Modular indirect suspended/ceiling mount fixture

Abstract

A modular troffer-style fixture particularly well-suited for use with solid state light sources. The fixture comprises a reflector that includes parallel rails running along its length, providing a mount mechanism and structural support. An exposed heat sink is disposed proximate to the reflector. The portion of the heat sink facing the reflector functions as a mount surface for the light sources. The heat sink is hollow through the center in the longitudinal direction. The hollow portion defines a conduit through which electrical conductors can be run to power light emitters. One or more light sources disposed along the heat sink mount surface emit light toward the reflector where it can be mixed and/or shaped before it is emitted from the troffer as useful light. End caps are arranged at both ends of the reflector and heat sink, allowing for the easy connection of multiple units in a serial arrangement.

Claims

1. A lighting assembly comprising: an elongated heat sink supporting at least one LED for emitting light; a reflector disposed proximate to and distanced from the heat sink, wherein the reflector comprises a front surface facing the heat sink for receiving the light and a back surface; at least one elongated rail along the back surface; and a mounting bracket connected to the at least one elongated rail for mounting the lighting assembly to a surface.

2. The lighting assembly of claim 1 further comprising a first end cap secured to a first end of the reflector and a second end cap secured to a second end of the reflector.

3. The lighting assembly of claim 2 wherein the first end cap is mounted to the first end using a first snap-fit connection and the second end cap is mounted to the second end using a second snap-fit connection.

4. The lighting assembly of claim 1 wherein the at least one LED emits uplight and the front surface faces downward when the lighting assembly is mounted to the surface.

5. The lighting assembly of claim 1 wherein the front surface is reflective.

6. The lighting assembly of claim 1 wherein the front surface is a diffuse white reflector.

7. The lighting assembly of claim 1 wherein the at least one elongated rail comprises two elongated rails disposed substantially parallel to one another.

8. The lighting assembly of claim 1 wherein the mounting bracket is substantially U-shaped.

9. The lighting assembly of claim 7 wherein the mounting bracket includes a first end that engages a first one of the two elongated rails and a second end that engages a second one of the two elongated rails.

10. The lighting assembly of claim 1 wherein the mounting bracket is removably connected to the at least one rail.

11. The lighting assembly of claim 2 wherein the first end cap and the second end cap each comprise two separate pieces joined together.

12. A modular lighting assembly comprising: a first lighting assembly comprising: a first elongated heat sink supporting at least one first LED for emitting light; a first reflector disposed proximate to and distanced from the first heat sink, wherein the first reflector comprises a first front surface facing the first heat sink for receiving the light from the at least one first LED; and a first end cap secured to a first end of the first reflector and a second end cap secured to a second end of the first reflector; and a second lighting assembly comprising: a second elongated heat sink supporting at least one second LED for emitting light; a second reflector disposed proximate to and distanced from the second heat sink, wherein the second reflector comprises a second front surface facing the second heat sink for receiving the light from the at least one second LED; and a third end cap secured to a first end of the second reflector and a fourth end cap secured to a second end of the second reflector; wherein one of the first end cap and the second end cap is releasably connectable to at least one of the third end cap and the fourth end cap.

13. The modular lighting assembly of claim 12 wherein one of the first end cap and the second end cap is releasably connectable to at least one of the third end cap and the fourth end cap using a snap-fit connection.

14. The modular lighting assembly of claim 12 further comprising a cable connector for electrically connecting the first lighting assembly to the second lighting assembly.

15. The modular lighting assembly of claim 12 wherein the first lighting assembly has a first length and the second lighting assembly has a second length, wherein the first length is different than the second length.

16. A lighting assembly comprising: a reflector comprising a front surface for receiving light; and an elongated heat sink supporting at least one LED for emitting light disposed proximate to and distanced from the front surface of the reflector, wherein the front surface and the heat sink are exposed to the ambient environment and, wherein the heat sink has a first end including a mounting surface supporting the at least one LED and a second end, wherein the first end is wider than the second end; wherein the at least one LED emits uplight and the front surface faces downward when the lighting assembly is in a mounted position.

