Note: Descriptions are shown in the official language in which they were submitted.
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MODULAR LED LIGHTING APPARATUS FOR SOCKET ENGAGEMENT
Field of the Disclosure
[0001] The present disclosure relates generally to modular lighting
apparatus and
methods of assembly, installation and replacement of such apparatus. In
various aspects,
methods and apparatus according to the disclosure facilitate ease of
manufacture, installation
and replacement of modular lighting apparatus components as well as thermal
efficiency
during operation. In one aspect, such lighting apparatus and methods employ
LED-based
light sources to provide visible light in a variety of environments and for a
variety of lighting
applications.
Background
[0002] LED-based lighting fixtures are employed for a variety of
illumination
applications. In some cases, the lighting fixture may include a controller,
one or more LED-
based light sources, and may further include one or more components to
facilitate heat
dissipation, in one incorporated unit. To replace any one element of such an
incorporated
unit may require either replacement of the entire lighting fixture or repair
by a skilled
technician. Additionally, physically exchanging new LED-based light sources
for the
existing LED-based light sources can be difficult if different LED-based
lighting assemblies
are desired, or if the existing LED-based source(s) fail.
[0003] Recessed lighting is a popular lighting option for both new
construction and
remodeling. With recessed lighting, the majority of a lighting fixture is
disposed
substantially behind or recessed into an architectural surface or feature,
such as a ceiling (or
wall, or soffit). The lighting fixture typically includes a housing (sometimes
commonly
referred to as a "can"), a bulb such as an incandescent, fluorescent or
halogen bulb, and some
means for electrically connecting the fixture to a source of operating power.
With new
construction, the fixture is typically supported by hangars attached to
joists. When
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to reduce the amount of ceiling (or other architectural surface) that is
removed,
the fixture may be inserted through a ceiling hole and attached to the drywall
forming the
ceiling, wherein the ceiling hole provides a light exit aperture for light
generated by the
fixture's bulb.
Summary
[0004] Various embodiment of the present disclosure are directed to modular
lighting
fixtures that allow convenient installation and removal of LED-based light-
generating
modules as well as controller modules that may be employed to control the
light-generating
modules. In one example, a modular lighting fixture includes a housing that is
configured to
be recessed into or otherwise disposed behind an architectural surface such as
ceiling, wall, or
soffit, in new or existing construction scenarios. The fixture housing
includes a socket
configured to facilitate one or more of a mechanical, electrical and thermal
coupling of the
light-generating module to the fixture housing. The ability to easily engage
and disengage the
LED-based light-generating module with the socket, without removing the
fixture housing
itself, allows for straightforward replacement of the light-generating module
upon failure, or
exchange with another module having different light-generating
characteristics. Modular
lighting controllers (also referred to as "controller modules") for such
fixtures also may be
easily installed in or removed from the fixture housing, in some instances via
the same access
route by which the light-generating module is installed and removed.
[0005] Thus, according to various aspect of the disclosure, modular
lighting fixtures are
provided in which a single housing may accommodate different LED-based light-
generating
modules that may be switched in and out of the housing. In this regard, light-
generating
modules according to various embodiments of the present disclosure may mimic
the ease of
installation and replacement of conventional incandescent, fluorescent or
halogen light bulbs
in that a new light-generating module can be inserted into the housing without
changes to the
fixture. A new light-generating module may be inserted, for example, when a
previous light-
generating module stops working or an improved or different light-generating
module is
desired.
[0006] As indicated above, according to one aspect of the disclosure, a
socket or other
attachment element facilitates the attachment of a light-generating module to
a housing of a
lighting fixture. In addition to providing a mechanical connection between the
light-
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generating module and the lighting fixture, the socket also may provide an
electrical
connection and/or a thermal connection. For example, the socket may include
electrical
connections that provide drive signals and operating power to a light-
generating module
when the light-generating module is inserted into or otherwise coupled to the
socket.
According to another aspect of the disclosure, a socket or other attachment
element may
facilitate thermal diffusion in at least two manners. First, the socket may be
configured to
interact with the light-generating module so that the light-generating module
achieves a
thermal connection with the housing or other component of the lighting
fixture. Second, the
socket itself may be thermally conductive and help to transfer heat to the
housing and/or
directly to surrounding air (e.g., via a front light-exit face of the light-
generating module).
[0007] According to another aspect of the disclosure, a removable light-
generating
module is itself configured to facilitate heat transfer away from the light
sources present in
the module. The heat transfer is achieved in some embodiments by using a
thermally
conductive chassis for the light-generating module to facilitate transfer of
heat away from a
front side (light exit face) of the light-generating module. In some
embodiments, a thermally
conductive base plate is attached to a rear side of the light-generating
module to facilitate
transfer of heat to a housing or other part of a lighting fixture, in some
cases via the socket.
[0008] According to another aspect of the disclosure, the engagement and
disengagement
of a light-generating module with the socket of a lighting fixture is
accomplished via a simple
rotating motion. In this regard, installing and removing an LED-based light-
generating
module from a modular lighting fixture may have a familiar feel similar to the
process of
changing a conventional incandescent light bulb.
[0009] In particular, in one exemplary implementation, the socket is
configured as a
collar with screw-type threads, and the module is configured so as to be
attachable to and
detachable from a socket via a threaded grip ring that is placed over the
module and engages
with the threads on the socket via rotation, thereby "sandwiching" the module
between the
grip ring and socket. According to another aspect of the disclosure, a
removable light-
generating module includes a number of hexagonally-shaped LED subassemblies.
In some
embodiments, the grip ring is rotatable relative to the module so that the
orientation of the
LED subassemblies is not affected by the rotation of the grip ring (i.e., the
module itself does
not rotate in the socket as the grip ring is rotated). Additionally, the
relative rotation of the
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grip ring may allow a connector to be directly mounted to light-generating
module without
concern for the effects of twisting on the connector.
[0010] In other embodiments, no grip ring is used to secure the light-
generating module
to the socket, and electrical connections between the light-generating module
and the socket
are achieved through connections of post (or threads) on the light-generating
module and
corresponding threads (or posts) on the socket. That is to say, electrical
contacts may be
provided on the engagement elements themselves in some embodiments.
[0011] According to another aspect of the disclosure, a controller module
may be used in
connection with a light-generating module in a lighting fixture
implementation. According to
another aspect of the disclosure, a controller module may have a physical
structure that is
configured for installation in a specific type of lighting fixture housing.
For example, a
controller module may have one or more rounded edges to facilitate placement
or removal of
the controller module from a recessed lighting fixture which is not itself
removable from an
architectural feature such as a ceiling.
[0012] In one embodiment, a controller module itself may have an internal
modular
construction. More specifically, the controller module may be configured for
interchangeability of components that are used for receiving input control
signals and/or data
at a "front-end" input interface (e.g., coupled to a user interface, control
network, sensor,
etc.). The controller module further may be configured for interchangeability
of components
that are used for outputting control signals and/or data and/or power at a
"back-end" output
interface to the light-generating module. In this regard, the controller
module may be flexible
in its ability to communicate with various light-generating modules and/or
networks,
computers, or other controllers without the need for numerous hardware and/or
software
components being simultaneously present within the controller module. Such a
configuration
may save on space and/or cost when producing controller modules for modular
lighting
fixtures and other applications.
[0013] According to another aspect, a light-generating module for a modular
lighting
fixture may be configured with some nominal data storage and processing
capability for
providing information to a controller associated with the lighting fixture and
packaged as a
separate controller module of the fixture. For example, the light-generating
module may
provide information on one or more of the type of light sources present in the
light-generating
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module, their power requirements, operating temperature, operating time or
temperature
history, calibration parameters and the like, so that a separate controller
module may provide
appropriate drive signals and operating power to the light-generating module.
[0014] According to another aspect of the disclosure, a controller module
is configured to
receive information, data and or control signals from a light-generating
module relating to
some operating parameter or characteristic associated with the light-
generating module. The
controller module may be programmed to alter its outgoing control signals
and/or power
output to the light-generating module based on the information received from
the light-
generating module. For example, the light-generating module may indicate to
the controller
the voltage or current levels desired for operation of that particular light-
generating module,
and the controller may provide the appropriate voltage and current levels
based on that
information.
[0015] According to another aspect of the disclosure, a battery or other
auxiliary power
source is provided in an LED lighting fixture such that the LED lighting
fixture may be used
for emergency lighting in addition to its primary lighting purpose.
[0016] In sum, as discussed in greater detail below, one embodiment of the
present
disClosure is directed to a light-generating apparatus comprising an LED
assembly, a plurality
of optical components, and a chassis coupled to the LED assembly and including
a plurality
of chambers in which the plurality of optical components respectively are
held. The LED
assembly comprises an assembly substrate and a plurality of LED subassemblies
coupled to
the assembly substrate. Each LED subassembly of the plurality of LED
subassemblies forms
at least one of a mechanical connection, an electrical connection, and a first
thermal
connection to the assembly substrate. The chassis is configured such that each
optical
component of the plurality of optical components is disposed in an optical
path of a
corresponding one of the plurality of LED subassemblies.
[0017] Another embodiment is directed to a light-generating apparatus
comprising a
thermally conductive chassis through which light exits from the apparatus, an
LED assembly
to generate the light, and a thermally conductive base plate. The LED assembly
is disposed
between the thermally conductive base plate and the thermally conductive
chassis. The LED
assembly and the thermally conductive chassis form a first thermal connection
to facilitate
first heat dissipation from the LED assembly via the thermally conductive
chassis. The LED
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assembly and the thermally conductive base plate form a second thermal
connection to
facilitate second heat dissipation from the LED assembly via the thermally
conductive base
plate.
[0018] Another embodiment is directed to a light-generating apparatus
comprising a
circular chassis and a circular printed circuit board substrate coupled to the
circular chassis.
The circular printed circuit board substrate includes at least one chip-on-
board LED module.
[0019] Another embodiment is directed to a lighting control apparatus,
comprising at
least one connection mechanism configured to permit a modular installation and
removal of
at least a first circuit board including input circuitry configured to receive
at least one input
signal including information relating to lighting, and a second circuit board
including output
circuitry configured to output at least one lighting control signal that is
based at least in part
on the information included in the at least one input signal. The at least one
connection
mechanism provides at least one electrical connection between the first
circuit board and the
second circuit board when both the first and second circuit boards are coupled
to the at least
one connection mechanism.
[0020] Another embodiment is directed to a modular lighting fixture,
comprising a fixture
housing having at least one thermally conductive portion, and a socket mounted
to the at least
one thermally conductive portion of the fixture housing. The socket is
configured to facilitate
a thermal conduction path between a light-generating module installed in the
socket and the
at least one thermally conductive portion of the fixture housing.
[0021] Another embodiment is directed to a modular lighting fixture,
comprising a fixture
housing having at least one light exit aperture, a socket mounted to the
fixture housing and
accessible via the at least one light exit aperture, a light-generating module
installed in and
removable from the socket via the at least one light exit aperture, and a
controller module to
control the light-generating module. The controller module is disposed in the
fixture housing
and accessible via the at least one light exit aperture to facilitate
installation and removal of
the controller module.
[0022] Another embodiment is directed to a modular lighting fixture,
comprising a fixture
housing, a socket mounted to the fixture housing, a light-generating module
installed in and
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removable from the socket, and a controller module to control the light-
generating module,
the controller module disposed in or proximate to the fixture housing. The
light-generating
module is configured to provide information to the controller module relating
to at least one
characteristic of the light generating module, and the controller module is
configured to
control the light-generating module based at least in part on the information
provided by the
light-generating module.
[0023] As used herein for purposes of the present disclosure, the term
"LED" should be
understood to include any electroluminescent diode or other type of carrier
injection/junction-
based system that is capable of generating radiation in response to an
electric signal. Thus,
the term LED includes, but is not limited to, various semiconductor-based
structures that emit
light in response to current, light emitting polymers, organic light emitting
diodes (OLEDs),
electroluminescent strips, and the like.
[0024] In particular, the term LED refers to light emitting diodes of all
types (including
semi-conductor and organic light emitting diodes) that may be configured to
generate
radiation in one or more of the infrared spectrum, ultraviolet spectrum, and
various portions
of the visible spectrum (generally including radiation wavelengths from
approximately 400
nanometers to approximately 700 nanometers). Some examples of LEDs include,
but are not
limited to, various types of infrared LEDs, ultraviolet LEDs, red LEDs, blue
LEDs, green
LEDs, yellow LEDs, amber LEDs, orange LEDs, and white LEDs (discussed further
below).
It also should be appreciated that LEDs may be configured and/or controlled to
generate
radiation having various bandwidths (e.g., full widths at half maximum, or
FWHM) for a
given spectrum (e.g., narrow bandwidth, broad bandwidth), and a variety of
dominant
wavelengths within a given general color categorization.
[0025] For example, one implementation of an LED configured to generate
essentially
white light (e.g., a white LED) may include a number of dies which
respectively emit
different spectra of electroluminescence that, in combination, mix to form
essentially white
light. In another implementation, a white light LED may be associated with a
phosphor
material that converts electroluminescence having a first spectrum to a
different second
spectrum. In one example of this implementation, electroluminescence having a
relatively
short wavelength and narrow bandwidth spectrum "pumps" the phosphor material,
which in
turn radiates longer wavelength radiation having a somewhat broader spectrum.
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[0026] It should also be understood that the term LED does not limit the
physical and/or
electrical package type of an LED. For example, as discussed above, an LED may
refer to a
single light emitting device having multiple dies that are configured to
respectively emit
different spectra of radiation (e.g., that may or may not be individually
controllable). Also,
an LED may be associated with a phosphor that is considered as an integral
part of the LED
(e.g., some types of white LEDs). In general, the term LED may refer to
packaged LEDs,
non-packaged LEDs, surface mount LEDs, chip-on-board LEDs, T-package mount
LEDs,
radial package LEDs, power package LEDs, LEDs including some type of
encasement and/or
optical element (e.g., a diffusing lens), etc.
[0027] The term "light source" should be understood to refer to any one or
more of a
variety of radiation sources, including, but not limited to, LED-based sources
(including one
or more LEDs as defined above), incandescent sources (e.g., filament lamps,
halogen lamps),
fluorescent sources, phosphorescent sources, high-intensity discharge sources
(e.g., sodium
vapor, mercury vapor, and metal halide lamps), lasers, other types of
electroluminescent
sources, pyro-luminescent sources (e.g., flames), candle-luminescent sources
(e.g., gas
mantles, carbon arc radiation sources), photo-luminescent sources (e.g.,
gaseous discharge
sources), cathode luminescent sources using electronic satiation, galvano-
luminescent
sources, crystallo-luminescent sources, kine-luminescent sources, thermo-
luminescent
sources, triboluminescent sources, sonoluminescent sources, radioluminescent
sources, and
luminescent polymers.
[0028] A given light source may be configured to generate electromagnetic
radiation
within the visible spectrum, outside the visible spectrum, or a combination of
both. Hence,
the terms "light" and "radiation" are used interchangeably herein.
