Lighting system having a sealing system

• US 9,746,159 B1
• Filed: 05/04/2015
• Issued: 08/29/2017
• Est. Priority Date: 03/03/2015
• Status: Active Grant

• Current Assignee: Korrus Incorporated (MKD Electric, Inc.)
• Original Assignee: EcoSense Lighting Inc.
• Inventors: Fletcher, Robert, Adams, Edward R, Pickard, Paul, Petluri, Raghuram L. V.
• Primary Examiner(s): Hanley, Britt D
• Application Number:
  US14/702,765
• Time in Patent Office: 848 Days
• Field of Search: None
• CPC Class Codes: F21V 14/02 by movement of light sources in vehicle head lamps F21S41/657
• 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 21/30 Pivoted housings or frames
• CPC Class Codes: F21V 23/023 Power supplies in a casing F21V23/003 takes precedence
• CPC Class Codes: F21V 3/00 Globes; Bowls; Cover glasses with refracting properties F21V5/00; with reflecting properties F21V7/00; characterised by cooling arrangements F21V29/506
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21V 5/048 the lens being a simple lens adapted to cooperate with a point-like source for emitting mainly in one direction and having an axis coincident with the main light transmission direction, e.g. convergent or divergent lenses, plano-concave or plano-convex lenses
• CPC Class Codes: F21V 7/0083 Array of reflectors for a cluster of light sources, e.g. arrangement of multiple light sources in one plane combination of two or more reflectors F21V7/0025
• CPC Class Codes: F21V 7/04 Optical design
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

Lighting system including housing having base plate, and housing wall projecting in upward direction. Container with LED in housing having visible light-transmissive top plate and container wall projecting in downward direction. Gasket is configured for forming seal between container wall and base plate to form sealed container. Rail interposed between interior side of housing wall and exterior side of container wall. Rail has first side facing towards interior side of housing wall and second side facing toward exterior side of container wall. First raised region forms part of interior side of housing wall or part of first side of rail. Second raised region forms part of exterior side of container wall or part of second side of rail. First raised region is configured for limiting movement of rail away from base plate along upward direction, and second raised region is configured for limiting such movement of container wall.

Claims

1. A lighting system, comprising:

a housing having a base plate and a housing wall, the housing wall projecting in an upward direction away from the base plate, the housing wall having an end and an interior side;

a container in the housing, the container having a visible light-transmissive top plate and a container wall, the container wall projecting in a downward direction away from the top plate toward the base plate, the container wall having an end and an exterior side;

a gasket interposed between the base plate and the end of the container wall, the gasket being configured for forming a seal between the container wall and the base plate to form a sealed container;

a lighting module in the container, the lighting module including a semiconductor light-emitting device (“

SLED”

), the SLED being configured for emitting light emissions along a central light emission axis toward the top plate;

a rail interposed between the interior side of the housing wall and the exterior side of the container wall, the rail having a first side facing towards the interior side of the housing wall and having a second side facing toward the exterior side of the container wall;

a first raised region forming a part of the interior side of the housing wall or forming a part of the first side of the rail, and a second raised region forming a part of the exterior side of the container wall or forming a part of the second side of the rail;

wherein the first raised region is configured for limiting movement of the rail away from the base plate along the upward direction, and wherein the second raised region is configured for limiting movement of the container wall away from the base plate along the upward direction.

2. The lighting system of claim 1, wherein the first raised region forms a part of the interior side of the housing wall, and wherein the second raised region forms a part of the exterior side of the container wall.

3. The lighting system of claim 2, wherein the first side of the rail includes a first recess configured for receiving the first raised region, and wherein the second side of the rail includes a second recess for receiving the second raised region.

4. The lighting system of claim 3, wherein the second recess is configured for permitting movement of the container wall through a selected distance along the upward and downward directions with the second raised region being received in the second recess.

5. The lighting system of claim 4, wherein the first recess is configured for permitting movement of the rail through a selected distance along the upward and downward directions with the first raised region being received in the first recess.