17. The lighting assembly of claim 16 further comprising a first end cap secured to a first end of the heat sink and the reflector and a second end cap secured to a second end of the heat sink and the reflector.

18. The lighting assembly of claim 17 wherein the first end cap and the second end cap maintain a desired spacing between the heat sink and the reflector.

19. The lighting assembly of claim 16 wherein the heat sink is hollow.

20. The lighting assembly of claim 17 wherein at least one of the first end cap and the second end cap comprises a removable side cover that provides access to a power connection.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a lighting assembly according to an embodiment of the present invention.

(2) FIG. 2 is a perspective view of a cut-away portion of a lighting assembly according to an embodiment of the present invention.

(3) FIG. 3 is a perspective view of a portion of a lighting assembly according to an embodiment of the present invention.

(4) FIG. 4 is another perspective view of a cut-away portion of a lighting assembly according to an embodiment of the present invention.

(5) FIG. 5a is a perspective view of a cross-sectional portion of a heat sink that can be used in a lighting assembly according to an embodiment of the present invention.

(6) FIG. 5b is a cross-sectional view of a heat sink that can be used in a lighting assembly according to an embodiment of the present invention.

(7) FIG. 6 is a perspective view of an end portion of a heat sink that can be used in a lighting assembly according to an embodiment of the present invention.

(8) FIGS. 7a-c are top plan views of portions of several light strips that may be used in lighting assemblies according to embodiments of the present invention.

(9) FIG. 8 is a perspective view of an end cap that can be used in a lighting assembly according to an embodiment of the present invention.

(10) FIG. 9 is a perspective view of a modular lighting assembly according to an embodiment of the present invention.

(11) FIG. 10a is a cross-sectional view of a reflector that may be used in lighting assemblies according to embodiments of the present invention.

(12) FIG. 10b is a close-up view of a portion of a reflector that may be used in lighting assemblies according to embodiments of the present invention.

DETAILED DESCRIPTION

(13) Embodiments of the present invention provide a modular troffer-style fixture that is particularly well-suited for use with solid state light sources, such as LEDs. The fixture comprises a reflector having a surface on one side and a back surface on the opposite side. The back surface includes parallel rails that run along the length of the reflector, providing a mount mechanism as well structural support to the reflector. To facilitate the dissipation of unwanted thermal energy away from the light sources, a heat sink is disposed proximate to the surface of the reflector. The portion of the heat sink facing the reflector functions as a mount surface for the light sources, creating an efficient thermal path from the sources to the ambient. The heat sink, which is exposed to the ambient room environment, is hollow through the center in the longitudinal direction. The hollow portion defines a conduit through which electrical conductors (e.g., wires) can be run to power light emitters. One or more light emitters disposed along the heat sink mount surface emit light toward the reflector where it can be mixed and/or shaped before it is emitted from the troffer as useful light. End caps are arranged at both ends of the reflector and heat sink. One of the end caps houses electronics for powering the light emitters. The end caps are constructed to allow for the easy connection of multiple units in a serial arrangement.

(14) FIG. 1 is a perspective view of a lighting assembly 100 according to an embodiment of the present invention. The lighting assembly 100 is particularly well-suited for use as a fixture for solid state light emitters, such as LEDs or vertical cavity surface emitting lasers (VCSELs), for example. However, other kinds of light sources may also be used. A reflector 102 is disposed proximate to an elongated heat sink 104, both of which are described in detail herein. The reflector 102 comprises a surface 106 that faces toward the heat sink 104 and a back surface 108 (shown in FIG. 2) on the opposite side. First and second end caps 110, 112 are arranged at both ends of the reflector 102 and the heat sink 104 to maintain the distance between the two elements and provide the structural support for the assembly 100.