Additionally, a light
source may include as an integral component one or more filters (e.g., color
filters), lenses, or
other optical components. Also, it should be understood that light sources may
be configured
for a variety of applications, including, but not limited to, indication,
display, and/or
illumination. An "illumination source" is a light source that is particularly
configured to
generate radiation having a sufficient intensity to effectively illuminate an
interior or exterior
space. In this context, "sufficient intensity" refers to sufficient radiant
power in the visible
spectrum generated in the space or environment (the unit "lumens" often is
employed to
represent the total light output from a light source in all directions, in
terms of radiant power
or "luminous flux") to provide ambient illumination (i.e., light that may be
perceived
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indirectly and that may be, for example, reflected off of one or more of a
variety of
intervening surfaces before being perceived in whole or in part).
[0029] The term "spectrum" should be understood to refer to any one or more
frequencies
(or wavelengths) of radiation produced by one or more light sources.
Accordingly, the term
"spectrum" refers to frequencies (or wavelengths) not only in the visible
range, but also
frequencies (or wavelengths) in the infrared, ultraviolet, and other areas of
the overall
electromagnetic spectrum. Also, a given spectrum may have a relatively narrow
bandwidth
(e.g., a FWHM having essentially few frequency or wavelength components) or a
relatively
wide bandwidth (several frequency or wavelength components having various
relative
strengths). It should also be appreciated that a given spectrum may be the
result of a mixing
of two or more other spectra (e.g., mixing radiation respectively emitted from
multiple light
sources).
[0030] For purposes of this disclosure, the term "color" is used
interchangeably with the
term "spectrum." However, the term "color" generally is used to refer
primarily to a property
of radiation that is perceivable by an observer (although this usage is not
intended to limit the
scope of this term). Accordingly, the terms "different colors" implicitly
refer to multiple
spectra having different wavelength components and/or bandwidths. It also
should be
appreciated that the term "color" may be used in connection with both white
and non-white
light.
[0031] The term "color temperature" generally is used herein in connection
with white
light, although this usage is not intended to limit the scope of this term.
Color temperature
essentially refers to a particular color content or shade (e.g., reddish,
bluish) of white light.
The color temperature of a given radiation sample conventionally is
characterized according
to the temperature in degrees Kelvin (K) of a black body radiator that
radiates essentially the
same spectrum as the radiation sample in question. Black body radiator color
temperatures
generally fall within a range of from approximately 700 degrees K (typically
considered the
first visible to the human eye) to over 10,000 degrees K; white light
generally is perceived at
color temperatures above 1500-2000 degrees K.
[0032] Lower color temperatures generally indicate white light having a
more significant
red component or a "warmer feel," while higher color temperatures generally
indicate white
light having a more significant blue component or a "cooler feel." By way of
example, fire
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has a color temperature of approximately 1,800 degrees K, a conventional
incandescent bulb
has a color temperature of approximately 2848 degrees K, early morning
daylight has a color
temperature of approximately 3,000 degrees K, and overcast midday skies have a
color
temperature of approximately 10,000 degrees K. A color image viewed under
white light
having a color temperature of approximately 3,000 degree K has a relatively
reddish tone,
whereas the same color image viewed under white light having a color
temperature of
approximately 10,000 degrees K has a relatively bluish tone.
[0033] The term "lighting fixture" is used herein to refer to an apparatus
including one or
more light sources of same or different types. A given lighting fixture may
have any one of a
variety of mounting arrangements for the light source(s), enclosure/housing
arrangements and
shapes, and/or electrical and mechanical connection configurations.
Additionally, a given
lighting fixture optionally may be associated with (e.g., include, be coupled
to and/or
packaged together with) various other components (e.g., control circuitry)
relating to the
operation of the light source(s). An "LED-based lighting fixture" refers to a
lighting fixture
that includes one or more LED-based light sources as discussed above, alone or
in
combination with other non LED-based light sources. A "multi-channel" lighting
fixture
refers to an LED-based or non LED-based lighting fixture that includes at
least two light
sources configured to respectively generate different spectrums of radiation,
wherein each
different source spectrum may be referred to as a "channel" of the multi-
channel lighting
fixture.
[0034] The term "controller" is used herein generally to describe various
apparatus
relating to the operation of one or more light sources. A controller can be
implemented in
numerous ways (e.g., such as with dedicated hardware) to perform various
functions
discussed herein. A "processor" is one example of a controller which employs
one or more
microprocessors that may be programmed using software (e.g., microcode) to
perform
various functions discussed herein. A controller may be implemented with or
without
employing a processor, and also may be implemented as a combination of
dedicated
hardware to perform some functions and a processor (e.g., one or more
programmed
microprocessors and associated circuitry) to perform other functions. Examples
of controller
components that may be employed in various embodiments of the present
disclosure include,
but are not limited to, conventional microprocessors, application specific
integrated circuits
(ASICs), and field-programmable gate arrays (FPGAs).
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[0035] In various implementations, a processor or controller may be
associated with one
or more storage media (generically referred to herein as "memory," e.g.,
volatile and non-
volatile computer memory such as RAM, PROM, EPROM, and EEPROM, floppy disks,
compact disks, optical disks, magnetic tape, etc.). In some implementations,
the storage
media may be encoded with one or more programs that, when executed on one or
more
processors and/or controllers, perform at least some of the functions
discussed herein.
Various storage media may be fixed within a processor or controller or may be
transportable,
such that the one or more programs stored thereon can be loaded into a
processor or
controller so as to implement various aspects of the present disclosure
discussed herein. The
terms "program" or "computer program" are used herein in a generic sense to
refer to any
type of computer code (e.g., software or microcode) that can be employed to
program one or
more processors or controllers.
[0036] The term "addressable" is used herein to refer to a device (e.g., a
light source in
general, a lighting fixture, a controller or processor associated with one or
more light sources
or lighting fixtures, other non-lighting related devices, etc.) that is
configured to receive
information (e.g., data) intended for multiple devices, including itself, and
to selectively
respond to particular information intended for it. The term "addressable"
often is used in
connection with a networked environment (or a "network," discussed further
below), in
which multiple devices are coupled together via some communications medium or
media.
[0037] In one network implementation, one or more devices coupled to a
network may
serve as a controller for one or more other devices coupled to the network
(e.g., in a
master/slave relationship). In another implementation, a networked environment
may include
one or more dedicated controllers that are configured to control one or more
of the devices
coupled to the network. Generally, multiple devices coupled to the network
each may have
access to data that is present on the communications medium or media; however,
a given
device may be "addressable" in that it is configured to selectively exchange
data with (i.e.,
receive data from and/or transmit data to) the network, based, for example, on
one or more
particular identifiers (e.g., "addresses") assigned to it.
[0038] The term "network" as used herein refers to any interconnection of
two or more
devices (including controllers or processors) that facilitates the transport
of information (e.g.
for device control, data storage, data exchange, etc.) between any two or more
devices and/or
among multiple devices coupled to the network. As should be readily
appreciated, various
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implementations of networks suitable for interconnecting multiple devices may
include any
of a variety of network topologies and employ any of a variety of
communication protocols.
Additionally, in various networks according to the present disclosure, any one
connection
between two devices may represent a dedicated connection between the two
systems, or
alternatively a non-dedicated connection. In addition to carrying information
intended for the
two devices, such a non-dedicated connection may carry information not
necessarily intended
for either of the two devices (e.g., an open network connection). Furthermore,
it should be
readily appreciated that various networks of devices as discussed herein may
employ one or
more wireless, wire/cable, and/or fiber optic links to facilitate information
transport
throughout the network.
[0039] The term "user interface" as used herein refers to an interface
between a human
user or operator and one or more devices that enables communication between
the user and
the device(s). Examples of user interfaces that may be employed in various
implementations
of the present disclosure include, but are not limited to, switches,
potentiometers, buttons,
dials, sliders, a mouse, keyboard, keypad, various types of game controllers
(e.g., joysticks),
track balls, display screens, various types of graphical user interfaces
(GUIs), touch screens,
microphones and other types of sensors that may receive some form of human-
generated
stimulus and generate a signal in response thereto.
[0040] The following patents and patent applications are disclosed:
[0041] U.S. Patent No. 6,016,038, issued January 18, 2000, entitled
"Multicolored LED
Lighting Method and Apparatus;"
[0042] U.S. Patent No. 6,211,626, issued April 3, 2001 to Lys et al,
entitled "Illumination
Components;"
[0043] U.S. Patent No. 6,548,967, issued April 15, 2003, entitled
"Universal Lighting
Network Methods and Systems;"
[0044]
[0045] U.S. Patent Application Publication No. 2003/0133292, published July
17, 2003,
entitled "Methods and Apparatus for Generating and Modulating White Light
Illumination
Conditions;"
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100461 U.S. Patent Application Publication No. 2004/0052076, published
March 18,
2004, entitled "Controlled Lighting Methods and Apparatus;" and
[0047] U.S. Patent No. 7,344,279, issued March 18, 2008, entitled "Thermal
Management Methods and Apparatus for Lighting Devices."
[0048] It should be appreciated that all combinations of the foregoing
concepts and
additional concepts discussed in greater detail below are contemplated as
being part of the
inventive subject matter disclosed herein. In particular, all combinations of
claimed subject
matter appearing at the end of this disclosure are contemplated as being part
of the inventive
subject matter disclosed herein. It should also be appreciated that
terminology explicitly
employed herein should be accorded a meaning most consistent with the
particular concepts
disclosed herein.
Brief Description of the Drawings
[0049] Fig. 1 is a diagram illustrating a lighting fixture according to one
embodiment of
the disclosure.
[0050] Fig. 2 is a diagram illustrating a networked lighting system
according to one
embodiment of the disclosure.
[0051] Fig. 3 is a perspective, partial cut away bottom view of a lighting
fixture
according to one embodiment of the disclosure.
[0052] Fig. 4 is a perspective bottom view of the lighting fixture of Fig.
3.
[0053] Fig. 5 is a perspective top view of the lighting fixture of Figs. 3
and 4.
[0054] Fig. 6 is a partially exploded perspective bottom view of a lighting
fixture
according to another embodiment of the disclosure.
[0055] Fig. 7 is a perspective view of a light-generating module and socket
combination
according to one embodiment of the disclosure.
[0056] Fig 8 is a perspective cut away view of the light-generating module
of Fig. 7.
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[0057] Fig. 9 is an exploded view of a light-generating module and a socket
according to
one embodiment of the disclosure.
[0058] Fig. 10 is a front view of an LED assembly of the light-generating
module of Fig.
9, according to one embodiment of the disclosure.
= [0059] Fig. 11 is a rear view of the LED assembly of Fig. 10.
[0060] Fig. 12 illustrates a jig for use in assembling the LED assembly of
Figs. 10 and
11, according to one embodiment of the disclosure.
[0061] Fig. 13 illustrates LED subassemblies positioned on the jig of Fig.
12.
[0062] Fig. 14 illustrates the addition of a printed circuit board to the
LED subassemblies
of Fig. 13.
[0063] Fig. 15 is a perspective view of a secondary optic component
according to one
embodiment of the disclosure.
[0064] Fig. 16 is a perspective view of a secondary optic component
according to another
embodiment of the disclosure.
[0065] Fig. 17 is a perspective view of the secondary optic component of
Fig. 16.
[0066] Fig. 18 is a perspective front view of a light-generating module
showing
ornamental features of the module, according to one embodiment of the
disclosure.
[0067] Fig. 19 is a perspective rear view of a light-generating module
according to one
embodiment of the disclosure.
[0068] Fig. 20 is a side view of a light-generating module according to one
embodiment
of the disclosure.
[0069] Fig. 21 is a top view of a light-generating module according to one
embodiment of
the disclosure.
[0070] Fig. 22 is a cross-sectional view taken along line 22-22 of Fig. 21.
[0071] Fig. 23 is a perspective view of the light-generating module of Fig.
21.
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[0072] Fig. 24 is a rear view of the light-generating module of Fig. 21.
[0073] Fig. 25 is a front view of a chassis of the light-generating module
of Fig. 9,
according to one embodiment of the disclosure.
[0074] Fig. 26 is a rear view of the chassis of Fig. 25.
[0075] Fig. 27 is an exploded view of a light-generating module according
to an
alternative embodiment of the disclosure.
[0076] Fig. 28 is another exploded view of the light-generating module of
Fig. 27.
[0077] Fig. 29 is a perspective rear view of a chassis of the light-
generating module of
Figs. 27 and 28, including electrical contacts and connections according to
one embodiment
of the disclosure.
[0078] Fig. 30 is a perspective front view of the chassis of Fig. 29.
[0079] Fig. 31 is a top view of electrical connections present in the
chassis of Figs. 29
and 30 according to one embodiment of the disclosure.
[0080] Fig. 32 is a perspective view of a light-generating module including
a heat sink
according to one embodiment of the disclosure.
[0081] Fig. 33 is a cross-sectional view of the light-generating module of
Fig. 32.
[0082] Fig. 34 is an exploded view of a light-generating module including a
fan
according to one embodiment of the disclosure.
[0083] Fig. 35 is an exploded view of a light-generating module including a
fan
according to another embodiment of the disclosure.
[0084] Fig. 36 is a perspective view of a heat sink for a light-generating
module.
[0085] Fig. 37 is a top view of the heat sink of Fig. 36.
[0086] Fig. 38 is a cross-sectional view of the heat sink of Fig. 36.
[0087] Fig. 39 is a cross-sectional side view of a recessed joist-mount
lighting fixture
according to one embodiment of the disclosure.
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[0088] Fig. 40 is a perspective view of a recessed joist-mount lighting
fixture according
to one embodiment of the disclosure.
[0089] Fig. 41 shows a light-generating module being removed from a
recessed joist-
mount lighting fixture.
[0090] Fig. 42 illustrates a light-generating module being attached to a
socket according
to one embodiment of the disclosure.
[0091] Fig. 43 illustrates a socket attached to a heat sink according to
one embodiment of
the disclosure;
[0092] Figs. 44A and 44B illustrate an alternative embodiment of a light-
generating
module and a socket.
[0093] Fig. 45 is a cross-sectional side view of an engagement arrangement
according to
one embodiment of the disclosure.
[0094] Fig. 46 is a perspective view of another embodiment of a light-
generating module
and a socket;
[0095] Fig. 47 is a front view of the light-generating module of Fig. 46.
[0096] Fig. 48 is a perspective view of a rectangular light-generating
module and socket
according to one embodiment of the disclosure.
[0097] Fig. 49 is a perspective view of a lighting fixture configured to
receive upwardly-
facing light-generating modules.
[0098] Figs. 50 and 51 illustrate light-generating modules and sockets
according to two
alternative embodiments of the disclosure.
[0099] Fig. 52 is a perspective view of a light-generating module according
to another
embodiment of the disclosure.
[00100] Fig. 53 is a perspective view of a light-generating module configured
to be
upwardly facing.
