Multiple panel troffer-style fixture
09777897 · 2017-10-03
Assignee
Inventors
- Paul Kenneth Pickard (Morrisville, NC, US)
- Mark D. Edmond (Raleigh, NC, US)
- Gerald Negley (Chapel Hill, NC, US)
- Eric Tarsa (Goleta, CA, US)
Cpc classification
F21V23/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2103/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S8/026
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2105/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F21V1/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V11/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V5/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V23/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S8/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Lighting fixtures are described utilizing a plurality of light sources, or light engines, which are mounted together in a modular fashion in the light fixture opening. In some embodiments, the plurality of light sources can comprise lighting panels that together form the overall fixture light source. The present invention is particularly applicable to troffer-style lighting fixtures that can be arranged with a plurality of lighting panels arranged in the troffer opening to illuminate the space below the troffer. Embodiments of the present invention can also utilize solid state light sources for the lighting panels, with some embodiments utilizing light emitting diodes (LEDs).
Claims
1. A light fixture, comprising: a plurality of lighting panels in a light fixture opening, each of said lighting panels emitting a substantially uniform light across its emission surface and emitting in substantially the same direction; and a power distribution system, each of said panels connected to said power distribution system, said power distribution system comprising a fixture printed circuit board (PCB) that extends along a central spine of said light fixture.
2. The light fixture of claim 1, wherein at least some of said lighting panels are removable.
3. The light fixture of claim 1, wherein at least some of said lighting panels are removable and replaceable.
4. The light fixture of claim 1, wherein said lighting panels are mounted in substantially the same plane.
5. The light fixture of claim 1, wherein said light fixture opening comprises a ceiling opening.
6. The light fixture of claim 1, wherein said light fixture opening comprises a troffer-style light fixture opening.
7. The light fixture of claim 1, wherein said lighting panels further comprise a solid state light source.
8. The light fixture of claim 1, wherein said panels further comprises light emitting diodes (LEDs) arranged to emit light through said emission surface.
9. The light fixture of claim 8, wherein one or more of said panels further comprises a waveguide, said panel's LEDs mounted along at least one edge of, and emitting light down its said waveguide.
10. The light fixture of claim 9, wherein a surface of said waveguide comprises a plurality of planar interruptions arranged to cause light to escape from said waveguide at said interruptions.
11. The light fixture of claim 10, wherein said interruptions comprise cuts or indents.
12. The light fixture of claim 10, comprising different concentrations or sizes of interruptions at different areas of said waveguide.
13. The light fixture of claim 10, wherein said interruptions comprise a controlled gradient profile.
14. The light fixture of claim 8, wherein said panels further comprise a back surface opposite said emission surface, wherein said LEDs are mounted to said back surface to emit light directly on said emission surface.
15. The light fixture of claim 14, wherein said emission surface comprises a diffuser.
16. The light fixture of claim 14 wherein portions of said back surface around said comprises a diffuse or reflective coating/layer.
17. The light fixture of claim 8, wherein said panels further comprise a back surface opposite said emission surface, and a plurality of LEDs along one edge of said panel and emitting light on said back surface.
18. The light fixture of claim 17, wherein said back surface comprises a specular reflector to reflect said LED light through said emission surface.
19. The light fixture of claim 17, wherein said back reflector comprises a diffuse layer to diffuse and reflect said LED light through said emission surface.
20. The light fixture of claim 19, wherein said diffuse layer comprises a virtual light source.
21. The light fixture of claim 1, further comprising a reflective frame, said light panels mounted to said reflective frame.