6. The lighting system of claim 1, wherein the first raised region is located at the end of and forms a part of the interior side of the housing wall, and wherein the second raised region is located at the end of and forms a part of the exterior side of the container wall.

7. The lighting system of claim 1, wherein the first raised region includes a flange located at the end of the housing wall and forming a part of the interior side of the housing wall, and wherein the second raised region includes a flange located at the end of and forming a part of the exterior side of the container wall.

8. The lighting system of claim 7, further including a bar configured for forming the flange at the end of the housing wall.

9. The lighting system of claim 8, wherein the end of the housing wall has a groove, and wherein the bar has a raised region configured for being received by the groove for attaching the bar to the end of the housing wall.

10. The lighting system of claim 8, wherein the bar has a groove, and wherein the end of the housing wall has a raised region configured for being received by the groove for attaching the bar to the end of the housing wall.

11. The lighting system of claim 8, wherein the bar is flexible.

12. The lighting system of claim 1, wherein the first raised region forms a part of the first side of the rail, and wherein the second raised region forms a part of the second side of the rail.

13. The lighting system of claim 12, wherein the interior side of the housing wall includes a recess configured for receiving the first raised region, and wherein the exterior side of the container wall includes a recess for receiving the second raised region.

14. The lighting system of claim 13, wherein the second recess is configured for permitting movement of the container wall through a selected distance along the upward and downward directions with the second raised region being received in the second recess.

15. The lighting system of claim 14, wherein the first recess is configured for permitting movement of the rail through a selected distance along the upward and downward directions with the first raised region being received in the rail.

16. The lighting system of claim 1, wherein the first raised region forms a part of the interior side of the housing wall, and wherein the second raised region forms a part of the second side of the rail.

17. The lighting system of claim 1, wherein the first raised region forms a part of the first side of the rail, and wherein the second raised region forms a part of the exterior side of the container wall.

18. The lighting system of claim 1, further including another raised region forming a part of the interior side of the housing wall or forming a part of the first side of the rail.

19. The lighting system of claim 1, further including an additional raised region forming a part of the exterior side of the container wall or forming a part of the second side of the rail.

20. The lighting system of claim 1, wherein the top plate has a perimeter, and wherein the container wall projects away from the perimeter of the top plate.

21. The lighting system of claim 20, wherein the second raised region is continuous in a direction along the perimeter of the top plate.

22. The lighting system of claim 21, wherein the second raised region includes a raised rib being continuous in the direction along the perimeter of the top plate.

23. The lighting system of claim 20, wherein the first raised region is continuous in a direction along the perimeter of the top plate.

24. The lighting system of claim 23, wherein the first raised region includes a raised rib being continuous in the direction along the perimeter of the top plate.

25. The lighting system of claim 20, including a plurality of the second raised regions being spaced apart in a direction along the perimeter of the top plate.

26. The lighting system of claim 20, including a plurality of the first raised regions being spaced apart in a direction along the perimeter of the top plate.

27. The lighting system of claim 1, including a plurality of raised ridges forming a part of the interior side of the housing wall or forming a part of the first side of the rail, wherein the plurality of the raised ridges are configured for spacing the first side of the rail apart from the interior side of the housing wall.

28. The lighting system of claim 1, including another plurality of raised ridges forming a part of the exterior side of the container wall or forming a part of the second side of the rail, wherein the another plurality of the raised ridges are configured for spacing the second side of the rail apart from the exterior side of the container wall.

29. The lighting system of claim 1, wherein the rail is configured for compressing a portion of the gasket between the base plate and the end of the container wall.

30. The lighting system of claim 29, wherein the lighting system is configured for compressing the rail between the first raised region and the second raised region.

31. The lighting system of claim 29, wherein the gasket is configured for forming a water-resistant sealed container together with the end of the container wall.

32. The lighting system of claim 29, wherein the end of the container wall has a ridge configured for being placed in contact with a surface of the gasket.

33. The lighting system of claim 1, wherein the housing wall has an opening configured for inserting the rail into the housing and for interposing the rail between the interior side of the housing wall and the exterior side of the container wall.