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[00101] Fig. 54 is a cross-sectional view of the light-generating module of
Fig. 53 and an
associated socket.
[00102] Fig. 55 is cross-sectional view of a lighting fixture including two
upwardly-facing
light-generating modules.
[00103] Figs. 56A-56E illustrate various embodiments of upwardly-facing light-
generating modules.
[00104] Fig. 57 is a perspective exploded view of a light-generating module
according to
one embodiment of the disclosure.
[00105] Fig. 58 is a perspective view of a lighting fixture according to one
embodiment of
the disclosure.
[00106] Fig. 59 is a perspective view of a lighting fixture according to one
embodiment of
the disclosure.
[00107] Fig. 60 shows a series of lighting fixture positions as the lighting
fixture is
installed in an architectural feature.
[00108] Figs. 61, 62 and 63 are perspective views of the lighting fixture of
Fig. 59.
[00109] Fig. 64 is a perspective view of another embodiment of a lighting
fixture.
[00110] Figs. 65, 66 and 67 are perspective views of the lighting fixture of
Fig. 64.
[00111] Fig. 68 is a perspective view of a lighting fixture mounted behind an
architectural
feature according to one embodiment of the disclosure.
[00112] Figs. 69A, 69B and 69C show three orthogonal views of the lighting
fixture of
Fig. 68.
[00113] Fig. 70 shows a controller module for a lighting fixture according to
one
embodiment of the disclosure.
[00114] Figs. 71A, 71B, 71C are perspective views of a controller module with
various
connectors.
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[00115] Figs. 72, 73, 74, and 75 illustrate steps of installing a controller
module in a
housing according to one embodiment of the disclosure.
[00116] Fig. 76 illustrates a controller module including internal modular
input and output
interfaces.
[00117] Fig. 77 illustrates a schematic view of an auxiliary power supply.
Detailed Description
[00118] Various embodiments of the present disclosure are described below,
including
certain embodiments relating particularly to LED-based light sources. It
should be
appreciated, however, that the present disclosure is not limited to any
particular manner of
implementation, and that the various embodiments discussed explicitly herein
are primarily
for purposes of illustration. For example, the various concepts discussed
herein may be
suitably implemented in a variety of environments involving LED-based light
sources, other
types of light sources not including LEDs, environments that involve both LEDs
and other
types of light sources in combination, and environments that involve non-
lighting-related
devices alone or in combination with various types of light sources.
[00119] Fig. 1 illustrates one example of various components that may
constitute a lighting
fixture 100 according to one embodiment of the present disclosure. Some
general examples
of LED-based lighting fixtures including components similar to those that are
described
below in connection with Fig. 1 may be found, for example, in U.S. Patent No.
6,016,038,
issued January 18, 2000 to Mueller et al., entitled "Multicolored LED Lighting
Method and
Apparatus," and U.S. Patent No. 6,211,626, issued April 3, 2001 to Lys et al,
entitled
"Illumination Components ".
[00120] In various embodiments of the present disclosure, the lighting fixture
100 shown
in Fig. 1 may be used alone or together with other similar lighting fixtures
in a system of
lighting fixtures (e.g., as discussed further below in connection with Fig.
2). Used alone or in
combination with other lighting fixtures, the lighting fixture 100 may be
employed in a
variety of applications including, but not limited to, interior or exterior
space (e.g.,
architectural) lighting and illumination in general, direct or indirect
illumination of objects or
spaces, theatrical or other entertainment-based/special effects lighting,
decorative lighting,
safety-oriented lighting, lighting associated with (or illumination of)
displays and/or
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merchandise (e.g. for advertising and/or in retail/consumer environments),
combined lighting
or illumination and communication systems, etc., as well as for various
indication, display
and informational purposes.
[00121] In one embodiment, the lighting fixture 100 shown in Fig. 1 may
include one or
more light sources 104A, 104B, 104C, and 104D (shown collectively as 104),
wherein one or
more of the light sources may be an LED-based light source that includes one
or more light
emitting diodes (LEDs). In one aspect of this embodiment, any two or more of
the light
sources may be adapted to generate radiation of different colors (e.g. red,
green, blue); in this
respect, as discussed above, each of the different color light sources
generates a different
source spectrum that constitutes a different "channel" of a "multi-channel"
lighting fixture.
Although Fig. 1 shows four light sources 104A, 1Q4B, 104C, and 104D, it should
be
appreciated that the lighting fixture is not limited in this respect, as
different numbers and
various types of light sources (all LED-based light sources, LED-based and non-
LED-based
light sources in combination, etc.) adapted to generate radiation of a variety
of different
colors, including essentially white light, may be employed in the lighting
fixture 100, as
discussed further below.
[00122] As shown in Fig. 1, the lighting fixture 100 also may include a
controller 105 that
is configured to output one or more control signals to drive the light sources
so as to generate
various intensities of light from the light sources. For example, in one
implementation, the
controller 105 may be configured to output at least one control signal for
each light source so
as to independently control the intensity of light (e.g., radiant power in
lumens) generated by
each light source; alternatively, the controller 105 may be configured to
output one or more
control signals to collectively control a group of two or more light sources
identically. Some
examples of control signals that may be generated by the controller to control
the light
sources include, but are not limited to, pulse modulated signals, pulse width
modulated
signals (PWM), pulse amplitude modulated signals (PAM), pulse code modulated
signals
(PCM) analog control signals (e.g., current control signals, voltage control
signals),
combinations and/or modulations of the foregoing signals, or other control
signals. In one
aspect, particularly in connection with LED-based sources, one or more
modulation
techniques provide for variable control using a fixed current level applied to
one or more
LEDs, so as to mitigate potential undesirable or unpredictable variations in
LED output that
may arise if a variable LED drive current were employed. In another aspect,
the controller
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105 may control other dedicated circuitry (not shown in Fig. 1) which in turn
controls the
light sources so as to vary their respective intensities.
[00123] In general, the intensity (radiant output power) of radiation
generated by the one
or more light sources is proportional to the average power delivered to the
light source(s)
over a given time period. Accordingly, one technique for varying the intensity
of radiation
generated by the one or more light sources involves modulating the power
delivered to (i.e.,
the operating power of) the light source(s). For some types of light sources,
including LED-
based sources, this may be accomplished effectively using a pulse width
modulation (PWM)
technique.
[00124] In one exemplary implementation of a PWM control technique, for each
channel
of a lighting fixture a fixed predetermined voltage Vsource is applied
periodically across a
given light source constituting the channel. The application of the voltage
Vsource may be
accomplished via one or more switches, not shown in Fig. 1, controlled by the
controller 105.
While the voltage Vsource is applied across the light source, a predetermined
fixed current
'source (e.g., determined by a current regulator, also not shown in Fig. 1) is
allowed to flow
through the light source. Again, recall that an LED-based light source may
include one or
more LEDs, such that the voltage Vsource may be applied to a group of LEDs
constituting the
source, and the current "source may be drawn by the group of LEDs. The fixed
voltage Vsource
across the light source when energized, and the regulated current 'source
drawn by the light
source when energized, determines the amount of instantaneous operating power
P source of the
light source (Psource = Vsource = 'source). As mentioned above, for LED-based
light sources,
using a regulated current mitigates potential undesirable or unpredictable
variations in LED
output that may arise if a variable LED drive current were employed.
[00125] According to the PWM technique, by periodically applying the voltage
V.,
.ource to
the light source and varying the time the voltage is applied during a given on-
off cycle, the
average power delivered to the light source over time (the average operating
power) may be
modulated. In particular, the controller 105 may be configured to apply the
voltage Vsource to
a given light source in a pulsed fashion (e.g., by outputting a control signal
that operates one
or more switches to apply the voltage to the light source), preferably at a
frequency that is
greater than that capable of being detected by the human eye (e.g., greater
than approximately
100 Hz). In this manner, an observer of the light generated by the light
source does not
perceive the discrete on-off cycles (commonly referred to as a "flicker
effect"), but instead
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the integrating function of the eye perceives essentially continuous light
generation. By
adjusting the pulse width (i.e. on-time, or "duty cycle") of on-off cycles of
the control signal,
the controller varies the average amount of time the light source is energized
in any given
time period, and hence varies the average operating power of the light source.
In this
manner, the perceived brightness of the generated light from each channel in
turn may be
varied.
[00126] As discussed in greater detail below, the controller 105 may be
configured to
control each different light source channel of a multi-channel lighting
fixture at a
predetermined average operating power to provide a corresponding radiant
output power for
the light generated by each channel. Alternatively, the controller 105 may
receive
instructions (e.g., "lighting commands") from a variety of origins, such as a
user interface
118, a signal source 124, or one or more communication ports 120, that specify
prescribed
operating powers for one or more channels and, hence, corresponding radiant
output powers
for the light generated by the respective channels. By varying the prescribed
operating
powers for one or more channels (e.g., pursuant to different instructions or
lighting
commands), different perceived colors and brightness levels of light may be
generated by the
lighting fixture.
[00127] In one embodiment of the lighting fixture 100, as mentioned above, one
or more
of the light sources 104A, 104B, 104C, and 104D shown in Fig. 1 may include a
group of
multiple LEDs or other types of light sources (e.g., various parallel and/or
serial connections
of LEDs or other types of light sources) that are controlled together by the
controller 105.
Additionally, it should be appreciated that one or more of the light sources
may include one
or more LEDs that are adapted to generate radiation having any of a variety of
spectra (i.e.,
wavelengths or wavelength bands), including, but not limited to, various
visible colors
(including essentially white light), various color temperatures of white
light, ultraviolet, or
infrared. LEDs having a variety of spectral bandwidths (e.g., narrow band,
broader band)
may be employed in various implementations of the lighting fixture 100.
[00128] In another aspect of the lighting fixture 100 shown in Fig. 1, the
lighting fixture
100 may be constructed and arranged to produce a wide range of variable color
radiation.
For example, in one embodiment, the lighting fixture 100 may be particularly
arranged such
that controllable variable intensity (i.e., variable radiant power) light
generated by two or
more of the light sources combines to produce a mixed colored light (including
essentially
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white light having a variety of color temperatures). In particular, the color
(or color
temperature) of the mixed colored light may be varied by varying one or more
of the
respective intensities (output radiant power) of the light sources (e.g., in
response to one or
more control signals output by the controller 105). Furthermore, the
controller 105 may be
particularly configured to provide ccintrol signals to one or more of the
light sources so as to
generate a variety of static or time-varying (dynamic) multi-color (or multi-
color
temperature) lighting effects. To this end, in one embodiment, the controller
may include a
processor 102 (e.g., a microprocessor) programmed to provide such control
signals to one or
more of the light sources. In various aspects, the processor 102 may be
programmed to
provide such control signals autonomously, in response to lighting commands,
or in response
to various user or signal inputs.
[00129] Thus, the lighting fixture 100 may include a wide variety of colors of
LEDs in
various combinations, including two or more of red, green, and blue LEDs to
produce a color
mix, as well as one or more other LEDs to create varying colors and color
temperatures of
white light. For example, red, green and blue can be mixed with amber, white,
UV, orange,
IR or other colors of LEDs. Such combinations of differently colored LEDs in
the lighting
fixture 100 can facilitate accurate reproduction of a host of desirable
spectrums of lighting
conditions, examples of which include, but are not limited to, a variety of
outside daylight
equivalents at different times of the day, various interior lighting
conditions, lighting
conditions to simulate a complex multicolored background, and the like. Other
desirable
lighting conditions can be created by removing particular pieces of spectrum
that may be
specifically absorbed, attenuated or reflected in certain environments.
[00130] As shown in Fig. 1, the lighting fixture 100 also may include a memory
114 to
store various information. For example, the memory 114 may be employed to
store one or
more lighting commands or programs for execution by the processor 102 (e.g.,
to generate
one or more control signals for the light sources), as well as various types
of data useful for
generating variable color radiation (e.g., calibration information, discussed
further below).
The memory 114 also may store one or more particular identifiers (e.g., a
serial number, an
address, etc.) that may be used either locally or on a system level to
identify the lighting
fixture 100. In various embodiments, such identifiers may be pre-programmed by
a
manufacturer, for example, and may be either alterable or non-alterable
thereafter (e.g., via
some type of user interface located on the lighting fixture, via one or more
data or control
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signals received by the lighting fixture, etc.). Alternatively, such
identifiers may be
determined at the time of initial use of the lighting fixture in the field,
and again may be
alterable or non-alterable thereafter.
[00131] One issue that may arise in connection with controlling multiple light
sources in
the lighting fixture 100 of Fig. 1, and controlling multiple lighting fixtures
100 in a lighting
system (e.g., as discussed below in connection with Fig. 2), relates to
potentially perceptible
differences in light output between substantially similar light sources. For
example, given
two virtually identical light sources being driven by respective identical
control signals, the
actual intensity of light (e.g., radiant power in lumens) output by each light
source may be
measurably different. Such a difference in light output may be attributed to
various factors
including, for example, slight manufacturing differences between the light
sources, normal
wear and tear over time of the light sources that may differently alter the
respective
spectrums of the generated radiation, etc. For purposes of the present
discussion, light
sources for which a particular relationship between a control signal and
resulting output
radiant power are not known are referred to as "uncalibrated" light sources.
[00132] The use of one or more uncalibrated light sources in the lighting
fixture 100
shown in Fig. 1 may result in generation of light having an unpredictable, or
"uncalibrated,"
color or color temperature. For example, consider a first lighting fixture
including a first
uncalibrated red light source and a first uncalibrated blue light source, each
controlled in
response to a corresponding lighting command having an adjustable parameter in
a range of
from zero to 255 (0-255), wherein the maximum value of 255 represents the
maximum
radiant power available (i.e., 100%) from the light source. For purposes of
this example, if
the red command is set to zero and the blue command is non-zero, blue light is
generated,
whereas if the blue command is set to zero and the red command is non-zero,
red light is
generated. However, if both commands are varied from non-zero values, a
variety of
perceptibly different colors may be produced (e.g., in this example, at very
least, many
different shades of purple are possible). In particular, perhaps a particular
desired color (e.g.,
lavender) is given by a red command having a value of 125 and a blue command
having a
value of 200.
[00133] Now consider a second lighting fixture including a second uncalibrated
red light
source substantially similar to the first uncalibrated red light source of the
first lighting
fixture, and a second uncalibrated blue light source substantially similar to
the first
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uncalibrated blue light source of the first lighting fixture. As discussed
above, even if both of
the uncalibrated red light sources are controlled in response to respective
identical
commands, the actual intensity of light (e.g., radiant power in lumens) output
by each red
light source may be measurably different. Similarly, even if both of the
uncalibrated blue
light sources are controlled in response to respective identical commands, the
actual light
output by each blue light source may be measurably different.
[00134] With the foregoing in mind, it should be appreciated that if multiple
uncalibrated
light sources are used in combination in lighting fixtures to produce a mixed
colored light as
discussed above, the observed color (or color temperature) of light produced
by different
lighting fixtures under identical control conditions may be perceivably
different.