22. The light fixture of claim 21, wherein said power distribution system is mounted to said reflective frame.
23. The light fixture of claim 1, wherein said power distribution system comprises a power spine.
24. The light fixture of claim 1, wherein said power distribution system comprises a wiring harness.
25. The light fixture of claim 1, having an AC/DC converter.
26. The light fixture of claim 1, wherein each of said lighting panels comprises a DC/DC converter.
27. The light fixture of claim 1, wherein said lighting panels have the same size.
28. A troffer-style lighting fixture, comprising: a plurality of lighting panels, each of said lighting panels comprising a solid state light source; a frame, said lighting panels mounted to said frame; a source of electrical power, each of said lighting panels electrically connected to said source of electrical power to cause said solid state light source to emit light; a power spine comprising a fixture printed circuit board (PCB) running down the center of said frame, said power spine comprising connectors to receive each of said light panels and to provide an electrical connection between said source of electrical power and each of said light panels.
29. The lighting fixture of claim 28, sized to fit in the opening in a ceiling T-grid.
30. The lighting fixture of claim 28, wherein said frame comprises reflective surfaces.
31. The light fixture of claim 28, wherein said frame comprises curved surfaces.
32. The light fixture of claim 28, wherein said lighting panels are removably mounted to said frame.
33. A light fixture, comprising: a plurality of lighting panels having a plurality of solid state light sources, said plurality of lighting panels emitting light out a light fixture opening; an AC/DC converter providing a first DC signal along a central spine of said light fixture to each of said plurality of lighting panels; and a plurality of DC/DC converters, each of which is on a respective one of said lighting panels and providing a second DC signal to said solid state light sources.
34. The light fixture of claim 33, further comprising a power distribution mechanism to conduct said first DC signal to said lighting panels.
35. The light fixture of claim 33, wherein solid state light sources comprise light emitting diodes (LEDs).
36. The light fixture of claim 33, sized to fit in a T-grad ceiling opening.
37. The light fixture of claim 33, comprising a troffer-style light fixture.
38. The light fixture of claim 33, wherein said lighting panels are mounting in substantially the same plane.
39. The light fixture of claim 35, wherein each of said lighting panels has an emission surface, and wherein one or more of said panels further comprising a waveguide, said panel's LEDs mounted along at least one edge of, and emitting light down its said waveguide and out said emission surface.
40. The light fixture of claim 35, wherein each of said lighting panels has an emission surface, and wherein one or more of said lighting panels further comprise a back surface opposite said emission surface, wherein said LEDs are mounted to said back surface to emit light directly on said emission surface.
41. The light fixture of claim 35, wherein each of said lighting panels has an emission surface wherein said panels further comprise a back surface opposite said emission surface, and a plurality of LEDs along one edge of said panel, said LED emitting light on said back surface.
42. The light fixture of claim 33, further comprising a reflective frame, said lighting panels mounted to said frame.
43. The light fixture of claim 42, further comprising a power spine mounted to said reflective frame.
44. A lighting fixture lighting panel, comprising: a waveguide for confining LED light between its opposing planar surfaces, one of said planar surfaces being a panel emission surface; an array of light emitting diodes (LEDs) mounted to an LED printed circuit board (PCB) on at least one edge of said waveguide and emitting light into said waveguide; planar interruptions at different areas of said panel emission surface, wherein said planar interruptions provide a uniform emission pattern from the panel; and a DC/DC converter on said LED PCB to provide an electrical signal for driving said array of LEDs, wherein said LED PCB comprises conductors configured such that said LED PCB can be plugged into connectors on an external structure to secure said panel to said external structure and provide an electrical connection.
45. The lighting panel of claim 44, wherein said interruptions comprise cuts or indents.
46. The light fixture of claim 44, wherein said interruptions comprise different concentrations or sizes at different areas of said waveguide.