34. The lighting system of claim 33, further including a detachable cover for the opening.

35. The lighting system of claim 33, including another rail being interposed between the interior side of the housing wall and the exterior side of the container wall, the another rail having a first side facing towards the interior side of the housing wall and having a second side facing toward the exterior side of the container wall.

36. The lighting system of claim 35, wherein the housing wall has another opening configured for inserting the another rail into the housing and for interposing the another rail between the interior side of the housing wall and the exterior side of the container wall.

37. The lighting system of claim 1, wherein the rail is flexible.

38. The lighting system of claim 37, wherein the rail is arcuately shaped and is located between the interior side of the housing wall and the exterior side of the container wall.

39. The lighting system of claim 1, wherein the rail is a visible light-reflective rail.

40. The lighting system of claim 1, wherein the top plate is a visible light-transparent top plate.

41. The lighting system of claim 1, wherein the top plate is a visible light-translucent top plate.

42. The lighting system of claim 1, wherein the top plate includes a lens.

43. The lighting system of claim 42, wherein the top plate includes a diverging or converging lens.

44. The lighting system of claim 43, wherein the top plate includes a diverging lens screen.

45. The lighting system of claim 44, wherein the diverging lens screen includes a lenticular or microprismatic surface.

46. The lighting system of claim 1, further including a lens in the container, the lens having a lens axis and being interposed between the SLED and the top plate of the container, wherein the lens axis is aligned with the central light emission axis of the SLED.

47. The lighting system of claim 46, wherein the lens in the container is a diverging or converging lens.

48. The lighting system of claim 47, wherein the lens in the container is a converging lens having a frusto-conical shape and a total internal reflection side surface.

49. The lighting system of claim 46, wherein the top plate includes a lens.

50. The lighting system of claim 49, wherein the top plate includes a diverging or converging lens.

51. The lighting system of claim 50, wherein the top plate includes a diverging lens screen.

52. The lighting system of claim 51, wherein the diverging lens screen includes a lenticular or microprismatic surface.

53. The lighting system of claim 47, further including a carrier in the container, the carrier being configured for positioning the lens in the container with the lens axis as being aligned with the central light emission axis.

54. The lighting system of claim 53, further including a primary visible light reflector configured for being positioned in the container between the gasket and the carrier, wherein the primary visible light reflector is configured for redirecting some of the light emissions of the SLED along the central light emission axis.

55. The lighting system of claim 53, wherein the container wall includes a raised feature configured for positioning the lens in the carrier.

56. The lighting system of claim 1, including an additional lighting module in the container, the additional lighting module including an additional SLED, the additional SLED being configured for emitting additional light emissions along an additional central light emission axis toward the top plate, the additional central light emission axis being spaced apart along a longitudinal axis over the base plate away from the central light emission axis.

57. The lighting system of claim 20, wherein the top plate has a curvilinear perimeter.

58. The lighting system of claim 57, wherein the top plate has a circular or elliptical perimeter.

59. The lighting system of claim 20, wherein the housing includes another housing wall, the another housing wall projecting in another upward direction away from the base plate, the another housing wall having another end and another interior side;

and wherein the container has another container wall, the another container wall projecting in another downward direction away from the top plate toward the base plate, the another container wall having another end and another exterior side; and

wherein the gasket is interposed between the base plate and the another end of the another container wall.

60. The lighting system of claim 59, wherein a portion of the housing wall is detachable, and wherein the lighting system is configured for insertion of the container in the housing with the portion of the housing wall as being detached.

61. The lighting system of claim 59, wherein a portion of the container wall is configured for being resiliently deformed, and wherein the lighting system is configured for insertion of the container in the housing with the portion of the container wall as being resiliently deformed.

62. The lighting system of claim 59, wherein the top plate, the container wall and the another container wall integrally form the container.

63. The lighting system of claim 59, wherein the base plate, the housing wall and the another housing wall integrally form the housing.