Specifically, consider again the "lavender" example above; the "first
lavender" produced by
the first lighting fixture with a red command having a value of 125 and a blue
command
having a value of 200 indeed may be perceivably different than a "second
lavender" produced
by the second lighting fixture with a red command having a value of 125 and a
blue
command having a value of 200. More generally, the first and second lighting
fixtures
generate uncalibrated colors by virtue of their uncalibrated light sources.
[00135] In view of the foregoing, in one embodiment of the present disclosure,
the lighting
fixture 100 includes calibration means to facilitate the generation of light
having a calibrated
(e.g., predictable, reproducible) color at any given time. In one aspect, the
calibration means
is configured to adjust (e.g., scale) the light output of at least some light
sources of the
lighting fixture so as to compensate for perceptible differences between
similar light sources
used in different lighting fixtures.
[00136] For example, in one embodiment, the processor 102 of the lighting
fixture 100 is
configured to control one or more of the light sources so as to output
radiation at a calibrated
intensity that substantially corresponds in a predetermined manner to a
control signal for the
light source(s). As a result of mixing radiation having different spectra and
respective
calibrated intensities, a calibrated color is produced. In one aspect of this
embodiment, at
least one calibration value for each light source is stored in the memory 114,
and the
processor is programmed to apply the respective calibration values to the
control signals
(commands) for the corresponding light sources so as to generate the
calibrated intensities.
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[00137] In one aspect of this embodiment, one or more calibration values may
be
determined once (e.g., during a lighting fixture manufacturing/testing phase)
and stored in the
memory 114 for use by the processor 102. In another aspect, the processor 102
may be
configured to derive one or more calibration values dynamically (e.g. from
time to time) with
the aid of one or more photosensors, for example. In various embodiments, the
photosensor(s) may be one or more external components coupled to the lighting
fixture, or
alternatively may be integrated as part of the lighting fixture itself. A
photosensor is one
example of a signal source that may be integrated or otherwise associated with
the lighting
fixture 100, and monitored by the processor 102 in connection with the
operation of the
lighting fixture. Other examples of such signal sources are discussed further
below, in
connection with the signal source 124 shown in Fig. 1.
[00138] One exemplary method that may be implemented by the processor 102 to
derive
one or more calibration values includes applying a reference control signal to
a light source
(e.g., corresponding to maximum output radiant power), and measuring (e.g.,
via one or more
photosensors) an intensity of radiation (e.g., radiant power falling on the
photosensor) thus
generated by the light source. The processor may be programmed to then make a
comparison
of the measured intensity and at least one reference value (e.g., representing
an intensity that
nominally would be expected in response to the reference control signal).
Based on such a
comparison, the processor may determine one or more calibration values (e.g.,
scaling
factors) for the light source. In particular, the processor may derive a
calibration value such
that, when applied to the reference control signal, the light source outputs
radiation having an
intensity that corresponds to the reference value (i.e., an "expected"
intensity, e.g., expected
radiant power in lumens).
[00139] In various aspects, one calibration value may be derived for an entire
range of
control signal/output intensities for a given light source. Alternatively,
multiple calibration
values may be derived for a given light source (i.e., a number of calibration
value "samples"
may be obtained) that are respectively applied over different control
signal/output intensity
ranges, to approximate a nonlinear calibration function in a piecewise linear
manner.
[00140] In another aspect, as also shown in Fig. 1, the lighting fixture 100
optionally may
include one or more user interfaces 118 that are provided to facilitate any of
a number of
user-selectable settings or functions (e.g., generally controlling the light
output of the lighting
fixture 100, changing and/or selecting various pre-programmed lighting effects
to be
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generated by the lighting fixture, changing and/or selecting various
parameters of selected
lighting effects, setting particular identifiers such as addresses or serial
numbers for the
lighting fixture, etc.). In various embodiments, the communication between the
user interface
118 and the lighting fixture may be accomplished through wire or cable, or
wireless
transmission.
[00141] In one implementation, the controller 105 of the lighting fixture
monitors the user
interface 118 and controls one or more of the light sources 104A, 104B, 104C
and 104D
based at least in part on a user's operation of the interface. For example,
the controller 105
may be configured to respond to operation of the user interface by originating
one or more
control signals for controlling one or more of the light sources.
Alternatively, the processor
102 may be configured to respond by selecting one or more pre-programmed
control signals
stored in memory, modifying control signals generated by executing a lighting
program,
selecting and executing a new lighting program from memory, or otherwise
affecting the
radiation generated by one or more of the light sources.
[00142] In particular, in one implementation, the user interface 118 may
constitute one or
more switches (e.g., a standard wall switch) that interrupt power to the
controller 105. In one
aspect of this implementation, the controller 105 is configured to monitor the
power as
controlled by the user interface, and in turn control one or more of the light
sources based at
least in part on a duration of a power interruption caused by operation of the
user interface.
As discussed above, the controller may be particularly configured to respond
to a
predetermined duration of a power interruption by, for example, selecting one
or more pre-
programmed control signals stored in memory, modifying control signals
generated by
executing a lighting program, selecting and executing a new lighting program
from memory,
or otherwise affecting the radiation generated by one or more of the light
sources.
[00143] Fig. 1 also illustrates that the lighting fixture 100 may be
configured to receive
one or more signals 122 from one or more other signal sources 124. In one
implementation,
the controller 105 of the lighting fixture may use the signal(s) 122, either
alone or in
combination with other control signals (e.g., signals generated by executing a
lighting
program, one or more outputs from a user interface, etc.), so as to control
one or more of the
light sources 104A, 104B, 104C and 104D in a manner similar to that discussed
above in
connection with the user interface.
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[00144] Examples of the signal(s) 122 that may be received and processed by
the
controller 105 include, but are not limited to, one or more audio signals,
video signals, power
signals, various types of data signals, signals representing information
obtained from a
network (e.g., the Internet), signals representing one or more
detectable/sensed conditions,
signals from lighting fixtures, signals consisting of modulated light, etc. In
various
implementations, the signal source(s) 124 may be located remotely from the
lighting fixture
100, or included as a component of the lighting fixture. In one embodiment, a
signal from
one lighting fixture 100 could be sent over a network to another lighting
fixture 100.
[00145] Some examples of a signal source 124 that may be employed in, or used
in
connection with, the lighting fixture 100 of Fig. 1 include any of a variety
of sensors or
transducers that generate one or more signals 122 in response to some
stimulus. Examples of
such sensors include, but are not limited to, various types of environmental
condition sensors,
such as thermally sensitive (e.g., temperature, infrared) sensors, humidity
sensors, motion
sensors, photosensors/light sensors (e.g., photodiodes, sensors that are
sensitive to one or
more particular spectra of electromagnetic radiation such as
spectroradiometers or
spectrophotometers, etc.), various types of cameras, sound or vibration
sensors or other
pressure/force transducers (e.g., microphones, piezoelectric devices), and the
like.
[00146] Additional examples of a signal source 124 include various
metering/detection
devices that monitor electrical signals or characteristics (e.g., voltage,
current, power,
resistance, capacitance, inductance, etc.) or chemical/biological
characteristics (e.g., acidity, a
presence of one or more particular chemical or biological agents, bacteria,
etc.) and provide
one or more signals 122 based on measured values of the signals or
characteristics. Yet other
examples of a signal source 124 include various types of scanners, image
recognition
systems, voice or other sound recognition systems, artificial intelligence and
robotics
systems, and the like. A signal source 124 could also be a lighting fixture
100, another
controller or processor, or any one of many available signal generating
devices, such as
media players, MP3 players, computers, DVD players, CD players, television
signal sources,
camera signal sources, microphones, speakers, telephones, cellular phones,
instant messenger
devices, SMS devices, wireless devices, personal organizer devices, and many
others.
[00147] In one embodiment, the lighting fixture 100 shown in Fig. 1 also may
include one
or more optical elements 130 to optically process the radiation generated by
the light sources
104A, 104B, 104C, and 104D. For example, one or more optical elements may be
configured
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so as to change one or both of a spatial distribution and a propagation
direction of the
generated radiation. In particular, one or more optical elements may be
configured to change
a diffusion angle of the generated radiation. In one aspect of this
embodiment, one or more
optical elements 130 may be particularly configured to variably change one or
both of a
spatial distribution and a propagation direction of the generated radiation
(e.g., in response to
some electrical and/or mechanical stimulus). Examples of optical elements that
may be
included in the lighting fixture 100 include, but are not limited to,
reflective materials,
refractive materials, translucent materials, filters, lenses, mirrors, and
fiber optics. The
optical element 130 also may include a phosphorescent material, luminescent
material, or
other material capable of responding to or interacting with the generated
radiation.
[00148] As also shown in Fig. 1, the lighting fixture 100 may include one or
more
communication ports 120 to facilitate coupling of the lighting fixture 100 to
any of a variety
of other devices. For example, one or more communication ports 120 may
facilitate coupling
multiple lighting fixtures together as a networked lighting system, in which
at least some of
the lighting fixtures are addressable (e.g., have particular identifiers or
addresses) and are
responsive to particular data transported across the network.
[00149] In particular, in a networked lighting system environment, as
discussed in greater
detail further below (e.g., in connection with Fig. 2), as data is
communicated via the
network, the controller 105 of each lighting fixture coupled to the network
may be configured
to be responsive to particular data (e.g., lighting control commands) that
pertain to it (e.g., in
some cases, as dictated by the respective identifiers of the networked
lighting fixtures). Once
a given controller identifies particular data intended for it, it may read the
data and, for
example, change the lighting conditions produced by its light sources
according to the
received data (e.g., by generating appropriate control signals to the light
sources). In one
aspect, the memory 114 of each lighting fixture coupled to the network may be
loaded, for
example, with a table of lighting control signals that correspond with data
the processor 102
of the controller receives. Once the processor 102 receives data from the
network, the
processor may consult the table to select the control signals that correspond
to the received
data, and control the light sources of the lighting fixture accordingly.
[00150] In one aspect of this embodiment, the processor 102 of a given
lighting fixture,
whether or not coupled to a network, may be configured to interpret lighting
instructions/data
that are received in a DMX protocol (as discussed, for example, in U.S.
Patents 6,016,038
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and 6,211,626), which is a lighting command protocol conventionally employed
in the
lighting industry for some programmable lighting applications. For example, in
one aspect,
considering for the moment a lighting fixture based on red, green and blue
LEDs (i.e., an "R-
G-B" lighting fixture), a lighting command in DMX protocol may specify each of
a red
channel command, a green channel command, and a blue channel command as eight-
bit data
(i.e., a data byte) representing a value from 0 to 255. The maximum value of
255 for any one
of the color channels instructs the processor 102 to control the corresponding
light source(s)
to operate at maximum available power (i.e., 100%) for the channel, thereby
generating the
maximum available radiant power for that color (such a command structure for
an R-G-B
lighting fixture commonly is referred to as 24-bit color control). Hence, a
command of the
format [R, 0, B] = [255, 255, 255] would cause the lighting fixture to
generate maximum
radiant power for each of red, green and blue light (thereby creating white
light).
[00151] It should be appreciated, however, that lighting fixtures suitable for
purposes of
the present disclosure are not limited to a DMX command format, as lighting
fixtures
according to various embodiments may be configured to be responsive to other
types of
communication protocols/lighting command formats so as to control their
respective light
sources. In general, the processor 102 may be configured to respond to
lighting commands in
a variety of formats that express prescribed operating powers for each
different channel of a
multi-channel lighting fixture according to some scale representing zero to
maximum
available operating power for each channel.
[00152] In one embodiment, the lighting fixture 100 of Fig. 1 may include
and/or be
coupled to one or more power sources 108. In various aspects, examples of
power source(s)
108 include, but are not limited to, AC power sources, DC power sources,
batteries, solar-
based power sources, thermoelectric or mechanical-based power sources and the
like.
Additionally, in one aspect, the power source(s) 108 may include or be
associated with one or
more power conversion devices that convert power received by an external power
source to a
form suitable for operation of the lighting fixture 100.
[00153] While not shown explicitly in Fig. 1, but as discussed in greater
detail further
below, the lighting fixture 100 may be implemented in any one of several
different structural
configurations according to various embodiments of the present disclosure.
Examples of
such configurations include, but are not limited to, an essentially linear or
curvilinear
configuration, a circular configuration, an oval configuration, a rectangular
configuration,
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combinations of the foregoing, various other geometrically shaped
configurations, various
two or three dimensional configurations, and the like. A given lighting
fixture also may have
any one of a variety of mounting arrangements for the light source(s),
enclosure/housing
arrangements and shapes to partially or fully enclose the light sources,
and/or electrical and
mechanical connection configurations.
[00154] Additionally, one or more optical elements as discussed above may be
partially or
fully integrated with an enclosure/housing arrangement for the lighting
fixture. Furthermore,
the various components of the lighting fixture discussed above (e.g.,
processor, memory,
power, user interface, etc.), as well as other components that may be
associated with the
lighting fixture in different implementations (e.g., sensors/transducers,
other components to
facilitate communication to and from the unit, etc.) may be packaged in a
variety of ways; for
example, in one aspect, any subset or all of the various lighting fixture
components, as well
as other components that may be associated with the lighting fixture, may be
packaged
together. In another aspect, packaged subsets of components may be coupled
together
electrically and/or mechanically in a variety of manners, as discussed below.
[00155] Fig. 2 illustrates an example of a networked lighting system 200
according to one
embodiment of the present disclosure. In the embodiment of Fig. 2, a number of
lighting
fixtures or fixtures 100, similar to those discussed above in connection with
Fig. 1, are
coupled together to form the networked lighting system. It should be
appreciated, however,
that the particular configuration and arrangement of lighting fixtures shown
in Fig. 2 is for
purposes of illustration only, and that the disclosure is not limited to the
particular system
topology shown in Fig. 2.
[00156] Additionally, while not shown explicitly in Fig. 2, it should be
appreciated that the
networked lighting system 200 may be configured flexibly to include one or
more user
interfaces, as well as one or more signal sources such as sensors/transducers.
For example,
one or more user interfaces and/or one or more signal sources such as
sensors/transducers (as
discussed above in connection with Fig. 1) may be associated with any one or
more of the
lighting fixtures of the networked lighting system 200. Alternatively (or in
addition to the
foregoing), one or more user interfaces and/or one or more signal sources may
be
implemented as "stand alone" components in the networked lighting system 200.
Whether
stand alone components or particularly associated with one or more lighting
fixtures 100,
these devices may be "shared" by the lighting fixtures of the networked
lighting system.
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Stated differently, one or more user interfaces and/or one or more signal
sources such as
sensors/transducers may constitute "shared resources" in the networked
lighting system that
may be used in connection with controlling any one or more of the lighting
fixtures of the
system.
