing.

9. A lighting assembly as recited in claim 1, further comprising a rim, said rim having a rim external surface and a rim internal surface, said fixture housing having a fixture housing internal surface, said rim external surface facing said fixture housing internal surface.

10. A lighting assembly as recited in claim 9, further comprising:

at least two clips attached to said fixture housing and extending away from a periphery of said fixture housing; and

at least a first drawstring which, when pulled, causes said clips to retract toward said periphery of said fixture housing, said rim obstructing said first drawstring from view through an opening defined by said rim internal surface.

11. A lighting assembly as recited in claim 9, further comprising at least a first control device attached to said fixture housing, said rim obstructing said first control device from view through an opening defined by said rim internal surface.

12. A lighting assembly as recited in claim 9, further comprising mounting screws which connect said fixture housing to a construction element, said rim internal surface defining an opening through which light from said at least a first solid state light emitter can pass, said rim obstructing the mounting screws from view through said opening.

13. A lighting assembly as recited in claim 1, wherein said first electrically conductive leg extends into said heat transfer material at least 50% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.

14. A lighting assembly as recited in claim 1, wherein said first electrically conductive leg extends into said heat transfer material at least 75% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.

15. A lighting assembly as recited in claim 1, wherein said first electrically conductive leg extends into said heat transfer material at least 90% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.

16. A lighting assembly, comprising:

a light engine housing;

a circuit board;

a heat transfer material;

at least a first electrically conductive leg; and

at least a first solid state light emitter,

said first solid state light emitter being in contact with a first end of said first electrically conductive leg,

said first electrically conductive leg extending through said circuit board,

a second end of said first electrically conductive leg extending into said heat transfer material.

17. A lighting assembly as recited in claim 16, wherein said first electrically conductive leg extends into said heat transfer material at least 50% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.

18. A lighting assembly as recited in claim 16, wherein said first electrically conductive leg extends into said heat transfer material at least 75% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.

19. A lighting assembly as recited in claim 16, wherein said first electrically conductive leg extends into said heat transfer material at least 90% of a distance from said circuit board to a surface of said light engine housing which is opposite said circuit board relative to said heat transfer material.

20. A lighting assembly as recited in claim 16, wherein said heat transfer material is positioned within a space defined between said light engine housing and said circuit board.

21. A lighting assembly as recited in claim 16, wherein an axis of symmetry of said first leg is substantially parallel to an axis of symmetry of said light engine housing.

22. A lighting assembly as recited in claim 16, wherein an axis of symmetry of said first solid state light emitter is substantially parallel to an axis of symmetry of said light engine housing.

23. A lighting assembly as recited in claim 16, wherein heat sink fins extend from said light engine housing away from said heat transfer material.

24. A lighting assembly as recited in claim 16, wherein said heat transfer material comprises at least one material selected from the group consisting of epoxy and silicon carbide.

25. A lighting assembly, comprising:

a light engine housing;

a circuit board;

at least a first solid state light emitter, and

means for transferring heat from said first solid state light emitter.

26. A method of installing a lighting assembly, comprising:

connecting an electrical conductor on a lighting assembly to an electrical supply component, said lighting assembly comprising a fixture housing and at least two clips attached to said fixture housing and extending away from a periphery of said fixture housing; and

inserting said lighting assembly through a hole in a construction element such that said clips engage said construction element.

27. A method as recited in claim 26, wherein said construction element is selected from the group consisting of a wall, a floor and a ceiling.

28. A method as recited in claim 26, further comprising positioning a lens in said fixture housing and turning said lens, whereby said lens becomes engaged with said fixture housing and is held in place.

29. A method as recited in claim 28, wherein said turning said lens comprises rotating said lens about an axis substantially coaxial with an axis of said fixture housing.

30. A method as recited in claim 26, further comprising positioning a rim such that an external surface of said rim faces an internal surface of said fixture housing.

31. A method as recited in claim 26, wherein said electrical supply component comprises an electrical wire.

32. A method as recited in claim 26, wherein:

said lighting assembly comprises;

said fixture housing;

a light engine housing;

a circuit board;

a heat transfer material;

at least a first electrically conductive leg; and

at least a first emitter,

said first solid state light emitter is in contact with a first end of said first electrically conductive leg,

said electrically conductive leg is electrically connected to said electrical conductor,

said first electrically conductive leg extends through said circuit board,

a second end of said first electrically conductive leg extends into said heat transfer material,

said heat transfer material is in contact with said light engine housing, and

said light engine housing is connected to said fixture housing.

33. A method as recited in claim 32, wherein said first emitter is a solid state light emitter.

34. A method as recited in claim 33, wherein said solid state light emitter is an LED.

35. A method of changing a light emitter in a lighting assembly, comprising:

retracting clips attached to a fixture housing out of contact with a construction element;

moving said lighting assembly through a hole in a construction element; and

disconnecting an electrical conductor on said lighting assembly from an electrical supply component, said lighting assembly comprising a fixture housing and at least two clips attached to said fixture housing and extending away from a periphery of said fixture housing.

36. A method as recited in claim 35, wherein:

said lighting assembly comprises a fixture housing, a light engine housing, a light engine and at least a first light emitter, said first light emitter being mounted on said light engine, said light engine being mounted on said light engine housing, and

said method further comprises;

removing said light engine housing from said fixture housing;

removing said light engine from said light engine housing;

attaching a replacement light engine to said light engine housing; and

attaching said light engine housing to said fixture housing.

37. A method as recited in claim 36, wherein said method further comprises inserting said lighting assembly through said hole in said construction element such that said clips engage said construction element.

38. A method as recited in claim 35, wherein:

said lighting assembly comprises a fixture housing, a light engine housing, a light engine and at least a first light emitter, said first light emitter being mounted on said light engine, said light engine being mounted on said light engine housing, and

said method further comprises;

removing said light engine housing from said fixture housing;

removing said first light emitter from said light engine;

attaching a replacement light emitter on said light engine; and

attaching said light engine housing to said fixture housing.

39. A method as recited in claim 38, wherein said method further comprises inserting said lighting assembly through said hole in said construction element such that said clips engage said construction element.

40. A method as recited in claim 38, wherein said method further comprises inserting said lighting assembly through said hole in said construction element such that said clips engage a second construction element.

41. A method as recited in claim 35, wherein:

said lighting assembly comprises;

said fixture housing;

a light engine housing;

a circuit board;

a heat transfer material;

at least a first electrically conductive leg; and

at least a first emitter,

said first solid state light emitter is in contact with a first end of said first electrically conductive leg,

said electrically conductive leg is electrically connected to said electrical conductor,

said first electrically conductive leg extends through said circuit board,

a second end of said first electrically conductive leg extends into said heat transfer material,

said heat transfer material is in contact with said light engine housing, and

said light engine housing is connected to said fixture housing.

42. A method as recited in claim 41, wherein said first emitter is a solid state light emitter.

43. A method as recited in claim 42, wherein said solid state light emitter is an LED.