47. The light fixture of claim 44, wherein said interruptions comprise a controlled gradient profile.
48. The light fixture of claim 44, further comprising a connection for mounting in a T-grid ceiling opening.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
(15) Embodiments of the present invention can be directed to many different light fixtures with the embodiments described herein directed to troffer-style fixtures that are particularly well-suited for use with solid state light sources, such as LEDs. The fixtures can comprise a plurality of lighting panels or light engines (“lighting panels” or “light panels”), each of which has a plurality of LEDs as its light source. In some embodiments, the panels can be arranged to provide a substantially even light source, such as white light, with the light from the LEDs dispersed or mixed so as to minimize or eliminate LED emission “hot spots”. The panels can be mounted in a lighting fixture opening, such as a conventional troffer-style opening, with the panels mounted so that their emission illuminates the space below the troffer. In some embodiments, the panels can be mounted so that they are in the same plane. In other embodiments the lighting panels can be mounted in parallel planes, while in other embodiments the panels can be mounted at different angles to produce the desired light fixture emission pattern.
(16) Some embodiments of the present invention can comprise components, such as panels and frames on and spanning across the ceiling T-grid opening. In some of these embodiments, the mounting or reflective frame can be located in and supported directly by the ceiling's T-grid, with the lighting panels then mounted to the reflective grid. In other embodiments, the lighting panels can be mounted directly in the T-grid opening without the need for a reflective frame. Embodiments of the present invention can be used without a troffer pan, with these embodiments consuming much less space in the ceiling area above the T-grid.
(17) By using lighting panels in a modular approach, the present invention provides enhanced flexibility in lighting fixture design, installation and repair. The lighting fixtures according to the present invention can use different types of lighting panels that can be arranged in many different ways to provide a substantially uniform light emission from its emission surface. Some light panel embodiments can be arranged to be edge lit with a plurality of LEDs, and can comprise a waveguide to disperse the light from the LEDs to provide even emission across the panel. In still other embodiments, a lighting panel can be back lit with an array of LEDs emitting onto a diffuser panel that helps disperse the LED light. In still other embodiments, the panels can comprise indirect emission arrangements, wherein the panels can be edge lit with a plurality of LEDs that are arranged to emit onto a diffuser/reflector that mixes the light to provide an even emission. These are only a few of the different arrangements that can be used for the lighting panels, and in some embodiments the lighting fixtures can have the same types of panels, while in other lighting fixtures different types of lighting panels can be used in a particular fixture. Different numbers of panels can be used in different lighting fixtures, with the number of panels dependent upon a number of factors some of which include the size of the light fixture opening, the size of the lighting panels, and the mounting angles of the lighting panels.
(18) In some embodiments the light fixture can use panels that are the same size, while in other embodiments the fixtures can use different sized lighting panels. In other embodiments, the panels can cover or fill the entire light fixture opening, while in other embodiments, the panels can cover or fill less than the entire lighting fixture opening.
(19) Some conventional LED based troffer-style fixtures can comprise a light engine arranged with an array of LEDs, reflectors/diffuser, and power supply or ballast. For some of these, failure of one or more of the components can require replacement of the entire light fixture or light engine. In some light fixture embodiments according to the present invention, each lighting panel can have its own electrical connection to the lighting fixture, with each panel being removable and replaceable. This arrangement allows for one of the panels to be replaced in case of failure or malfunction of the panel's LEDs or power supply. This helps avoid the expense and inconvenience of removing the entire light fixture and/or its light engine. The failure can be localized to one particular panel, resulting in quick, convenient and cost-effective light fixture repair. Many different electrical connection arrangements can be used, that can be provided in many different locations in the light fixture opening. In some embodiments, a power connection spine can be included in the lighting fixture that carries a light fixture power signal, and is arranged so that each of the panels can easily connect to the spine for power. In some embodiments, the power connection spine can run down one of the surfaces of the light fixture's reflective frame, such as a longitudinal surface of the frame.
(20) Some conventional LED based troffer-style light fixtures can also comprise power supply or ballast can also comprise various components and circuitry to dirve the fixture's light engine. Some of these can include an AC/DC converter and one or more DC/DC converters. These types of power supplies drive the entire light engine and as a result can comprise large and costly components. Furthermore, they can require setting of the output drive signal to provide the desired light engine light emission, with this setting typically done at the factory during light engine fabrication. If the ballast or power supply fails after installation, it can be difficult to replace and set in the field and in some instances the entire troffer or light engine needs to be replaced.