[00157] As shown in the embodiment of Fig. 2, the lighting system 200 may
include one
or more lighting fixture controllers (hereinafter "LUCs") 208A, 208B, 208C,
and 208D,
wherein each LUC is responsible for communicating with and generally
controlling one or
more lighting fixtures 100 coupled to it. Although Fig. 2 illustrates one
lighting fixture 100
coupled to each LUC, it should be appreciated that the disclosure is not
limited in this
respect, as different numbers of lighting fixtures 100 may be coupled to a
given LUC in a
variety of different configurations (serially connections, parallel
connections, combinations
of serial and parallel connections, etc.) using a variety of different
communication media and
protocols.
[00158] In the system of Fig. 2, each LUC in turn may be coupled to a central
controller
202 that is configured to communicate with one or more LUCs. Although Fig. 2
shows four
LUCs coupled to the central controller 202 via a generic connection 204 (which
may include
any number of a variety of conventional coupling, switching and/or networking
devices), it
should be appreciated that according to various embodiments, different numbers
of LUCs
may be coupled to the central controller 202. Additionally, according to
various
embodiments of the present disclosure, the LUCs and the central controller may
be coupled
together in a variety of configurations using a variety of different
communication media and
protocols to form the networked lighting system 200. Moreover, it should be
appreciated that
the interconnection of LUCs and the central controller, and the
interconnection of lighting
fixtures to respective LUCs, may be accomplished in different manners (e.g.,
using different
configurations, communication media, and protocols).
[00159] For example, according to one embodiment of the present disclosure,
the central
controller 202 shown in Fig. 2 may by configured to implement Ethernet-based
communications with the LUCs, and in turn the LUCs may be configured to
implement
DMX-based communications with the lighting fixtures 100. In particular, in one
aspect of
this embodiment, each LUC may be configured as an addressable Ethernet-based
controller
and accordingly may be identifiable to the central controller 202 via a
particular unique
address (or a unique group of addresses) using an Ethernet-based protocol. In
this manner,
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the central controller 202 may be configured to support Ethernet
communications throughout
the network of coupled LUCs, and each LUC may respond to those communications
intended
for it. In turn, each LUC may communicate lighting control information to one
or more
lighting fixtures coupled to it, for example, via a DMX protocol, based on the
Ethernet
communications with the central controller 202.
[00160] More specifically, according to one embodiment, the LUCs 208A, 208B,
and
208C shown in Fig. 2 may be configured to be "intelligent" in that the central
controller 202
may be configured to communicate higher level commands to the LUCs that need
to be
interpreted by the LUCs before lighting control information can be forwarded
to the lighting
fixtures 100. For example, a lighting system operator may want to generate a
color changing
effect that varies colors from lighting fixture to lighting fixture in such a
way as to generate
the appearance of a propagating rainbow of colors ("rainbow chase"), given a
particular
placement of lighting fixtures with respect to one another. In this example,
the operator may
provide a simple instruction to the central controller 202 to accomplish this,
and in turn the
central controller may communicate to one or more LUCs using an Ethernet-based
protocol
high level command to generate a "rainbow chase." The command may contain
timing,
intensity, hue, saturation or other relevant information, for example. When a
given LUC
receives such a command, it may then interpret the command and communicate
further
commands to one or more lighting fixtures using a DMX protocol, in response to
which the
respective sources of the lighting fixtures are controlled via any of a
variety of signaling
techniques (e.g., PWM).
[00161] It should again be appreciated that the foregoing example of using
multiple
different communication implementations (e.g., Ethernet/DMX) in a lighting
system
according to one embodiment of the present disclosure is for purposes of
illustration only,
and that the disclosure is not limited to this particular example.
[00162] From the foregoing, it may be appreciated that one or more lighting
fixtures as
discussed above are capable of generating highly controllable variable color
light over a wide
range of colors, as well as variable color temperature white light over a wide
range of color
temperatures.
[00163] Fig. 3 illustrates a perspective, partial cutaway view of a lighting
fixture 100
having modular construction according to one embodiment of the disclosure. A
light-
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generating module 300, such as an LED-based module, is attachable to and
detachable from a
mating socket 302. The socket 302 is fixedly coupled to a housing 304 (e.g.,
via screws
inserted through holes 306 in flanges 308 of the socket 302), and the light-
generating module
300 may be easily installed in the housing 304, via the socket 302, to form
the lighting fixture
100. In some exemplary implementations, the housing 304 may serve as a heat
sink (e.g., the
housing may be formed from a significantly thermally conductive material, such
as die-cast
or extruded metal). The lighting fixture 100 of this embodiment further
includes a controller
module 105 as a separate component from the light-generating module 300 that
may be
permanently or replaceably mounted within the housing 304.
[00164] In some embodiments, the light-generating module 300 may be
implemented in a
relatively straightforward manner, including one or more LED-based light
sources and
connectors for connection of the LEDs to drive signals and operating power. In
other
embodiments, the light-generating module 300 may include a variety of
components,
including but not limited to thermal dissipation elements, on-board memory
and/or control
features, and optical components. When the light-generating module 300 is
attached to the
housing 304 via the socket 302, the light-generating module 300 may be
electrically
connected to the controller module 105 via a connector 310.
[00165] In some embodiments, as illustrated in Fig. 3, the overall shape of
the light-
generating module 300 may resemble a hockey puck. For example, in some
embodiments, a
circular light-generating module may have a diameter of approximately three
inches and a
thickness of approximately one inch. In some embodiments, the thickness of the
light-
generating module near the center of the light-generating module is greater
than the thickness
near the edges.
[00166] Fig. 4 shows a perspective view of a fully assembled modular lighting
fixture 100
similar to that shown in Fig. 3, including a reflector cone 314 and mounting
brackets 316.
The reflector cone 314 may be removable to facilitate replacement of the light-
generating
module 300 and/or the controller module 105.
[00167] Fig. 5 shows a top perspective view of the fully assembled lighting
fixture 100. In
some embodiments of the lighting fixture, the lighting fixture 100 includes
thermal
dissipation elements 320 (fins in this embodiment) for transferring heat away
from the light-
generating module 300 and/or the controller module 105. For example, the
socket 302 may
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be formed with a thermally conductive material to facilitate transfer of heat
from the light-
generating module 300 to the housing 304, which in turn transfers heat to the
fins or other
suitable thermal dissipation elements. Wiring knockouts 322 and a wiring
compartment door
324 are also visible in this view. In some embodiments, separate thermal
dissipation
elements (i.e., thermally isolated from thermal dissipation elements that
transfer heat away
from the light-generating module) are provided for transferring heat away from
the controller
module 105, while in other embodiments, the same thermal dissipation elements
transfer heat
away from both the light-generating module 300 and the controller module 105.
[00168] Fig. 6 illustrates a perspective view of another embodiment of a
modular lighting
fixture 100-1 which includes a housing 304-1 having a shape that differs from
the
embodiment illustrated in Figs. 3-5. The embodiment illustrated in Fig. 6 may
be useful for
installation and/or removal through holes in ceilings or walls, as discussed
in more detail
further below. Similar to the embodiment of Figs. 3-5, the lighting fixture
100-1 includes a
light-generating module 300, a socket 302 and a reflector cone 314.
[00169] In some embodiments, the controller module 105 associated with a given
lighting
fixture may be disposed internally within the housing, as illustrated in Fig.
3, while in other
embodiments, the controller module 105 may be disposed externally (e.g., in a
junction box
such as the junction box shown in Fig. 68).
[00170] Figs. 7 and 8 illustrate perspective views of an assembled light-
generating module
300 attached to the socket 302 of the lighting fixture according to one
embodiment of the
disclosure. Fig. 9 illustrates an exploded perspective view of the light-
generating module
300, the socket 302 and a grip ring 332. The illustrations of Figs. 7-9
represent one
embodiment of a light-generating module, and each component described with
reference to
Figs. 7-9 is not necessarily required to form a light-generating module
according to other
embodiments.
[00171] With reference to Figs. 7-9, the components of the light-generating
module 300
according to one embodiment include a light-passing (e.g., transparent or
translucent) face
plate 330, the grip ring 332, secondary optic components 334, a chassis 336,
an LED
assembly 338, and an aluminum base plate 340. In the embodiment of Figs. 7-9,
the chassis
336 is configured as a metal die-cast component to facilitate heat transfer
(in other
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embodiments, as discussed below in connection with Figs. 27-31, a similar
chassis may be
formed as an injected molded component made of plastic.) The chassis 336 is
configured to
support a number of the secondary optic components 334.
[00172] In the module shown in Fig. 9, the LED assembly 338 includes multiple
hexagonally-shaped LED subassemblies 344 (hereafter "LED hex subassemblies")
which are
sandwiched between a thermally conductive base plate (aluminum base plate 340)
and a
printed circuit board substrate 346. The combination of the base plate 340,
hex
subassemblies 344 and printed circuit board 346 may in turn be covered with an
electrically
insulating and thermally conducting layer 348 and coupled to the chassis 336
(e.g., via screws
which pass through holes in the base plate and engage with threaded bores in
the chassis
336). The light-passing face plate 330 also is optionally employed in the
light-generating
module 300, and may be held in place by the grip ring 332. Base plate 340 may
include a
cut-out or through-hole 350 to accommodate a connector 352 which connects to
the LED
assembly 338. With reference again to Fig. 3, in one implementation, the
connector 352
essentially serves as a first electrical connector portion which engages with
the connector 310
in the fixture housing 304, which connector serves as a complimentary second
electrical
connection portion when the light-generating module is installed in the socket
302.
[00173] With respect to heat management, dissipating heat through the front
face (light
exit face) of the light-generating module may aid in thermal efficiency. In
assembling the
light-generating module 300 of Fig. 9, an electrically insulating and
thermally conducting
layer 348 may be employed between the LED assembly 338 and the chassis 336, as
illustrated in Fig. 9. In this manner, thermal transfer may occur via the
front of the LED
assembly (via the printed circuit board 346, the thermally conducting layer
348, and the die-
cast metal chassis 336), as well as via the rear of the LED assembly 338 (via
optional thermal
paste or grease, the base plate 340, and ultimately to a housing or other heat
sink to which the
base plate may in turn be coupled, e.g., see Fig. 3). Components other than
the chassis may
be made from thermally conductive material, and various of the die-cast
components may be
painted/anodized black to facilitate heat transfer.
[00174] While the particular embodiment shown in Figs. 7-9 illustrates a
module that
accommodates six LED hex subassemblies 344, it should be appreciated that the
disclosure is
not limited in this respect, as different configurations and numbers of LED
subassemblies 344
may be employed in other embodiments. Additionally, in any of the embodiments
described
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herein, an LED subassembly having a shape other than a hexagonal shape may be
substituted
for an LED hex subassembly.
[00175] Fig. 10 is a close-up front view of the LED assembly 338 of the light-
generating
module 300 illustrated in Fig. 9. In particular, Fig. 10 illustrates six LED
hex subassemblies
344 (e.g., OSTAR subassemblies, which are described in more detail below)
coupled to a
printed circuit board 346. As can be seen in Fig. 10, each hex subassembly 344
includes six
individual LED junctions 358 that are electrically interconnected in the
subassembly so as to
be operated simultaneously in response to a drive signal applied to the
subassembly. Each
subassembly also includes a primary optic 360 which may be a lens configured
to provide a
Lambertian beam shape. As discussed below, the hex subassemblies 344 are
coupled to a
rear or bottom surface of the printed circuit board 346, and the printed
circuit board is
configured with through holes for the primary optic 360 of each hex
subassembly 344. Large
through-holes 364 in the printed circuit board 346 facilitate attachment of
the base plate 340
and the LED assembly 338 to the chassis 336.
[00176] In one implementation, the LED hex subassemblies 344 may be components
manufactured under the name OSTAR by OSRAM Opto Semiconductors Gmbh (see
http://wvvw.osram-os.com/ostar-lighting). Each OSTAR subassembly 344 may
provide up
to 400 lumens of radiation at an operating current of 700 milliamps from six
LED junctions
that are driven simultaneously to provide white light having a color
temperature of
approximately 5600 degrees Kelvin.
[00177] In one aspect, LED hex subassemblies 344, exemplified by the OSTAR
products,
may be implemented as "chip-on-board" LED subassemblies or modules. In a chip-
on-board
assembly, an unpackaged silicon die (i.e., semiconductor chip) is attached
directly onto the
surface of a substrate (e.g., an FR-4 printed circuit board, a flexible
printed circuit board, a
ceramic substrate, etc.) and wire bonded to form electrical connections to the
substrate. An
epoxy resin or a silicone coating is then applied on top of the die/chip to
encapsulate and
protect the die/chip. In one exemplary OSTAR configuration, the LED hex
subassembly
includes four or six LED semiconductor chips mounted on a ceramic substrate,
which is in
turn mounted directly to a surface of a metal core printed circuit board. To
protect the
semiconductor chips from environmental influences such as moisture, the chips
may be
coated with a clear silicone encapsulant.
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[00178] Each OSTAR includes an aluminum core substrate to facilitate thermal
dissipation, on top of which is disposed electrical connections, the LED
junctions
(semiconductor chips), and an integrated primary lens (as one example of a
primary optic) to
provide a Lambertian beam shape. The hexagonally-shaped substrate is provided
with
multiple perimeter cut-outs and/or through-holes to permit coupling of the
subassemblies via
screws to the chassis 336 and also to facilitate registration of the
individual hex
subassemblies to a common substrate, as well as optional secondary optics.
Electrical
connections to the hex subassemblies may be made by soldering to contacts on
the top of the
subassembly, or by employing spring type contacts. An aluminum substrate of
the OSTARs
may be, in some embodiments, placed in direct contact with thermally
conductive features,
such as the base plate 340, the socket 302, and/or the fixture housing 304, to
facilitate a
thermal conduction path away from the LED subassemblies.
[00179] While an example of an LED hex subassembly constituted by an OSTAR
component is discussed above, it should be appreciated that the disclosure is
not limited in
this respect, as LED hex subassemblies having other configurations, including
one or more
LEDs configured to generate essentially white light having a variety of color
temperatures
and/or light having a variety of non-white colors, may be employed in light-
generating
modules according to various embodiments.
[00180] In particular, in one exemplary implementation, one or more LED
subassemblies
of a given LED assembly may generate white light having a first color
temperature, and one
or more others of the LED subassemblies may generate white light having a
different second
color temperature, such that a given light-generating module may be configured
as a multi-
channel LED-base light source. Likewise, a lighting fixture including such a
multi-channel
light-generating module may be configured with a multi-channel controller
module
configured to independently control the multiple channels of the multi-channel
light-
generating module. In this manner, the light-generating module may be
configured to
generate either of the different color temperatures, or an arbitrary
combination of the different
color temperatures. Thus, lighting fixtures according to the present
disclosure may be
particularly configured to provide for controllable variable color-temperature
white light from
a single light-generating module.