(15) In this embodiment of the lighting assembly 100, the heat sink 104 is exposed to the ambient environment. This structure is advantageous for several reasons. For example, air temperature in a typical residential or commercial room is much cooler than the air above the fixture (or the ceiling if the fixture is mounted above the ceiling plane). The air beneath the fixture is cooler because the room environment must be comfortable for occupants; whereas in the space above the fixture, cooler air temperatures are much less important. Additionally, room air is normally circulated, either by occupants moving through the room or by air conditioning. The movement of air throughout the room helps to break the boundary layer, facilitating thermal dissipation from the heat sink 104. Also, in ceiling-mounted embodiments, a room-side heat sink configuration prevents improper installation of insulation on top of the heat sink as is possible with typical solid state lighting applications in which the heat sink is disposed on the ceiling-side. This guard against improper installation can eliminate a potential fire hazard.

(16) FIG. 2 is a perspective view of a cut-away portion of the lighting assembly 100. The reflector 102 and heat sink 104 are mounted to the inside surface of the first end cap 110. In this particular embodiment, these elements are mounted using a snap-fit mechanism which provides reduced assembly time and cost. Other mounting means may also be used, such as pins, screws, adhesives, etc. The first end cap 110 maintains the desired spacing between the reflector 102 and the heat sink 104. The heat sink 104 comprises a mount surface 202 on which light emitters (e.g., LEDs) can be mounted. The mount surface 202 faces the surface 106 of the reflector 102. The emitters can be mounted such that they emit light toward the surface 106, or a certain portion thereof. The emitted light is then reflected off the surface 106 and out into the ambient as useful light.

(17) The reflector 102 can be constructed from many different materials. In one embodiment, the reflector 102 comprises a material which allows the reflector 102 to be extruded for efficient, cost-effective production. Some acceptable materials include polycarbonates, such as Makrolon 6265X or FR6901 (commercially available from Bayer) or BFL4000 or BFL2000 (commercially available from Sabic). Many other materials may also be used to construct the reflector 102. Using an extrusion process for fabrication, the reflector 102 is easily scalable to accommodate lighting assemblies of varying length.

(18) The surface 106 may be designed to have several different shapes to perform particular optical functions, such as color mixing and beam shaping, for example. Emitted light may be bounced off of one or more surfaces, including the surface 106. This has the effect of disassociating the emitted light from its initial emission angle. Uniformity typically improves with an increasing number of bounces, but each bounce has an associated optical loss. In some embodiments an intermediate diffusion mechanism (e.g., formed diffusers and textured lenses) may be used to mix the various colors of light.

(19) The surface 106 should be highly reflective in the wavelength ranges of the light emitters. In some embodiments, the surface 106 may be 93% reflective or higher. In other embodiments it may be at least 95% reflective or at least 97% reflective.

(20) The surface 106 may comprise many different materials. For many indoor lighting applications, it is desirable to present a uniform, soft light source without unpleasant glare, color striping, or hot spots. Thus, the surface 106 may comprise a diffuse white reflector such as a microcellular polyethylene terephthalate (MCPET) material or a Dupont/WhiteOptics material, for example. Other white diffuse reflective materials can also be used.

(21) 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. For example, LEDs emitting blue light may be used in combination with other sources of light, e.g., yellow light to yield a white light output. A diffuse reflective coating may 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 a diffuse surface in combination with other diffusive elements. In some embodiments, the surface may 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.

(22) By using a diffuse white reflective material for the surface 106 and by positioning the light sources to emit light first toward the surface 106 several design goals are achieved. For example, the surface 106 performs a color-mixing function, effectively doubling the mixing distance and greatly increasing the surface area of the source. Additionally, the surface luminance is modified from bright, uncomfortable point sources to a much larger, softer diffuse reflection. A diffuse white material also provides a uniform luminous appearance in the output. Harsh surface luminance gradients (max/min ratios of 10:1 or greater) that would typically require significant effort and heavy diffusers to ameliorate in a traditional direct view optic can be managed with much less aggressive (and lower light loss) diffusers achieving max/min ratios of 5:1, 3:1, or even 2:1.

