LED Lighting System

• US 20090067191A1
• Filed: 09/07/2007
• Published: 03/12/2009
• Est. Priority Date: 09/07/2007
• Status: Active Grant

• Current Assignee: Zodiac Pool Systems, LLC (Fluidra, S.A.)
• Original Assignee: Nexxus Lighting, Inc.
• Inventors: Faber, Stephen, Koren, Paul
• Granted Patent: US 7,699,515 B2
• Time in Patent Office: Days
• US Class Current: 362/580
• CPC Class Codes: F21V 29/75 with fins or blades having different shapes, thicknesses or spacing
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G02B 6/0006 Coupling light into the fibre in general G02B6/4298
• CPC Class Codes: G02B 6/3814 with cooling or heat dissipation means
• CPC Class Codes: G02B 6/3897 Connectors fixed to housings, casing, frames or circuit boards G02B6/44528 takes precedence

Abstract

A lighting system is provided having a light source with a housing, an LED engine, a controller, a heat sink, a connection device, and a power cable opening. The LED engine, controller and heat sink can be enclosed by the housing and sealed from atmosphere. The heat sink can be in thermal communication with the LED engine. The controller can be connected to a power cable inserted through the power cable opening. The controller can control at least one of power to the LED engine and a light output generated by the LED engine. A fiber optic cable can be connected to the LED engine by the connection device. The LED engine can communicate the light output through the fiber optic cable.

Claims

1. A lighting system comprising;

a light source having a housing, an LED engine, a controller, a heat sink, a connection device, and a power cable opening, wherein the LED engine, controller and heat sink are enclosed by the housing and sealed from atmosphere, wherein the heat sink is in thermal communication with the LED engine, wherein the controller is connected to a power cable inserted through the power cable opening, and wherein the controller controls at least one of power to the LED engine and a light output generated by the LED engine; and

a fiber optic cable connected to the LED engine by the connection device, wherein the LED engine communicates the light output through the fiber optic cable.

2. The system of claim 1, wherein the heat sink is not directly connected to the LED engine.

3. The system of claim 1, further comprising thermal putty positioned in proximity to the LED engine and the heat sink, wherein the thermal putty has a viscosity greater than 300,000 cP at 22°

C., and wherein the thermal putty has a thermal conductivity greater than 1.0 W/mK.

4. The system of claim 1, further comprising a thermal pad positioned in proximity to the LED engine and the heat sink, wherein the thermal putty has a Shore OO Hardness less than 55, and wherein the thermal pad has a thermal conductivity greater than 1.0 W/mK.

5. The system of claim 1, wherein the heat sink has a non-planar shape comprising a raised portion and a flush portion, and wherein the raised portion is closer to the LED engine than the flush portion.

6. The system of claim 1, wherein the controller controls the power to the LED engine and the light output generated by the LED engine.

7. The system of claim 1, wherein the light source has a fiber lens in proximity to the LED engine, and wherein the fiber lens focuses the light output generated by the LED engine.

8. The system of claim 1, wherein the connection device comprises a fiber head with a head channel therethrough, a fiber connector, and a fiber ferrule with a ferrule channel therethrough, wherein the fiber optic cable is positioned entirely through the head channel, wherein the fiber optic cable is positioned at least partially through the ferrule channel, and wherein the fiber connector fastens the fiber optic cable to the housing.

9. The system of claim 8, wherein the light source has a fiber lens in proximity to the LED engine, wherein the fiber lens focuses the light output generated by the LED engine, and wherein the finer lens is positioned partially through the ferrule channel.

10. The system of claim 8, wherein the fiber connector comprises a plurality of projections that engage with corresponding retaining clips along an outer surface of the housing.

11. The system of claim 1, wherein the heat sink is directly connected to the LED engine, and wherein the heat sink has a cylindrical shape with a plurality of radially extending fins.

12. The system of claim 11, wherein the light source has one or more brackets that are connected to an inner surface of the housing, and wherein the one or more brackets each slideably connect with a distal end of a corresponding one of the plurality of radially extending fins.

13. The system of claim 1, wherein the light source has an elongated cylindrical shape, wherein the heat sink has an elongated cylindrical shape, wherein the light source has a first end with the connection device positioned thereon, and wherein the light source has a second end with the power cable opening therethrough.

14. A light source for a lighting system, the light source comprising:

a housing, an LED engine, a controller, a heat sink, a fiber lens, a power cable opening, and a connection device, wherein the LED engine, controller, fiber lens and heat sink are enclosed by the housing, wherein the heat sink is in thermal communication with the LED engine, wherein the controller is connected to a power cable inserted through the power cable opening, wherein the controller controls at least one of power to the LED engine and a light output generated by the LED engine, wherein the LED engine and the fiber lens are connected to a fiber optic cable by the connection device, wherein the LED engine communicates the light output through the fiber optic cable, and wherein the fiber lens focuses the light output generated by the LED engine.

15. The light source of claim 14, wherein the controller controls the power to the LED engine and the light output generated by the LED engine.

16. The light source of claim 14, wherein the heat sink is not directly connected to the LED engine.

17. The light source of claim 14, wherein the heat sink has a non-planar shape comprising a raised portion and flush portion, and wherein the raised portion is closer to the LED engine than the flush portion.

18. The light source of claim 14, wherein the connection device comprises a fiber head with a head channel therethrough, a fiber connector, and a fiber ferrule with a ferrule channel therethrough, wherein the fiber optic cable is positioned entirely through the head channel, wherein the fiber optic cable is positioned at least partially through the ferrule channel, wherein the fiber lens is positioned partially through the ferrule channel, and wherein the fiber connector fastens the fiber optic cable to the housing.

19. The light source of claim 14, wherein the heat sink is directly connected to the LED engine, and wherein the heat sink has a cylindrical shape with a plurality of radially extending fins.

20. The light source of claim 14, further comprising a first end with the connection device positioned thereon and a second end with the power cable opening therethrough.

21. A method of providing light output for a lighting system, the method comprising:

enclosing and sealing an LED engine, a controller, a heat sink, and a fiber lens in a housing of a light source, wherein the heat sink is in thermal communication with the LED engine;

connecting a power cable to the controller through a power cable opening in the housing;

connecting a fiber optic cable to the LED engine and the fiber lens using a connection device extending outside of the housing; and

controlling power to the LED engine and a light output generated by the LED engine, wherein the LED engine communicates the light output through the fiber optic cable, and wherein the fiber lens focuses the light output generated by the LED engine.

22. The method of claim 21, further comprising positioning the heat sink remote from the LED engine, wherein the heat sink dissipates heat produced by the LED engine, wherein the heat sink has a non-planar shape comprising a raised portion and a flush portion, and wherein the raised portion is closer to the LED engine than the flush portion.