[00181] Fig. 11 is a close-up rear view of the LED assembly 338, showing the
rear
mounting of the hex subassemblies 344 to the printed circuit board 346, as
well as the
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electrical connector 352 that provides one or more drive signals for operating
the hex
subassemblies. From Fig. 11, a rear surface 368 of the aluminum substrate of
each hex
subassembly 344 is clearly visible. With reference again to Fig. 9, in one
aspect of this
embodiment, the rear surfaces of the hex subassemblies are coupled to the
aluminum base
plate 340 to facilitate thermal transfer from the back (or bottom surface) of
the hex
subassemblies. In one implementation, thermal grease or paste may be used to
adhere the
base plate 340 to the LED assembly 338, such that through-holes 370 in the
base plate 340
are aligned with the large through-holes 364 in the printed circuit board 346
to facilitate
attachment of the base plate and the LED assembly to the chassis 336. As
mentioned above,
the base plate 340 may include a center cut-out or through-hole to allow for
clearance of the
electrical connector 352.
[00182] From Figs. 9-11, it may also be observed that the printed circuit
board 346
includes a number of smaller registration through-holes 372 that are aligned
with semi-circle
cut outs 374 in the perimeters of the hex subassemblies 344. These through-
holes 372
facilitate the coupling of the subassemblies to the printed circuit board 346,
as discussed
below in connection with Figs. 12-14.
[00183] Fig. 12 illustrates a "jig" 380 that may be employed to facilitate
assembly of the
LED assembly 338. The jig 380 may be constructed of any rigid material, such
as an
aluminum plate. As shown in Fig. 12, the aluminum plate may include a number
of holes
into which are placed small pegs 384 and large pegs 386. As will be evident
from the
subsequent discussion and figures, the different sized pegs ensure proper
registration between
the hex subassemblies 344 and the printed circuit board 346.
[00184] More specifically, Fig. 13 illustrates multiple LED hex subassemblies
344
positioned on the small pegs 384 of the jig 380 shown in Fig. 12 so as to hold
the
subassemblies flat and in appropriate positions. Once in position, solder
paste may be
applied to electrical contact pads 388 on the top side of the subassemblies.
As shown in Fig.
14, the printed circuit board 346 is then positioned on the jig 380, over the
subassemblies
344, using the large pegs 386 which pass through the large through-holes 364
in the printed
circuit board 346. The printed circuit board also includes the smaller through-
holes 372 to
accommodate the small pegs 384.
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[00185] A side of the printed circuit board 346 adjacent to the hex
subassemblies (i.e., the
side opposite to that in view in Fig. 14) includes first electrical contacts
(e.g., copper pads ¨
not shown), in complementary positions to the contact pads 388 on the hex
subassemblies
344, which provide both mechanical attachment points and electrical
connections to the hex
subassemblies. In one implementation, these first electrical contacts have
counterpart second
electrical contacts 390 that appear on the opposite side of the printed
circuit board 346 (the
side in the view of Fig. 14) and the contact pairs on opposing sides of the
printed circuit
board may be connected via plated through-holes 392 in the middle of the
contacts.
Accordingly, once in position on the jig, with the solder paste sandwiched
between the
contact pads 388 of the hex subassemblies 344 and the first electrical
contacts of the printed
circuit board, heat may be applied to the second electrical contacts 390
(e.g., via a hot bar or
soldering iron tip), thereby causing the solder paste to melt and form
electrical and
mechanical bonds between the hex subassemblies and the printed circuit board.
The plated
through-holes 392 facilitate heat transfer through the contacts and also allow
visual
inspection of the solder bond.
[00186] In one implementation, the printed circuit board 346 may be made of
conventional
FR-4 (Flame Resistant 4) material, which is commonly used for making printed
circuit boards
and is a composite of a resin epoxy reinforced with a woven fiberglass mat. In
one aspect, a
printed circuit board 346 made of FR-4 may be fabricated as a relatively thin
substrate to
facilitate effective thermal transfer from the front (or top surface) of the
hex subassemblies.
Thus, when the LED assembly 338 is coupled to the die-cast chassis 336, the
metal of the
chassis further facilitates thermal transfer from the front (or light-exit
face) of the light-
generating module.
[00187] In another implementation, the printed circuit board may be made of a
flexible
circuit board material. Flexible circuit boards are used in some common
conventional
applications where flexibility, space savings, or production constraints limit
the serviceability
of rigid circuit boards or hand wiring. In addition to cameras, a common
application of
flexible circuits is in computer keyboard manufacturing; most keyboards made
today use
flexible circuits for the switch matrix. In one exemple, a flexible circuit
board may be
implemented as an appreciably thin substrate (e.g., on the order of a few
micrometers) using
thin flexible plastic or other insulating material and metal foil for
conductors.
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[00188] One example of a suitable flexible insulating material for flexible
circuit boards is
Kapton , which is a polyimide film developed by DuPont that can remain
stable in a wide
range of temperatures, from -269 C to +400 C (-452 F to 752 F). In
implementations of
LED assemblies using flexible circuit boards, windows may be cut into the
insulating
material on both the top and the bottom of the circuit board to expose contact
pad areas in the
conducting metal foil layer. Holes may be formed in the middle of these areas
to facilitate
the soldering process, as discussed above. In one aspect of implementations
using flexible
circuit boards, a non-planar LED assembly may be fabricated and appropriately
mounted to a
chassis to allow customized or predetermined patterns and directions of light
emission from
the LEDs of the hex subassemblies.
[00189] In implementations employing a flexible circuit board, an aluminum
base plate
serving as an alternative to the base plate 340 may be equipped with pegs
similar to those
illustrated in Fig. 12, such that the LED hex subassemblies first are mounted
in appropriate
positions on the rigid base plate. The pegs in the base plate then would also
serve to facilitate
registration of the flexible circuit board, which may be placed on top of the
hex
subassemblies and bonded to the subassemblies in a manner similar to that
described above.
[00190] Fig. 15 shows a close-up view of the secondary optic component 334 of
the light-
generating module 300 shown in Fig. 9. Each secondary optic component is
configured with
four posts 402 which engage with four corresponding small through-holes 372 of
the printed
circuit board to facilitate registration of the secondary optic over the
primary optic of an
associated LED hex subassembly 344. Each secondary optic 334 also may include
one or
more clips 404 to facilitate engagement of the secondary optic with one of the
secondary
optic receiving portions of the chassis 336. More specifically, with reference
to Figs. 9, 25
and 26, each secondary optic fits into a corresponding secondary optic
receiving portion or
chamber 502 of the chassis 336, and the one or more clips 404 engage with a
portion of a
bottom surface 504 of the chassis 336. The posts 402 of the secondary optic
pass through the
secondary optic receiving portion or chamber of the chassis, and engage with
the small
through-holes 372 and the perimeter semi-circle cut outs 374 of an associated
LED hex
subassembly (e.g., see Figs. 10 and 11) to ensure that the secondary optic is
appropriately
aligned with the primary optic of its associated LED hex subassembly. In
various aspects,
the secondary optic may be configured with baffled, curved, and/or reflective
surfaces to
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facilitate generation of a variety of beam profiles (e.g., narrow beam, medium
beam) for the
light radiated by the LED hex subassemblies.
[00191] A slightly different embodiment of a secondary optic component 334-1
is
illustrated in Figs. 16 and 17. In this embodiment, four posts 402-1 include a
flat outwardly-
facing surface 406 rather than a curved outwardly surface as shown in the
embodiment of
Fig. 15.
[00192] Figs. 18 and 19 are perspective views showing the ornamental design of
one
embodiment of a round puck-shaped light-generating module 300-1 including a
chassis 336-
1, abase plate 340-1 and a connector 352-1. Fig. 20 is a side view of the
light-generating
module 300-1 of Figs. 18 and 19. Fig. 21 is a top view showing the ornamental
design of
another embodiment of a round light-generating module 300-2 coupled to a
socket 302-2 via
a grip ring 332-2, wherein the flanges 308-2 of the socket are visible, and
Fig. 22 shows a
cross-sectional view of the light-generating module and grip ring taken along
line 22-22 of
Fig. 21. Fig. 23 is a perspective view of the light-generating module 300-2,
grip ring 332-2,
and socket 302-2 of Fig. 21. Fig. 24 is a perspective rear view of the light-
generating module
300-2 and grip ring 332-2 of Fig. 21.
[00193] In one exemplary implementation of the module, grip ring and socket
combination
illustrated in Figs. 22-24, the socket and grip ring essentially form two
mating collars,
wherein at least one exterior feature of the socket and at least one interior
feature of the grip
ring include complementary threads to facilitate a screw-type interlocking
mechanical
connection as the grip ring is placed on and rotated relative to the socket.
Accordingly, when
the light-generating module is installed in the socket, the grip ring is
configured to fit over at
least a portion of a perimeter of the light-generating module and hold the
light-generating
module in the socket via the screw-type (rotating) interlocking mechanical
connection.
[00194] Fig. 25 is a top view of the ornamental design of one embodiment of a
chassis
336-1 including multiple chambers 502. Fig. 26 is a bottom perspective view of
the chassis
336-1 of Fig. 25, illustrating multiple threaded bores formed in the body of
the chassis for
receiving screws that may be used to coupled the base plate and the LED
assembly to the
chassis.
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[00195] Figs. 27 and 28 illustrate two different exploded perspective views of
a light-
generating module 300-3 and grip ring 332-3 according to an alternative
embodiment of the
disclosure. Fig. 42 (discussed further below) illustrates a light-generating
module 300-3
based on the various components illustrated in the perspective views of Figs.
27 and 28,
wherein the assembled light-generating module 300-3 is coupled to a mating
socket 302-1 so
as to form a lighting fixture 100.
[00196] In the embodiment of Figs. 27 and 28, unlike the embodiment discussed
above in
connection with Figs. 7-9, an LED assembly 338-1 including a number of LED hex
subassemblies 344-1 is not arranged to be sandwiched between a thermally
conductive base
plate and a printed circuit board substrate, but instead is configured to be
inserted into a
chassis 336-2.
[00197] Figs. 29 and 30 illustrate various views of the chassis 336-2
including six
complementary receiving portions or chambers to accommodate six LED hex
subassemblies
344-1. In one aspect of this embodiment, the chassis 336-2 may be an injected
molded
component made of plastic. Additionally, the chassis 336-2 may be configured
to include a
number of electrical connectors 410 and contacts 412 integral with the body of
the chassis
336-2 so as to provide operating power to each of the LED hex subassemblies
344-1 from a
main connector assembly 352-2 disposed in a center channel of the chassis 336-
2. One
particular layout of the electrical contacts 412 and connectors 410 is shown
in a top view in
Fig. 31.
[00198] In various aspects, the electrical contacts or connectors of the
chassis 336-2 may
include: components which are insert-molded into the chassis; stamped pieces
which may be
pressed into the chassis during assembly; a flex printed circuit board (flex
PCB); or
conductive ink screened onto the molded chassis. The LED hex subassemblies 344-
1 may be
assembled into the chassis 336-2 by pressing to ensure satisfactory electrical
contact with the
contacts or connectors of the chassis. To facilitate satisfactory contact, the
chassis may
further include small fasteners or retention clips in the injection molded
plastic.
[00199] With reference again to Figs. 27 and 28, once the LED assembly 300-3
including
the LED hex subassemblies 344-1 is assembled in the chassis 336-2, a stamped
aluminum
base plate 340-2 may be attached to the chassis 336-2 via screws passing
through counter-
sunk through-holes 414 in the base plate 34-2 (see Fig. 28) (the base plate
material may also
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be copper, graphite or other suitable thermally conductive material). The base
plate 340-2
also includes a center through-hole 350-1 for the connector assembly 352-2,
although in some
embodiments, the through-hole 350-1 may not be in the center of the base plate
340-2, and in
some embodiments, no through-hole 350-1 is present. The base plate 340-2 may
provide a
thermal connection to a housing as described above with reference to Fig. 9. A
gap pad 414
may comprise a thermal material that is optionally positioned adjacent to a
bottom surface of
the aluminum base plate 340-2 and adhered via a thermal paste or thermal
grease. In general,
a gap pad may be employed to closely mate two surfaces and eliminate voids
that would exist
if two bare surfaces were mated.
[00200] In various implementations, other alternative thermal materials may be
employed,
such as viscous paste or liquid metal sandwiched between the plate and a thin
and slightly
convex sheet. When the light-generating module is lockingly engaged with the
socket, this
convex sheet deforms under compression to flatness against the fixture housing
(e.g., a heat
sink ¨ described below with reference to Fig. 43). Alternatively, a thin sheet
of very soft
metal, such as indium (Brinell hardness 0.9), that can deform under pressure,
can replace the
gap pad. In another aspect, the gap pad or other thermal material may be
manufactured with
wings or flaps that fold up through or around the base plate and were
pinched/captured when
the base plate is fastened to the chassis.
[00201] As discussed above, various components and/or subassemblies of the
light-
generating module 300 may be configured to conduct heat away from the light-
generating
module 300. In some embodiments, the chassis 336 may be die-cast in metal, or
formed with
another suitable thermally conducting material, such that heat may be
transmitted from the
LED assembly 338 to the face plate 330 and/or the grip ring 332. The
electrically insulating
and thermally conducting layer 348 discussed above may be interposed between
the LED
assembly 338 and the chassis 336 as part of facilitating thermal dissipation.
In this manner,
thermal dissipation may be facilitated from the front face and/or the sides of
the light-
generating module 300.
[00202] Thelma' dissipation also may be facilitated from the rear side of the
light-
generating module 300 in some embodiments. For example, a thermally conductive
base
plate 370 may be provided as a backing to the LED assembly 338 such that
thermal
dissipation is facilitated through the housing and/or socket to which the
light-generating
module 300 is attached.
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[00203] As illustrated in Figs. 32-39, in some embodiments, a light-generating
module
may include one or more active thermal dissipation components such as a fan,
and/or may
include passive thermal dissipation features such as fins or air circulation
paths or channels.
Such embodiments may be useful with certain LED assemblies and light-
generating modules
in that the use of thermal dissipation components may allow the light-
generating module to
be a stand-alone unit in terms of thermal dissipation. That is, thermal
coupling to a housing
or other fixture may not be required for suitable thermal dissipation. In this
manner,
flexibility may be achieved in terms of associating the light-generating
module with various
lighting fixtures and systems.
[00204] One embodiment of a light-generating module 300-4 employing thermal
dissipation fins 510 is illustrated in Figs. 32 and 33. In this embodiment,
the fins 510 are
integral to the light-generating module 300-4 in that the fins 510 are
included as part of a die-
cast metal light-generating module housing 512. An LED assembly 514 is
thermally coupled
to the die-cast housing 512 such that heat may be transferred to the thermal
dissipation fins
510. The module housing 512 includes an insert molded copper core 516 and an
injection
molded flange 518 for mating engagement with a socket 302-2, as shown in Fig.
33. Even
though the socket 302-2 in this embodiment is die-cast metal, the plastic
flange 518 prevents
any appreciable amount of heat from transferring to the socket 302-2 in this
embodiment. In
some embodiments, the socket 302-2 may be thermally conductive to facilitate
heat transfer.
[00205] The module housing 512 includes leaf springs 520 for forming operating
power
and control connections with the socket 302-2 when the light-generating module
300-4 is
engaged with the socket 302-2.