(23) The surface 106 can comprise materials other than diffuse reflectors. In other embodiments, the surface 106 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. For example, a semi-specular material may be used on the center region with a diffuse material used in the side regions to give a more directional reflection to the sides. Many combinations are possible.

(24) The reflector back surface 108 comprises elongated rails 204 that run longitudinally along the reflector 102. The rails 204 perform important dual functions. They provide a mechanism by which the assembly 100 can be mounted to an external surface, such as a ceiling. At the same time, the rails 204 also provide structural support, preventing longitudinal bending along the length of the assembly 100 which allows longer reflector components to be used. The rails 204 may comprise features on the inner and outer surfaces, such as inner flanges 208 and outer flanges 210. The flanges 208, 210 may interface with external elements, such as mounting structures, for example, and may take many different shapes depending on the design of the structures used for mounting. The rails 204 may also comprise many other features necessary for mounting or other purposes.

(25) In this particular embodiment, a U-shaped mount bracket 206 is connected to the inner flange 208. The outer flanges 210 may be used for alternate mounting configurations discussed herein. The mounting bracket 206 removably connects to the rails 204 using snap-fit or slide-fit mechanisms, for example. The mount bracket 206 can be used to mount the light assembly 100 to a surface, such as a ceiling, when the assembly is mounted by suspension. The mounting bracket 206 may be made of metal, plastic, or other materials that are strong enough to support the weight of the assembly 100.

(26) FIG. 3 is another perspective view of a portion of the lighting assembly 100. In this embodiment, the reflector 102 is connected to the end cap 110 with a snap-fit interface 302. The heat sink 104 (not shown in FIG. 3) may also be connected to the end cap 110 with a snap-fit interface. The end cap 110 may comprise access holes 304 to allow for an electrical conductor to be fed down from a ceiling, for example, if the assembly 100 is to be powered from an external source. The assembly 100 may also be powered by a battery that can be stored inside the end cap 110, eliminating the need for an external power source. The end cap 110 can be constructed as two separate pieces 110a, 110b which can be joined using a snap-fit mechanism or screws, for example, so that the end cap can be disassembled for easy access to the electronics housed within. In other embodiments, the end cap pieces 110a, 110b can be joined using an adhesive, for example. The end cap 110 may also comprise a removable side cover 306 to provide access to internal components.

(27) FIG. 3 also shows an alternate mounting means for the assembly 100. Hanging tongs 308 (shown in phantom) may be used to suspend the assembly 100 from a ceiling. Many buildings currently have this type of hanging mount system with the existing lighting fixtures used therein. Thus, the assembly 100 can be easily retrofit for installation in buildings that already have a mount system. In this particular embodiment, the reflector rails 204 are designed with inner and outer flanges 208, 210. Inner flanges 208 are designed to interface with a mount mechanism such as mounting bracket 206, for example. Outer flanges 210 are designed to interface with a mount mechanism such as hanging tongs 308, for example. It is understood that the reflector 102 can be designed to accommodate many different mounting structures and should not be limited to the exemplary embodiments shown herein.

(28) FIG. 4 is another perspective view of a cut-away portion of the lighting assembly 100. In this embodiment, the mount bracket 206 hooks on to the underside of the inner flange 208 as shown. The mount bracket 206 may be connected to the inner flange 208 in many other ways as well.

(29) FIG. 5a is a perspective view of a cross-sectional portion of a heat sink 500 that can be used in the lighting assembly 100. In this embodiment, the heat sink 500 is shaped to define two parallel longitudinal conduits 502 that run along the entire length of the heat sink body 504. The conduits 502 are designed to accommodate wires, cords, cables or other electrical conductors for providing power to light emitters (not shown). The conduits 502 should be large enough to carry the necessary power and signal cords. The heat sink 500 comprises a flat mount surface 506 on which light emitters can be mounted. The emitters can be mounted directly to the mount surface 506, or they can be disposed on a light strip which is then mounted to the mount surface 506 as discussed in more detail herein.