(21) The light fixtures according to the present invention can have different power supply arrangements to convert conventional AC power to a DC power signal appropriate to drive the LEDs in the lighting panels. The power supplies also comprise other electrical components to perform other functions, such as current compensation circuitry to compensate for variations in LED emission in response to temperature changes or over time or dimming circuitry. In some embodiments, the lighting fixtures can comprise one AC/DC power supply that converts conventional AC power supplied to a home or office, to a DC drive signal. Each of the panels can then comprise its own DC/DC power supply that converts the DC drive signal to a level to provide the desired emission from that panel. In some embodiments, the compensation circuitry can also be located at each of the panels to compensate for emission changes locally, at the respective panel. As further described below, this power supply arrangement can reduce or eliminate many of the shortcomings associated with having a single overall power supply for the light fixture.
(22) The panels according to the present invention can have many different shapes and sizes, with some embodiments being relatively thin, and having square or rectangular shapes. It is understood that other embodiments can have other shapes with many different numbers of sides, such as triangular, polygon, pentagon, hexagon, octagon, etc., while in other embodiments the panels can be oval or circular. As mentioned above, conventional troffer style light fixtures come in different sizes, and some embodiments of the panels can be sized such that different numbers of panels can be used to fill the different sized ceiling or troffer openings. For example, the panels can be sized and shaped such that a certain number of panels can be used to fill a 2 foot by 4 foot troffer opening, while a different number of lighting panels can be used to fill a 1 foot by 4 foot, or 2 foot by 2 foot troffer opening. Being able to use the same lighting panels in different sized openings provides flexibility in installing the light fixtures, and does not require the manufacturer, retailer, distributor or installer to supply or stock different sized troffers for these different applications.
(23) The invention is described herein with reference to certain embodiments, but it is understood that the invention can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. In particular, the present invention is described below in regards to troffer-style light fixtures, but it is understood that it is applicable to many other lighting styles, types and applications. The embodiments are also described with reference to certain lighting panels, but it is understood that many different lighting panels can be used that are arranged in many different ways. The components can have different shapes and sizes beyond those shown and different numbers of LEDs or LED chips can be included. Many different commercially available LEDs can be used in the lighting panels according to the present invention such as those commercially available from Cree, Inc. These can include, but not limited to Cree's XLamp® XP-E LEDs or XLamp® XP-G LEDs.
(24) It is understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. Furthermore, relative terms such as “inner”, “outer”, “upper”, “above”, “lower”, “beneath”, and “below”, and similar terms, may be used herein to describe a relationship of one element to another. It is understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.
(25) Although the terms first, second, etc., may be used herein to describe various elements, components, regions and/or sections, these elements, components, regions, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, or section from another. Thus, unless expressly stated otherwise, a first element, component, region, or section discussed below could be termed a second element, component, region, or section without departing from the teachings of the present invention.
(26) As used herein, the term “source” can be used to indicate a single light emitter or more than one light emitter functioning as a single source. Thus, the term “source” should not be construed as a limitation indicating either a single-element or a multi-element configuration unless clearly stated otherwise. For example, the lighting panels described herein as having a solid state light source, can have a single-element or multi-element configuration.
(27) Embodiments of the invention are described herein with reference to cross-sectional view illustrations that are schematic illustrations. As such, the actual thickness of elements can be different, and variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances are expected. Thus, the elements illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region of a device and are not intended to limit the scope of the invention.
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(29) Referring now to
(30) The troffer-style fixture 10 can also comprise a system or mechanism to distribute electrical power to the panels 18. In the embodiment shown, a DC signal from an AC/DC converter (described in more detail below) is distributed to the various lighting panels. The DC signal can be distributed in many different ways, such as through a wiring harness or through printed circuit boards (PCBs). The wiring harness or PCBs can run along different portions of the fixture and can have a connector arrangement for connecting to the electrical power to the lighting panels 18.