[00206] One embodiment of a light-generating module 300-5 including a fan 530
is
illustrated in Fig. 34. The fan 530 is disposed between an LED assembly 338-2
and a module
housing 512-1. The fan 530, which may be a low RPM fan, draws air into the
housing 512-1
through intake vents 532, and expels air from the module 300-5 through exhaust
vents 534.
During operation, heat is transferred from LED subassemblies 344-2 to thermal
dissipation
fins 510-1 through a metal core printed circuit board 346-1. The airflow
created by the fan
530 passes over the thermal dissipation fins 510-1 and removes heat from the
thermal
dissipation fins 510-1 before exiting the module housing 512-1 through the
exhaust vents
534. Any airflow which directly passes over the metal core printed circuit
board 346-1
and/or the LED subassemblies 344-2 also may remove heat. Of course the
particular
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arrangement or configuration of the thermal dissipation fins 510-1 may differ
from those
illustrated in this embodiment. More than one fan may be used for a given
light-generating
module 300-5. In some embodiments, operation of the fan 530 may be controlled
using
temperature sensing or measurements of the amount of energy supplied to the
LED assembly
338-2.
[00207] Another embodiment of a light-generating module 300-6 including a fan
530-1 is
illustrated in Fig. 35. For example, the fan 530-1, such as a low decibel fan,
can be disposed
in a heat sink 540, such as a die-cast heat sink. An LED assembly 338-3 (the
backside of
which is visible in Fig. 35) is thermally coupled to the heat sink 540 (e.g.,
with a gap pad,
viscous paste or liquid metal). The heat sink 540 has fins 510-2 which form
channels 542
through which air flows. The LED assembly 338-3 and a chassis 336-3 for
supporting
secondary optic components 334-2 may be removably attached to the heat sink
540, for
example with screws. In some embodiments, the LED assembly 338-3 and the
chassis 336-3
may be permanently attached to the heat sink 540 and the entire light-
generating module 300-
6 incorporating all of the components illustrated in Fig. 35 may be attachable
to and
removable from lighting fixture housings by a user. The heat sink 540 also may
serve as a
housing or a support for additional components, electronic or otherwise, for
the light-
generating module 300-6.
[00208] In one embodiment of a light-generating module 300-7 illustrated in
Figs. 36-38,
the thermal components include a thermally conductive base plate 340-3, fins
510-3, and a
cover 550. The components may be configured to facilitate a flow of air past
certain of the
thermal dissipation components (such as the fins 510-3), as shown in Figs. 37
and 38. For
example, in some embodiments, one or more fans 530-2 may be employed to
promote an air
flow through channels 542-1 formed by the fins 510-3.
[00209] The cover 550 may be configured to allow the light-generating module
300-7 to
be attached with screws to a housing 304-2 of a lighting fixture 100-2, or, in
some
embodiments, the cover may be configured to allow the light-generating module
300-7 to be
clipped or snapped into place within the fixture housing 304-2. The cover 550
may include
contacts 352-3 for operating power and/or control connectivity, or the cover
550 may include
a hole for allowing access to power and/or control contacts on an LED
subassembly.
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[00210] As may be seen in Fig. 39, a mounting bracket 316 may be designed to
mount, for
example, between joists, beams or similar architectural features of a ceiling
560, so that the
lighting fixture 100-2 is recessed, with the lower portion of the lighting
fixture 100-2 being
disposed substantially flush with the ceiling 560. The lighting fixture 100-2
may be
configured to hold a removable light-generating module (e.g., the light-
generating module
300-7). The lighting fixture 100-2 may include a controller, as well as other
components,
which may be disposed in a controller housing 562. A wiring compartment 564
may include
various electronic components, such as wires for supplying operating power and
data to the
light-generating module 100-2. The controller housing 562 and/or the wiring
compartment
564 may be configured to provide the recessed lighting fixture 100-2 with a
low vertical
profile, so as to minimize the height of the recessed lighting fixture 100-2
within the ceiling
560. In some embodiments, the profile of the recessed lighting fixture 100-2
may have an
approximately four inch depth above the ceiling 560, such as to connect to a
two-by-four stud
or joist without requiring additional space above the ceiling.
[00211] As illustrated in Figs. 40 and 41, the light-generating module 300-5
described with
reference to Fig. 34 (or another suitable light-generating module disclosed
herein) may be
used within a recessed joist-mount lighting fixture 100-2 according to yet
another
embodiment of the disclosure. The recessed lighting fixture 100-2 may include
a housing
304-2 and mounting brackets 316 configured for mounting the lighting fixture
100-2 in a
ceiling 560 or other suitable location. The light-generating module 300-5 is
shown being
removed from the recessed lighting fixture 100-2 in Fig. 41.
[00212] In some embodiments, the light-generating module 300 may include no
control
facilities within the module, or may include a very limited amount of memory,
processing or
control facilities within the light-generating module 300. For example, the
light-generating
module 300 may receive drive signals for LEDs from an external controller
module (that is, a
controller not disposed on the light-generating module 300) and provide no
further control of
the LEDs and provide no feedback or information to the external controller
module.
[00213] In some embodiments, the light-generating module 300 may include
various
memory, processing or control facilities on the light-generating module 300
itself. For
example, the light-generating module 300 may include a unique identification
code such a
serial number. The serial number may be available for reading by an external
controller
module, and information associated with the serial number may be present
within memory
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associated with the controller module, and/or information associated with the
serial number
may provided to the controller module from an external source. In one
embodiment, the
controller module reads the unique identification code of the light-generating
module 300 and
accesses a database that contains information specific to the light-generating
module 300. In
some embodiments, an identification code may identify a group of light-
generating modules
300 having similar or identical characteristics, and not identify a specific
light-generating
module 300.
[00214] The light-generating module 300 may include only an identification
code, from
which further information can be accessed, as discussed above. Alternatively,
in some
embodiments, the light-generating module 300 may include additional
information within
memory on the light-generating module 300. Examples of information which may
be
included on the light-generating module 300 include, but are not limited to:
operating power
requirements; operating power output rating; descriptions of LED sources;
light generating
characteristics or parameters relating to color or color temperature;
description of optical
beam angles; calibration parameters; operating temperature; instructions for
controller action
related to operating temperature; and historical data relating to temperature,
time or other
light generating characteristics.
[00215] The operating power requirements may be provided by the light-
generating
module 300 in terms of voltage or current, and may include any other suitable
information
regarding the supply of power to the light-generating module 300. The
operating power
output rating may provide an output rating in terms of watts or lumens, and
may include
information regarding any predicted degradation over time. A description of
LED-based
sources may include the type and/or number of ROB LEDs and/or white LEDs, and
color
temperature specifications. Information regarding the optical beam angles
and/or feasible
optical beam angles may be included in some embodiments. Information regarding
a
predicted usable life span may be included in some embodiments. The light-
generating
module 300 may communicate operating temperature measurements to the
controller, and, in
some embodiments, may provide data or instructions to the controller regarding
desired
power levels based on operating temperature measurements. For example, the
light-
generating module 300 may instruct the controller to reduce the power being
supplied to the
light-generating module 300 when a certain threshold operating temperature is
reached. In
some embodiments, historical data such as the number of hours of run-time, the
historical
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operating temperatures, or other data, may be supplied by the light-generating
module 300 to
the controller or other suitable device. In some embodiments, the information
and/or
instructions provided by the light-generating module 300 may be initiated by
the light-
generating module 300 itself and communicated to the controller. In some
embodiments, the
controller, or other reading device, may prompt the light-generating module
300 for
information, or read information directly from a memory module or other
suitable component
of the light-generating module 300.
[00216] As illustrated in Fig. 42, in some embodiments a socket 302 may be
employed to
replaceably attach a light-generating module to a housing or heat sink of a
lighting fixture. In
this embodiment, a grip ring 332 is rotatable on a molded ridge feature 580 of
the chassis
336-2 and includes embossed features (e.g., posts 582) that follow and engage
with a
complementary spiral path 584 on the socket 302 to lock the module to the
socket. In some
embodiments, the socket 302 also may include a key 586 to provide a straight
docking path
for the engagement of the light-generating module to the socket 302. The key
586 prevents
the light-generating module (other than the grip ring 332) from rotating
within the socket
302. In this manner, rotation of the grip ring 332 does not substantially
affect the orientation
of the LED assemblies. Additionally, the orientation of any connectors on the
back side of
the light-generating module does not change, thereby allowing orientation-
specific
connectors to be mated with complementary connectors on the housing.
[00217] By using posts 582 on an internal surface of the grip ring 332 and
spiral pathways
584 or screw-type threads on an exterior surface of the socket 302, in some
embodiments,
tool-less installation and removal of the light-generating module 300 from the
lighting fixture
may be achieved. In this regard, the light-generating module may be easily
attached to a
lighting fixture, and thermal, mechanical and electrical connections may
automatically occur
as a result of the attachment. Of course, in some embodiments, one or more
additional steps
may be required of the user to form all connections of the light-generating
module to the
housing. For example, in some embodiments, the physical and thermal coupling
of the light-
generating module to the housing may occur by twisting the light-generating
module into the
socket as described with reference to Fig. 42, and the electrical connection
of the light-
generating module to the housing may be subsequently achieved by separately
plugging a
connector of the light-generating module into a connector of the housing.
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[00218] In
one aspect, an electrical contact or other means may be incorporated with the
socket 302 to detect when the grip ring 332 has reached a locked position, so
that drive
signals and/or operating power to the LED hex subassemblies are not applied
unless the light-
generating module 300 is completely locked into the socket 302.
[00219] Fig. 43 illustrates one embodiment of the socket 302 mounted to a heat
sink 540-
1, which may form a thermally conductive portion of a fixture housing. The
socket 302 may
be bolted or otherwise fastened to the heat sink 540-1 using through-holes 306
in flanges 308.
A through-hole 590 may be provided in the heat sink 540-1 for an electrical
connector. In
some embodiments, other manners of securing the socket 302 to a heat sink,
housing, or
lighting fixture may be employed, and in some embodiments, the socket 302 may
be
integrally connected to the housing.
[00220] An attachment element other than a socket may be used in some
embodiments to
attach the light-generating module to the housing. For example, in some
embodiments, the
light-generating module may be attached to the housing using an adhesive. In
some
embodiments, fasteners such as screws or bolts may be used to attach the light-
generating
module, and in this manner, no socket may be present.
[00221] Figs. 44A and 44B illustrate an alternative embodiment of a socket 302-
3 in which
a stamped sheet 602 includes locking grooves 604 for receiving posts 606 of a
light-
generating module 300-8. To mount the light-generating module 300-8 to the
socket, the
posts 606 are inserted into the locking grooves 604 and turned clockwise. At
the end of the
rotation, a detent may be used to releasably lock the light-generating module
300-8 to the
socket 302-3. For example, a rounded end 610 of one or more of the posts 606
may engage
with a raised portion 612 of the stamped sheet to provide stability in the
attachment (see Fig.
45). A bent portion 614 of the stamped sheet may be biased to press on the
post 606 to
further secure the attachment.
[00222] A keyed center post 620 may be used to correctly orient contact pads
616 of the
light-generating module 300-8 with leaf spring contacts 618 present on the
stamped sheet
602. Of course the contact pads 616 instead may be present on the stamped
sheet 602 and the
leaf spring contacts 618 may be present on the light-generating module 300-8.
Other suitable
connection assemblies may be used to achieve electrical and/or mechanical
connections.
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[00223] Figs. 46 and 47 show another alternative embodiment of a socket 302-4
and light-
generating module 300-9. In this embodiment, the light-generating module 300-9
includes at
least two flexible wings 628 which can deform inwardly, thereby allowing
engagement
elements 630 to move inwardly when pressing the light-generating module into
the socket.
Once the engagement elements reach a groove 632 in the socket 302-4, the
flexible wings
628 move outwardly and the engagement elements engage with the groove 632 and
hold the
light-generating module 300-9 in the socket 302-4. A spring-biased contact
plate 636 is
disposed at a base of the socket 302-4 to facilitate electrical connection to
the light-generating
module. To remove the light-generating module 300-9 from the socket 302-4, a
user pushes
one or more of the flexible wings 628 inwardly to release the engagement
elements 630 from
the groove 632.
[00224] While each of the socket embodiments described thus far have used
circular
sockets as examples, it is important to note that a socket is not required to
be circular. For
example, in the embodiment of a socket 302-5 and a light-generating module 300-
10
illustrated in Fig. 48, the socket 302-5 is substantially rectangular. In this
embodiment, the
light-generating module 300-10 includes one or more tabs which engage with
corresponding
compliant catches 642 in a heat sink 540-2. The light-generating module 300-10
may
include a thermally conductive gap pad 644 to facilitate thermal conductance
to the heat sink
540-2. The heat sink 540-2 may be part of a lighting fixture 100-3 which
includes a hinged
mounting bracket 646.
[00225] Another embodiment of a substantially rectangular socket is
illustrated in Fig. 49.
A lighting fixture 100-4 which hangs from a ceiling is configured to hold
light-generating
modules that project light upwardly. One or more hangars 650 support the
lighting fixture
100-4 and also may provide a conduit for wires that carry operating power
and/or control
signals to a controller 105. One or more sockets 302-6 face upwardly and
include an
electrical connector 310 for engagement with an electrical connector on a
light-generating
module. A light-generating module may be secured to the lighting fixture 100-4
by passing a
screw through the light-generating module and into a threaded hole 652 present
on a base of
the socket 302-6.
[00226] Another embodiment of a substantially rectangular socket 302-7 is
illustrated in
Fig. 50. A light-generating module 300-11 which also is substantially
rectangular includes
LED assemblies 338 and "clicks" into place (snap-fits) in the socket 302-7.
The light-
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generating module 300-11 includes spring-biased catches 660 which protrude
into grooves
662 in the socket 302-7 to hold the light-generating module 300-11 in place.
In some
embodiments, the catches may be locked in the deployed or undeployed positions
with a tool.
The light-generating module 300-11 also includes an orientation notch 664
which helps align
the light-generating module 300-11 by mating with a corresponding protrusion
668 in the
socket 302-7. The light-generating module 300-11 may be formed with a die-cast
aluminum
housing and include integrated heat sink fins 510. In some embodiments, heat
sink fins may
be incorporated in the socket 302-7 and/or a housing to which the socket is
attached. The
socket 302-7 includes leaf springs 670 for operating power and data
connections, although
any suitable connectors may be used. The socket 302-7 may be attached to a
lighting fixture
using through-holes 306 in a socket flange 308.
[00227] Another embodiment of a socket 302-8 and light-generating module 300-
12 is
illustrated in Fig. 51. In this embodiment, the light-generating module 300-12
includes
pivoting hooks 694 which extend outwardly when pinch levers 696 are squeezed.
In this
embodiment, the light-generating module 300-12 is held within an extruded
aluminum
module housing 698.
