LED luminaire

• US 9,634,206 B1
• Filed: 05/02/2016
• Issued: 04/25/2017
• Est. Priority Date: 04/30/2015
• Status: Active Grant

• Current Assignee: CSE, Inc.
• Original Assignee: CSE, Inc.
• Inventors: Miedema, Gregory A.
• Primary Examiner(s): Ahmad, Khaja
• Application Number:
  US15/144,161
• Time in Patent Office: 358 Days
• Field of Search: None
• CPC Class Codes: F21S 8/04 intended only for mounting on a ceiling or the like overhead structures F21S8/02 takes precedence; details of ceiling bases F21V21/03
• CPC Class Codes: F21V 23/007 enclosed in a casing
• CPC Class Codes: F21Y 2105/18 annular; polygonal other than square or rectangular, e.g. for spotlights or for generating an axially symmetrical light beam
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 27/156 two-dimensional arrays
• CPC Class Codes: H01L 33/58 Optical field-shaping elements
• CPC Class Codes: H01L 33/62 Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls

Abstract

A compact light unit having light emitting diodes (LEDs) includes a circuit board assembly and a lens including optical structures, a front face, and a rim disposed about the front face. The lens may include a pocket on a back portion of the lens opposite the front face within which the circuit board assembly is mounted with the LEDs being optically aligned with the optical structures. The LED light unit further includes a bezel having an interior opening with the bezel configured to be mounted to the lens with the rim engaged with an interior portion of the bezel and the front face exposed through the interior opening. Various optical structures may be provided to direct light projected by the LEDs at different angles.

Claims

1. An LED light unit, said light unit comprising:

a circuit board assembly with a plurality of light emitting diodes (LEDs);

a lens, said lens including a plurality of optical structures, a front face, and a rim disposed about said front face, said lens further including a pocket on a back portion of said lens opposite said front face; and

a bezel, said bezel including an interior opening;

said circuit board assembly being mounted within said pocket of said lens whereby said LEDs are optically aligned with said optical structures, and wherein said bezel is configured to be mounted to said lens with said rim engaged with an interior portion of said bezel and said front face exposed through said interior opening.

2. The LED light unit of claim 1, wherein said rim of said lens is recessed from said front face.

3. The LED light unit of claim 2, wherein said front face is substantially flush with an exterior surface of said bezel at said interior opening of said bezel.

4. The LED light unit of claim 1, wherein said pocket of said lens includes a pocket tab and wherein said circuit board assembly includes a circuit board assembly tab, and wherein said pocket tab is configured to receive said circuit board assembly tab to orient said circuit board assembly relative to said lens.

5. The LED light unit of claim 1, wherein said optical structures comprise generally conical cavities in said lens, said optical structures including an exterior opening on said front face and an inner opening opposite said front face, with said LEDs being aligned with said inner openings.

6. The LED light unit of claim 5, wherein said inner opening of said optical structures is smaller than said exterior opening, and wherein said inner opening and said exterior opening of said optical structures are axially aligned relative to a perpendicular orientation with respect to said front face.

7. The LED light unit of claim 5, wherein said inner opening of said optical structures is smaller than said exterior opening, and wherein said optical structures comprise generally angled conical cavities in said lens whereby said inner opening of said optical structures is axially offset from said exterior opening relative to a perpendicular orientation with respect to said front face.

8. The LED light unit of claim 1, wherein said lens includes an inner surface opposite said front face, and wherein said optical structures include an inner protuberance projecting upward from said inner surface and an outer protuberance projecting outward from said front face, and wherein said optical structures direct light from said LEDs to substantially project at an angle relative to a plane defined by said front face.

9. The LED light unit of claim 8, wherein said inner protuberance of said optical structures is generally conical and includes a recess, with said recess being disposed in alignment with respective ones of said LEDs.

10. The LED light unit of claim 8, wherein said outer protuberance of said optical structures includes a first inclined portion, a second inclined portion, and a semicircular portion disposed between said first and second inclined portions, and wherein said second inclined portion defines a steeper angle relative to said front face than said first inclined portion relative to said front face.

11. The LED light unit of claim 10, wherein said first inclined portion of said optical structures is generally axially aligned with said inner protuberance.

12. The LED light unit of claim 11, further including an aperture disposed adjacent each said optical structure, with each said aperture extending through said lens.

13. The LED light unit of claim 1, wherein said rim of said lens includes mounting apertures, said mounting apertures configured for use in mounting said lens to a surface.

14. The LED light unit of claim 1, wherein said light unit is circular and wherein said rim is disposed about the entire periphery of said lens.

15. An LED light unit, said light unit comprising:

a circuit board assembly with a plurality of light emitting diodes (LEDs);

a lens, said lens including a plurality of optical structures, a front face, and a rim disposed about said front face; and

a bezel, said bezel including an interior opening;

said circuit board assembly being mounted with said lens whereby said LEDs are optically aligned with said optical structures, and wherein said bezel is configured to be mounted to said lens with said rim engaged with an interior portion of said bezel and said front face exposed through said interior opening.

16. The LED light unit of claim 15, wherein said optical structures comprise generally conical cavities in said lens, said optical structures including an exterior opening on said front face and an inner opening opposite said front face, with said LEDs being aligned with said inner openings.

17. The LED light unit of claim 16, wherein said inner opening of said optical structures is smaller than said exterior opening, and wherein said inner opening and said exterior opening of said optical structures are axially aligned relative to a perpendicular orientation with respect to said front face.

18. The LED light unit of claim 16, wherein said inner opening of said optical structures is smaller than said exterior opening, and wherein said optical structures comprise generally angled conical cavities in said lens whereby said inner opening of said optical structures is axially offset from said exterior opening relative to a perpendicular orientation with respect to said front face.

19. The LED light unit of claim 15, wherein said lens includes an inner surface opposite said front face, and wherein said optical structures include an inner protuberance projecting upward from said inner surface and an outer protuberance projecting outward from said front face, and wherein said optical structures direct light from said LEDs to substantially project at an angle relative to a plane defined by said front face.

20. The LED light unit of claim 19, wherein said inner protuberance of said optical structures is generally conical and includes a recess, with said recess being disposed in alignment with respective ones of said LEDs.

21. The LED light unit of claim 19, wherein said outer protuberance of said optical structures includes a first inclined portion, a second inclined portion, and a semicircular portion disposed between said first and second inclined portions, and wherein said second inclined portion defines a steeper angle relative to said front face than said first inclined portion relative to said front face.

22. The LED light unit of claim 21, wherein said first inclined portion of said optical structures is generally axially aligned with said inner protuberance.

23. The LED light unit of claim 22, further including an aperture disposed adjacent each said optical structure, with each said aperture extending through said lens.