64. The lighting system of claim 59, including another rail interposed between the interior side of the another housing wall and the exterior side of the another container wall, the another rail having a first side facing towards the interior side of the another housing wall and having a second side facing toward the exterior side of the another container wall;

and including a third raised region forming a part of the interior side of the another housing wall or forming a part of the first side of the another rail, and a fourth raised region forming a part of the exterior side of the another container wall or forming a part of the second side of the another rail;

wherein the third raised region is configured for limiting movement of the another rail away from the base plate along the another upward direction, and wherein the fourth raised region is configured for limiting movement of the another container wall away from the base plate along the another upward direction.

65. The lighting system of claim 64, wherein the another rail is configured for compressing a portion of the gasket between the base plate and the end of the another container wall.

66. The lighting system of claim 64, wherein the lighting system is configured for compressing the another rail between the third raised region and the fourth raised region.

67. The lighting system of claim 64, wherein the gasket is configured for forming a water-resistant sealed container together with the end of the container wall and the end of the another container wall.

68. The lighting system of claim 64, wherein the end of the another container wall has a ridge configured for being placed in contact with the surface of the gasket.

69. The lighting system of claim 64, wherein the another housing wall has another opening configured for inserting the another rail into the housing and for interposing the another rail between the interior side of the another housing wall and the exterior side of the another container wall.

70. The lighting system of claim 69, further including another detachable cover for the another opening.

71. The lighting system of claim 70, wherein the another rail is flexible.

72. The lighting system of claim 71, wherein the another rail is arcuately shaped and is located between the interior side of the another housing wall and the exterior side of the another container wall.

73. The lighting system of claim 64, wherein the top plate has a polygonal perimeter.

74. The lighting system of claim 64, wherein the perimeter of the top plate has a shape, and wherein the shape is:

a triangle;

a cone;

a square;

a diamond;

a rectangle;

a trapezoid;

a pentagon;

a hexagon;

a heptagon;

or an octagon.

75. The lighting system of claim 64, wherein the housing includes a third housing wall, the third housing wall projecting in a third upward direction away from the base plate, the third housing wall having a third end and a third interior side;

and wherein the container has a third container wall, the third container wall projecting in a third downward direction away from the top plate toward the base plate, the third container wall having a third end and a third exterior side; and

wherein the gasket is interposed between the base plate and the third end of the third container wall.

76. The lighting system of claim 75, including a third rail interposed between the interior side of the third housing wall and the exterior side of the third container wall, the third rail having a first side facing towards the interior side of the third housing wall and having a second side facing toward the exterior side of the third container wall;

and including a fifth raised region forming a part of the interior side of the third housing wall or forming a part of the first side of the third rail, and a sixth raised region forming a part of the exterior side of the third container wall or forming a part of the second side of the third rail;

wherein the fifth raised region is configured for limiting movement of the third rail away from the base plate along the third upward direction, and wherein the sixth raised region is configured for limiting movement of the third container wall away from the base plate along the third upward direction.

77. The lighting system of claim 76, wherein the housing includes a fourth housing wall, the fourth housing wall projecting in a fourth upward direction away from the base plate, the fourth housing wall having a fourth end and a fourth interior side;

and wherein the container has a fourth container wall, the fourth container wall projecting in a fourth downward direction away from the top plate toward the base plate, the fourth container wall having a fourth end and a fourth exterior side; and

wherein the gasket is interposed between the base plate and the fourth end of the fourth container wall.

78. The lighting system of claim 77, including a fourth rail interposed between the interior side of the fourth housing wall and the exterior side of the fourth container wall, the fourth rail having a first side facing towards the interior side of the fourth housing wall and having a second side facing toward the exterior side of the fourth container wall;

and including a seventh raised region forming a part of the interior side of the fourth housing wall or forming a part of the first side of the fourth rail, and an eighth raised region forming a part of the exterior side of the fourth container wall or forming a part of the second side of the fourth rail;

wherein the seventh raised region is configured for limiting movement of the fourth rail away from the base plate along the fourth upward direction, and wherein the eighth raised region is configured for limiting movement of the fourth container wall away from the base plate along the fourth upward direction.