(30) FIG. 5b is a cross-sectional view of the heat sink 500. A light strip 508 is shown disposed on the mount surface 506. As discussed in more detail herein, the light strip 506 comprises one or more light emitters 510 mounted thereto.

(31) FIG. 6 shows a perspective view of an end portion of the heat sink 500. A cable 602 is shown passing through one of the conduits 502. The hollow heat sink structure provides advantages over traditional heat sink designs. For example, the heat sink 500 requires less material to construct, reducing overall weight and cost. The heat sink 500 also provides a wire way for the necessary power and signal cabling. This configuration eliminates the need for a separate wire way along the length of the assembly, which also reduces material and fabrication costs. In this embodiment, the cable 602 comprises a six-wire system that is used to power and control the light emitters. The cable can comprise several types of connection adapters. This embodiment comprises cylindrical cable connectors 604 for easy connection to another adjacent assembly in an end-to-end serial (i.e., daisy chain) configuration, as discussed in more detail herein. Many different cabling and connection schemes are possible.

(32) The heat sink 500 can be constructed using many different thermally conductive materials. For example, the heat sink 500 may comprise an aluminum body 504. Similarly as the reflector 102, the heat sink 500 can be extruded for efficient, cost-effective production and convenient scalability.

(33) The heat sink mount surface 506 provides a substantially flat area on which one or more light sources can be mounted. In some embodiments, the light sources will be pre-mounted on light strips. FIGS. 7a-c show a top plan view of portions of several light strips 700, 720, 740 that may be used to mount multiple LEDs to the mount surface 506. Although LEDs are used as the light sources in various embodiments described herein, it is understood that other light sources, such as laser diodes for example, may be substituted in as the light sources in other embodiments of the present invention.

(34) Many industrial, commercial, and residential applications call for white light sources. The light assembly 100 may comprise one or more emitters producing the same color of light or different colors of light. In one embodiment, a multicolor source is used to produce white light. Several colored light combinations will yield white light. For example, it is known in the art to combine light from a blue LED with wavelength-converted yellow (blue-shifted-yellow or “BSY”) 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 BSY 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 BSY light is emitted in a much broader spectral range and, thus, is called unsaturated light.

(35) 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.

(36) The lighting strips 700, 720, 740 each represent possible LED combinations that result in an output spectrum that can be mixed to generate white light. Each lighting strip can include the electronics and interconnections necessary to power the LEDs. In some embodiments the lighting strip comprises a printed circuit board with the LEDs mounted and interconnected thereon. The lighting strip 700 includes clusters 702 of discrete LEDs, with each LED within the cluster 702 spaced a distance from the next LED, and each cluster 702 spaced a distance from the next cluster 702. If the LEDs within a cluster are spaced at too great distance from one another, the colors of the individual sources may become visible, causing unwanted color-striping. In some embodiments, an acceptable range of distances for separating consecutive LEDs within a cluster is not more than approximately 8 mm.

(37) The scheme shown in FIG. 7a uses a series of clusters 702 having two blue-shifted-yellow LEDs (“BSY”) and a single red LED (“R”). Once properly mixed the resultant output light will have a “warm white” appearance.

(38) The lighting strip 720 includes clusters 722 of discrete LEDs. The scheme shown in FIG. 7b uses a series of clusters 722 having three BSY LEDs and a single red LED. This scheme will also yield a warm white output when sufficiently mixed.

(39) The lighting strip 740 includes clusters 742 of discrete LEDs. The scheme shown in FIG. 7c uses a series of clusters 742 having two BSY LEDs and two red LEDs. This scheme will also yield a warm white output when sufficiently mixed.

(40) The lighting schemes shown in FIGS. 7a-c are meant to be exemplary. Thus, it is understood that many different LED combinations can be used in concert with known conversion techniques to generate a desired output light color.