(31) In the embodiment shown, the power distribution system or mechanism can comprise a fixture PCB 22 (or multiple PCBs) running down central spine 24 (i.e. power spine) of the frame 12. It is understood, however, that a wiring harness can also be used running along the central spine.
(32) Referring again to
(33) Power can be supplied to the lighting fixture 10 using many different power supply, ballast and circuits arranged to provide the desired drive signal for illuminating the LEDs in its lighting panels.
(34) Having respective DC/DC converters at each lighting panel can provide certain advantages. In conventional troffers having the AC/DC and DC/DC converters in one power supply can require setting of the output of the power supply at the factory to match it to the light engine of the particular troffer. Thus, if this type of combined power supply malfunctions or fails it can result in complex repair procedures or replacement of the entire troffer or light engine. By having the DC/DC converter integral to each lighting panel, the AC/DC converter does not need to be set at the factory. A failed or malfunctioning AC/DC converter can be easily replaced in the field. If an on-board DC/DC converter malfunctions or fails at the lighting panel, the entire lighting panel can be easily removed and replaced with a another functioning lighting panel. The DC/DC converter on the panel will have been set to the desired level for that particular panel, so the repair procedure does not require resetting in the field.
(35) Furthermore, the components for a combined AC/DC and DC/DC converters that drive the entire fixture can also be large and expensive. By making the DC/DC converter on-board and remote at each of the lighting panels, smaller and less expensive components can be used because of the reduced power needed from each converter. A DC/DC converter for the entire fixture would need to accommodate 40 watts of power, or more. By dividing that load into multiple portions or panels (e.g. eight panels), the individual panels need only see 5 watts. This allows for many of the DC/DC circuit components to be consolidated into purpose-build integrated circuits, reducing cost and size. The remote DC/DC converters can also be arranged closer to the LEDs on each lighting panel which can provide for greater driving efficiency and control.
(36) The lighting panels can be arranged to emit relatively even emission with different luminous flux, with some embodiments emitting at least 100 lumens, while other embodiments can emit at least 200 lumens. In still other embodiments the lighting panels can be arranged to emit at least 500 lumens, with the lighting panels in the embodiment shown emitting approximately 500 lumens each.
(37) In some embodiments, each of the lighting panels in a particular fixture can emit light with the same characteristics, such as emission intensity, color temperature, and color rendering index. This can result in the particular fixture emitting a substantially uniform emission across its opening. The panels can be arranged with LEDs that can generate different colors of light, with the many industrial, commercial, and residential applications calling for fixtures emitting white lights. The lighting panels according to the present invention may comprise one or more emitters producing the same color of light or different colors of light. In some embodiments, a multicolor source is used to produce white light, and several colored light combinations can be used to yield white light. For example, as discussed in U.S. Pat. Nos. 7,213,940 and 7,768,192, both of which are assigned to Cree, Inc., and both of which are incorporated herein by reference, it is known in the art to combine light from a blue LED with wavelength-converted yellow light to yield white light with correlated color temperature (CCT) in the range between 5000K to 7000K (often designated as “cool white”). Both blue and yellow light can be generated with a blue emitter by surrounding the emitter with phosphors that are optically responsive to the blue light. When excited, the phosphors emit yellow light which then combines with the blue light to make white. In this scheme, because the blue light is emitted in a narrow spectral range it is called saturated light. The yellow light is emitted in a much broader spectral range and, thus, is called unsaturated light.
(38) Another example of generating white light with a multicolor source is combining the light from green and red LEDs. RGB schemes may also be used to generate various colors of light. In some applications, an amber emitter is added for an RGBA combination. The previous combinations are exemplary; it is understood that many different color combinations may be used in embodiments of the present invention. Several of these possible color combinations are discussed in detail in U.S. Pat. No. 7,213,940 to Van de Ven et al.