[00228] One embodiment of a tool-free light-generating module 300-13 is
illustrated in
Fig. 52. The light-generating module 300-13 has an over-center latch 702 on
one side. When
a latch handle 704 is pulled, hooks 706 release from corresponding grooves in
a socket (not
shown). The latch 702 is configured to permit grasping by a user such that the
light-
generating module 300-13 may be installed and removed with a single hand and
without any
tools. In an alternative embodiment, a similar light-generating module may
have no latch,
but instead include flanges at the longitudinal ends for bolting to a socket
or fixture housing.
[00229] An embodiment that uses mounting hardware to attach a light-generating
module
300-14 to a socket or lighting fixture is illustrated in Fig. 53. The light-
generating module
300-14 includes two through-holes within the module for inserting screws 710
or other
hardware. The through-holes may be located between LED assemblies 338. The
screws 710
are fastened to threaded holes in the base of a socket or elsewhere on a
lighting fixture.
[00230] Referring now to Fig. 54, one embodiment of a light-generating module
300-15
being attached to a socket 302-9 is illustrated. The base of the socket 302-9
includes a
threaded hole 652 for receiving a screw 710 that passes through a through-hole
in the light-
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generating module 300-15. The base of the socket 302-9 also includes a
electrical connector
352 for receiving a corresponding electrical connector of the light-generating
module 300-15.
[00231] Figs. 55 and 56A-56E show various embodiments of lighting fixtures 100-
4 which
provide light in an upward direction using removable light-generating modules
300-15 that
are attached to sockets 302-10 in the lighting fixtures. Electrical connectors
are provided in
the socket bases and on the bottom of the light-generating modules 300-15. It
should be
evident from the figures that the controller module 105 may be in any one of a
number of
configurations.
[00232] Fig. 57 illustrates an exploded view of one embodiment of a
rectangular light-
generating module 300-16 which includes a fan 530-3 for thermal dissipation.
The light-
generating module 300-16 includes an acrylic face plate 330-2, secondary
optical components
334, a set of LED assemblies 338, a die-cast aluminum module housing 512-2
including
thermal dissipation channels 714, and a cover 716 for the fan 530-3 and the
thermal
dissipation channels 714. The fan 530-3 is a flat, unidirectional fan which
draws air into the
module housing 512-2 through intake vents 720, moves the air through the
thermal
dissipation channels 714 and ejects the air from the module housing 512-2
through exhaust
vents 722. A metal core printed circuit board 346 may be used as part of each
LED assembly
338 to aid in the transference of heat from the LED assemblies 338 to a
thermally conductive
base plate 340-4, and in turn to the thermal dissipation channels 714.
[00233] Fig. 58 illustrates one embodiment of a lighting fixture 100-5
including a housing
304-3 which can accommodate up to six light-generating modules 300-16. In this
embodiment, the light-generating modules 300-16 are snap-fit into the lighting
fixture 100-5
and operating power and control signal connections are made through connectors
on the base
of the light-generating modules 300-16 which engage with connectors 310 that
are positioned
on the housing 304-3.
[00234] In some embodiments of the present disclosure, a modular lighting
fixture is
configured such that the housing may be installed through an aperture in an
architectural
feature, such as a hole in a ceiling or a wall for example. In this regard,
the lighting fixture
may be installed as a recessed fixture in existing construction; that is, the
unit may be
installed in an aperture in an existing architectural surface or feature
without having to cut the
ceiling, wall or other architectural surface all the way to joists or other
support elements.
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[00235] In one embodiment, as illustrated in Fig. 59, a lighting fixture 100-1
is somewhat
L-shaped and configured for mounting in an architectural surface such as a
ceiling. A
mounting cone 802 includes mounting feet 804 for supporting and securing the
lighting
fixture 100-1 to the ceiling (or other architectural surface). A housing 304-1
extends
longitudinally away from the mounting cone 802 in one direction. The housing
304-1 may
include thermal dissipation elements 320 (e.g., fins). Further details of
embodiments of the
lighting fixture 100-1 are described below.
[00236] A sequence of installing the lighting fixture 100-1 in a ceiling 560
is illustrated in
Fig. 60. To start, a distal end 806 of the housing 304-1 is moved either
vertically or at an
angle somewhat off of vertical through an aperture 812 in the ceiling 516. As
the distal end
progresses further into the space behind the ceiling, the housing 304-1 is
rotated to bring the
housing 304-1 closer to a horizontal orientation. A proximal end 808 of the
housing 304-1 is
rounded in some embodiments to help with fitting through the aperture 812 as
the housing
304-1 is rotated. The mounting cone 802 is connected to the housing with a
hinge 810 so that
the mounting cone 802 remains substantially clear of the aperture 812 while
the housing 304-
1 is being rotated into place (Fig. 60 shows the mounting cone 802 maintaining
the same
orientation throughout the placement of the lighting fixture 100-1). After the
housing 304-1
reaches a horizontal orientation, the mounting cone 802 is pushed upwardly
until a flange 814
of the mounting cone 802 engages with an exposed surface of the ceiling 560.
When
initially placing the lighting fixture 100-1 in the ceiling 560, the mounting
feet 804 are
pivoted such that they do not inhibit insertion of the mounting cone 802 into
the aperture 812.
Once the flange 814 of the mounting cone 802 is engaged with the exposed
surface of the
ceiling 560, a screwdriver is used to rotate the mounting feet 804 and then
urge them
downwardly so that the mounting cone flange 814 and the mounting feet 804
sandwich the
ceiling 516.
[00237] Fig. 61 shows a perspective view from below of the lighting fixture
100-1 of Figs.
59 and 60. The mounting flange 814 may include a clear matte alzak reflector
816 or other
suitable reflector in some embodiments. The hinge 810 that connects the
mounting cone 802
and the housing 304-1 is visible at the proximal end 808 of the housing 304-1.
A controller
housing 818 is integrated into the housing 304-1 along a bottom portion of the
housing in this
embodiment. In some embodiments, the controller housing 818 and thus the
controller
module are thermally isolated from the housing 304-1.
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[00238] In some embodiments, as in the embodiment illustrated in Figs. 59-62,
the
housing 304-1 may be extruded. As shown in Fig. 62, through-holes 822 for
positioning
operating power and control input connectors may be positioned at a distal end
820 of the
controller housing 818.
[00239] Mounting hardware 826 for adjusting the mounting feet 804 is
illustrated in Fig.
63. Also visible in Fig. 63 is a user-replaceable light-generating module 300.
As with some
other embodiments disclosed herein, the light-generating module 300 may be
installed and
removed by turning a grip ring which interacts with a socket. In this regard,
once the lighting
fixture 100-1 is installed in the aperture of the ceiling (or other
architectural surface or
feature), the lighting fixture 100-1 provides the capability of tool-free
light-generating
module interchangeability. In some embodiments, the mounting hardware 826 may
be
configured to allow tool-free operation as well such that both installation of
the lighting
fixture 100-1 and replacement of the light-generating module 300 are tool-
free.
[00240] Instead of including an extruded fixture housing, in some embodiments
a lighting
fixture 100-1 includes a die-cast fixture housing 304-2. As illustrated in
Fig. 64, the housing
304-2 and the mounting cone 802 are not hingedly connected in some
embodiments.
Mounting hardware 826 and mounting feet 804 similar to the embodiment
illustrated in Fig.
59 may be used, although any suitable mounting hardware and mounting feet may
be
employed. A controller housing 818 may be positioned below and thermally
isolated from
the fixture housing 304-2. In some embodiments, the controller module and/or
the controller
housing 818 are thermally coupled to the fixture housing 304-2. In some
embodiments the
controller and/or the controller housing 818 are thermally coupled to a
separate heat sink (not
shown). Additional views of the embodiment of Fig. 64 are illustrated in Figs.
65-67.
[00241] Fig. 68 illustrates a frame-in kit and lighting fixture for new
construction
installation. Joist hangers 830 support a support plane 832, a junction box
834, and a hanging
brackets 316. Instead of being positioned on the bottom surface of the fixture
housing, a
controller module (not shown) may be placed in the junction box 834 in some
embodiments.
Dimensions of one embodiment of a lighting fixture 100-1 for use in new
construction
installations are shown in Fig. 69A, 69B and 69C. These dimensions are
provided by way of
example only and other dimensions are possible.
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[00242] One embodiment of a controller module 105 for modular lighting
fixtures
disclosed herein and other suitable lighting fixtures is illustrated in Fig.
70. The controller
module 105 receives, through input wiring 850, input operating power such as
"wall power"
(e.g., 110V AC or 220V AC). Data and/or input control signals also are
provided to the
controller module 105, and may be provided through the input wiring 850 as
well. As
outputs, the controller module provides low DC voltage and one or more control
signals to
the LED assemblies of the light-generating module through output wiring 852.
As discussed
above, the controller module 105 additionally may receive or exchange
information with
circuitry, memory or processing capabilities that may be present on the light-
generating
module. For example, the controller module 105 may receive identification
information from
the light-generating module.
[00243] One embodiment of a controller module 105 is illustrated with its
structural
packaging (controller housing 818) in Fig. 70. The configuration and
dimensions illustrated
are by way of example only, and other sizes, shapes and configurations may be
used. In this
embodiment, the controller housing 818 is constructed of stamped sheet steel
or stamped
sheet aluminum, although other construction materials and methods are
possible. In addition
to the input wiring 850 and the output wiring 852, the controller module may
include
indicator lights 856, a flexible elastomer pull tab 858 attached to a side of
the controller
housing 818, and a visual indicator 860 to aid the user in properly orienting
the controller
module when installing it in a housing. The controller housing 818 may have a
curved front
end 862 to facilitate insertion and removal of the controller housing 818. In
some
embodiments, the controller housing 818 may have a certain shape and/or
elements that
prevent insertion of the controller housing 818 in the incorrect orientation.
[00244] Figs. 71A ¨ 71C illustrate various input interfaces for the controller
module 105
which may be interchanged to select the manner of receiving control signal
input. In Fig.
71A, the controller module 105 includes input and output spring clips 870
which allow for
zero ¨ 10 volt control that can be linked from controller module to controller
module for
multiple units. In each of the embodiments of Figs. 71A-71C, input operating
power is
provided to the controller module 105 through the input wiring 850. Fig. 71B
shows the
controller module having an RF receiver 872 and a zone selector 874. In this
configuration,
the controller 105 is wireles sly controllable using radio frequency signals.
The zone selector
874 allows for group control and facilitates remapping. In Fig. 71C, the
controller module
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includes RJ-45 jacks 876 which allow Ethernet-based control signals to be used
for input. By
using two jacks, linking of multiple controller modules is possible.
[00245] Figs. 72, 73, 74 and 75 show four steps in a method of installing a
controller
module 105 in a recessed lighting fixture 100 which has already been installed
in an
architectural feature (for example, a ceiling 560).
[00246] In a first step, as shown in Fig. 72, the output wiring 852 and the
input wiring 850
of the controller module are connected to the associated wiring of the
lighting fixture and
wall power. Although not shown, a control input wire may be connected to a
control input
connector 880. The controller housing 818 is oriented with the aid of the
visual indicator
860. In a second step, as shown in Fig. 73, the controller module 105 is moved
through an
aperture 884 of the fixture housing 304 (e.g., a light exit aperture) and
rotated to a horizontal
orientation. Once in a horizontal orientation, the controller module 105 is
rotated about a
vertical axis into an operating orientation, as shown in Fig. 74. A clamping
element 888 is
then used to lock the controller module into place as shown in Fig. 75. To
remove the
controller module, the process is reversed and the pull-tab 858 is used to
pull the controller
module 105 away from the housing wall and toward the aperture 884.
[00247] In some embodiments, the controller modular may itself be configured
to be
modular in terms of the input and output interfaces. One embodiment of a
modular controller
module 105-1 is schematically illustrated in Fig. 76. The controller module
105-1 includes a
processor 102 (see Fig. 1) which may which processes the input signals and
determines
and/or delivers output power and/or drive signals for controlling the LED-
based light sources.
In some embodiments, the processor 102 is disposed on a motherboard. More
generally, the
controller module may include at least one connection mechanism 894 configured
to permit a
modular installation and removal of at least a first circuit board including
input circuitry 892
configured to receive at least one input signal including information relating
to lighting, and a
second circuit board including output circuitry 896 configured to output at
least one lighting
control signal that is based at least in part on the information included in
the at least one input
signal. In one aspect, the connection mechanism 894 provides at least one
electrical
connection between the first circuit board and the second circuit board when
both the first
and second circuit boards are coupled to the at least one connection
mechanism. In one
exemplary implementation, as mentioned above, this connection mechanism may be
provided
by a motherboard. In another aspect, a processor 102 may be disposed on the
mother board
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to process the at least one input signals and provide the at least one
lighting control signal
(e.g., one or more PWM drive signals).
[00248] More specifically, an interchangeable "front-end" interface, or
input interface
892, provides flexibility to the user in configuring the controller module 105
for receiving
control signals. For example, the user may use various input interface boards
and/or
connectors 894 to allow for input information to be provided via Ethernet,
DMX, DaIi,
wireless connection, analog control, or any other suitable connection. An
interchangeable
"back-end," or output interface 896 provides flexibility to the user in terms
of the number of
LED channels to be driven and/or the type of channels to be driven. For
example, depending
on the type of light-generating module being used, an output interface board
could provide for
a single channel/single color driving capability, or a different output
interface board may be
used to drive multiple channels for multiple colors or multiple color
temperatures. In
particular, in some embodiments, an output interface board may be used to
drive multiple
color temperature white LEDs. The output power may be sent to the LED-based
light sources
via output wiring 852.
[00249] According to another aspect of the disclosure, a battery or other
auxiliary power
source is provided in an LED lighting fixture such that the LED lighting
fixture may be used
for emergency lighting in addition to its primary lighting purpose. For
example, as shown in
Fig. 77, the controller module 105 may normally be coupled to a primary power
source such
as wall power 900, but in the event of a power loss, may couple instead to an
auxiliary power
source 902 such as a rechargeable battery or a large capacity capacitor. In
some embodiments,
a connection to an auxiliary source of line power may be used as an auxiliary
power source.
The controller module may be configured to automatically change over to using
the auxiliary
power source 902 as a power source for an LED lighting fixture when the
primary power
source is interrupted for a threshold amount of time.
[00250] Having thus described several illustrative embodiments, it is to be
appreciated
that various alterations, modifications, and improvements will readily occur
to those skilled in
the art. Such alterations, modifications, and improvements are intended to be
part of this
disclosure, and are intended to be within the scope of this disclosure. While
some examples
presented herein involve specific combinations of functions or structural
elements, it should
be understood that those functions and elements may be combined in other ways
according to
the present disclosure to accomplish the same or different objectives. In
particular, acts,
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elements, and features discussed in connection with one embodiment are not
intended to be
excluded from similar or other roles in other embodiments. Accordingly, the
scope of the
claims should not be limited by particular embodiments set forth herein, but
should be
construed in a manner consistent with the specification as a whole.