(41) FIG. 8 is a perspective view of the first end cap 110 of the lighting assembly 100. The end cap 110 is shown with the side cover 306 removed to expose electronics 802 which are mounted on a board 804. The electronics 802 are used to regulate the power to the light emitters and to control the brightness and color of the output light. The electronics 802 can also perform many other functions. The removable side cover 306 (not shown) provides access to the electronics 802, allowing for full testing during and after assembly. Such testing may be easily implemented using Pogo pins, for example. Once testing is finished the side cover 306 can be replaced to protect the electronics 802. The holes 304 on top of the end cap 110 provide additional top-side access to the electronics for a connection to an external junction box, for example. The board 804 is held place within the end cap 110 using tabs 806, although other means such as screws or adhesive may also be used. Because the first end cap 110 houses the electronics necessary to power/control the light emitters, the second end cap 112 (not shown in FIG. 8) may not contain any electronic components, allowing for a thinner profile. However, in some embodiments the second end cap 112 may contain additional electronics, batteries, or other components. The end cap 110 also includes space for the cable connectors 604, allowing for the lighting assembly 100 to be easily connected to another similar assembly as shown herein with reference to FIG. 9.

(42) FIG. 9 shows a perspective view of a modular lighting assembly 900 according to an embodiment of the present invention. Individual light assemblies (such as assembly 100) can be connected in an end-to-end serial (i.e., daisy chain) configuration. Each assembly 100 includes its own electronics 802 such that the individual assemblies 100 may be easily removed or added to the modular assembly 900 as needed. The assemblies 100 include connectors, such as cable connector 604 that allow for the serial connection. The connections between the assemblies 100 are made within the respective end caps 110 to protect the wired connections from outside elements. Respective first and second end caps can comprise snap-fit structures such that adjacent assemblies 100 may be easily connected, although other means may be used to connect adjacent assemblies. In one embodiment, the second end cap comprises snap-fit structures on two opposing surfaces to facilitate connection of adjacent assemblies 100. In another embodiment, both the first and second end caps 110, 112 comprise snap-fit structures on two sides.

(43) The modular assembly 900 comprises two individual assemblies 100 as shown. In this particular embodiment, each assembly 100 is approximately 8 ft long. However, because the reflector 102 and heat sink 104 components can be fabricated by extrusion, the assemblies 100 can easily be scaled to a desired length. For example, other modular assemblies could comprise individual units having lengths of 2 ft, 4 ft, 6 ft, etc. Additionally, individual units of different lengths can be combined to construct a modular assembly having a particular size. For example a 2 ft unit can be connected to an 8 ft unit to construct a 10 ft modular assembly. This is advantageous when designing modular assemblies for rooms having particular dimensions. Thus, it is understood that the assemblies can have many different lengths. More than two of the assemblies can be connected to provide a longer series.

(44) FIG. 10a is a cross-sectional view of another reflector that can be used in embodiments of the lighting assembly 100. In this particular embodiment, the reflector 150 comprises two different materials having different optical and structural properties and different relative costs. Similarly as the reflector 102, the reflector 150 comprises a surface 152 and a back surface 154. In one embodiment, the reflector 150 comprises a first light-transmissive base material 156 (e.g., a polycarbonate) which provides the basic structure of the device. At least a portion of the surface 152 comprises a second highly reflective material 158. The two materials 156, 158 can be coextruded for more convenient and cost-efficient fabrication of the reflector 150. For example, a cheaper bulk material may be used as the base material 152, requiring a smaller amount of the more expensive reflective material 154 to manufacture the reflector 150.

(45) The base material 156 provides structural support to the reflector 150 and allows for transmission through areas of the surface 152 where the reflective material 158 is very thin or non-existent. For example, the reflector 150 comprises transmissive windows 160 where little to no reflective material is disposed. FIG. 10b is a close-up view of a portion of the reflector 150 showing one such window. These windows 160 allow light to pass through them, providing uplight (i.e., light emitted from the back surface 154 of the reflector 150). The amount of uplight generated by the reflector 150 can be varied by regulating the thickness of reflective material 158 and/or the size and frequency of the windows 160 across the surface 152. Desired transmissive and reflective effects may be achieved using a non-uniform distribution of the reflective material 158 across the surface 152.

(46) 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.

(47) 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.