(39) Other lighting panel embodiments can utilize a series of clusters having two blue-shifted-yellow LEDs (“BSY”) and a single red LED (“R”). BSY refers to a color created when blue LED light is wavelength-converted by a yellow phosphor. The resulting output is a yellow-green color that lies off the black body curve. BSY and red light, when properly mixed, combine to yield light having a “warm white” appearance. These and other color combinations are described in detail in the previously incorporated patents to Van de Ven (U.S. Pat. Nos. 7,213,940 and 7,768,192). The lighting panels according to the present invention can use a series of clusters having two BSY LEDs and two red LEDs that can yield a warm white output when sufficiently mixed.
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(41) One advantage of a waveguide lighting panel embodiment is that they can be relatively thin, thereby consuming much less space in the ceiling. Different embodiments can have different thicknesses, with some being less than 25 mm thick. Other embodiments can be less than 10 mm thick. The embodiment shown can have a thickness of approximately 6 mm. The panels can also have different sizes, with some panels according to the present invention sized so that they can be used in different sized troffer openings. In the embodiment shown, the panel 100 can be square, with each edge being an approximately 1 foot long. This allows for eight panels to fill a 2 foot by 4 foot troffer opening fixture as shown in
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(43) Diffuse reflective coatings have the inherent capability to mix light from solid state light sources having different spectra (i.e., different colors). These coatings are particularly well-suited for multi-source designs where two different spectra are mixed to produce a desired output color point. A diffuse reflective coating may reduce or eliminate the need for additional spatial color-mixing schemes that can introduce lossy elements into the system; although, in some embodiments it may be desirable to use diffuse reflectors in combination with other diffusive elements. In some embodiments, the surfaces can also be coated with a phosphor material that converts the wavelength of at least some of the light from the light emitting diodes to achieve a light output of the desired color point.
(44) In other embodiments the coating/layer 156 can comprise materials other than diffuse reflectors. In other embodiments, the coating/layer can comprise a specular reflective material or a material that is partially diffuse reflective and partially specular reflective. In some embodiments, it may be desirable to use a specular material in one area and a diffuse material in another area. These are only some of the many combinations are possible.
(45) Like the embodiment above, the lighting panel also has a PCB 158 that can be arranged for connecting to electrical power and can have a DC/DC conversion circuit as discussed above. In this lighting panel embodiment, however, the LEDs 152 reside on the back surface 153 of the lighting panel 150, with the PCB 158 having conductors to transmit a drive signal to the LEDs 152. The PCB 158 is arranged generally at a right angle to the remainder of the lighting panel 150 for connection to electrical power at the central spine 24 (shown in
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(47) Like the embodiments above, the lighting panel 200 can comprise an LED PCB 210 holding the LEDs 202, and can also have a DC/DC power converter as described above. The lighting panel 200 can have different thicknesses, and like the embodiment above, some embodiments can be less than 50 mm thick. In other embodiments, the lighting panel can have a thickness in the range of 10-25 mm. The panel 200 can also have a square or rectangular shape of the different sizes mentioned
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(49) Like the embodiments above, the lighting panel 200 can comprise a LED PCB :210 holding the LEDs 222, and can also have a DC/DC power converter as described above. The lighting panel 220 can have different thicknesses, with some embodiments being less than 50 mm thick. In other embodiments, the lighting panel can have a thickness in the range of 10-25 mm, and can be one of the shapes or sizes mentioned above.
(50) It is understood that embodiments presented herein are meant to be exemplary. Embodiments of the present invention can comprise any combination of compatible features shown in the various figures, and these embodiments should not be limited to those expressly illustrated and discussed.
(51) Although the present invention has been described in detail with reference to certain preferred configurations thereof, other versions are possible. Therefore, the spirit and scope of the invention should not be limited to the versions described above.