Method of and apparatus for enhanced thermal isolation of low-profile LED lighting fixtures

• US 9,395,067 B2
• Filed: 10/06/2014
• Issued: 07/19/2016
• Est. Priority Date: 10/07/2013
• Status: Active Grant

• Current Assignee: Flextronics America LLC (Flextronics International Limited)
• Original Assignee: Flextronics America LLC (Flextronics International Limited)
• Inventors: Musser, Jordon, Jones, Randall, Barkhurst, Corey
• Primary Examiner(s): GRAMLING, SEAN P
• Application Number:
  US14/507,077
• Publication Number:
  US 20150098214A1
• Time in Patent Office: 652 Days
• Field of Search: 362/237, 362/240, 362/241, 362/249.02, 362/221, 362224-225
• US Class Current: 1/1
• CPC Class Codes: F21V 15/01 Housings, e.g. material or assembling of housing parts F21V15/02 takes precedence housings forming signs or letters G09F13/04
• CPC Class Codes: F21V 23/009 the casing being inside the housing of the lighting device
• CPC Class Codes: F21V 23/02 the elements being transformers, impedances or power supply units, e.g. a transformer with a rectifier
• CPC Class Codes: F21V 29/15 Thermal insulation
• CPC Class Codes: F21V 29/505 of reflectors
• CPC Class Codes: F21V 29/507 of means for protecting lighting devices from damage, e.g. housings
• CPC Class Codes: F21V 29/508 of electrical circuits
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2113/00 Combination of light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A LED assembly/structure and a method of manufacturing the same. The LED assembly comprises a housing body, one or more LED light emitting component hosting areas, a power unit hosting compartment, one or more light diffusing elements, and a cover. The housing body of the LED assembly serves as a thermal barrier between the power supply and the LED lighting elements, such that thermal stress is able to be reduced.

Claims

1. A method of manufacturing a LED assembly comprising:

a. coupling formed sheet metal to form a housing body, wherein the housing body comprises at least two recesses;

b. coupling at least one LED lighting element with each of the at least two recesses, wherein the housing body comprises at least three pieces of sheet metal including a first piece of sheet metal shaped to form the at least two recesses and a first partial portion of an enclosure for the power supply, a second piece of sheet metal shaped to form the at least two recesses and a second partial portion of the enclosure for the power supply and a third piece of sheet metal including upstanding arms hooked to capture and hold the first and the second pieces of sheet metal;

c. enclosing a power supply; and

d. coupling one or more diffusing lens to each of the LED lighting element.

2. The method of claim 1, wherein the two recesses are at the two sides of the power supply.

3. The method of claim 1, wherein each of the two recesses comprises a flat area coupling with the LED lighting element.

4. The method of claim 1, wherein the method comprises joining the pieces of sheet metal by clipping together without screws.

5. A lighting assembly comprising:

a. a housing body having an enclosed power supply compartment; and

b. a portion of the housing body forming a thermal barrier between the power supply and one or more LED panels, wherein the housing body comprises at least three pieces of sheet metal including a first piece of sheet metal shaped to form at least two recesses and a first partial portion of an enclosure for the power supply, a second piece of sheet metal shaped to form the at least two recesses and a second partial portion of the enclosure for the power supply and a third piece of sheet metal including upstanding arms hooked to capture and hold the first and the second pieces of sheet metal.

6. The lighting assembly of claim 5, wherein the housing body is formed by attaching formed metal sheets.

7. The lighting assembly of claim 5, wherein the LED panels is covered by one or more diffusing lens.

8. The lighting assembly of claim 5, wherein the LED panels are at two sides of the power supply.

9. The lighting assembly of claim 5, further comprising a cover, wherein the cover covers the power supply compartment holding the power supply.

10. The lighting assembly of claim 5, wherein the cover is a perforated stamped piece.

11. The lighting assembly of claim 5, wherein the housing body comprises a thermally reflective coating.

12. The lighting assembly of claim 5, wherein the lighting assembly couples with a LED greater than 100 Watts.

13. A low-profile LED lighting fixture comprising:

a. a body has a thickness less than 70 mm;

b. two lighting areas located at two sides of the fixture;

c. a concave at each of the two lighting areas; and

d. a diffusing lens covering each of the lighting areas, wherein the body comprises at least three pieces of sheet metal including a first piece of sheet metal shaped to form at least two recesses and a first partial portion of an enclosure for a power supply, a second piece of sheet metal shaped to form the at least two recesses and a second partial portion of the enclosure for the power supply and a third piece of sheet metal including upstanding arms hooked to capture and hold the first and the second pieces of sheet metal.

14. The low-profile LED lighting fixture of claim 13, further comprising two rows of holes facing each other.

15. The low-profile LED lighting fixture of claim 14, wherein the holes are heat dissipating holes located around a power supply.

16. The low-profile LED lighting fixture of claim 15, further comprising a thermal barrier between the power supply and a LED lighting element.

17. The low-profile LED lighting fixture of claim 13, wherein the body is formed by three pieces of formed sheet metal.

18. The low-profile LED lighting fixture of claim 13, wherein the diffusing lens is lower than a side wall of the body.