US 7,766,518 B2 · LED-based light-generating modules for socket engagement, and methods of assembling, installing and removing same

Abstract

Modular lighting fixtures that allow convenient installation and removal of LED-based light-generating modules and controller modules. In one example, a modular lighting fixture includes a housing configured to be recessed into or 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 for such fixtures also may be easily installed in or removed from the fixture housing via the same access route by which the light-generating module is installed and removed.

Claims52

Dependent claims

A light-generating apparatus, comprising:

an LED assembly, comprising:
an assembly substrate;
and
a plurality of LED subassemblies coupled to the assembly substrate, each LED subassembly of the plurality of LED subassemblies forming at least one of a mechanical connection, an electrical connection, and a first thermal connection to the assembly substrate;
a plurality of secondary optical components;
and a chassis coupled to the LED assembly and including a plurality of chambers in which the plurality of secondary optical components respectively are held, the chassis configured such that each secondary optical component of the plurality of secondary optical components is disposed in an optical path of a corresponding one of the plurality of LED subassemblies;
wherein the LED assembly is disposed between the thermally conductive base plate and the chassis.

4 more elements

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, wherein:
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;
and
the LED 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;
wherein 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 forming at least a third thermal connection to the assembly substrate:
wherein each LED subassembly comprises a thermally conductive substrate having a top surface and a bottom surface;
at least a portion of the top surface of each LED subassembly forms the third thermal connection to the assembly substrate;
at least a portion of a top surface of the assembly substrate forms the first thermal connection between the LED assembly and the thermally conductive chassis;
and the bottom surface of each LED subassembly forms at least a portion of the second thermal connection between the LED assembly and the thermally conductive base plate.

12 more elements

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, wherein:
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;
and
the LED 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;
wherein the assembly substrate includes a top surface facing the thermally conductive chassis and a bottom surface to which are coupled the plurality of LED subassemblies;
wherein 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 forming at least a third thermal connection to the assembly substrate
wherein each LED subassembly comprises a thermally conductive substrate having a top surface and a bottom surface;
at least a portion of the top surface of each LED subassembly forms the third thermal connection to the assembly substrate;
at least a portion of a top surface of the assembly substrate forms the first thermal connection between the LED assembly and the thermally conductive chassis;
and the bottom surface of each LED subassembly forms at least a portion of the second thermal connection between the LED assembly and the thermally conductive base plate
wherein each LED subassembly comprises:
an aluminum core substrate having a top surface facing the bottom surface of the assembly substrate;
and
a plurality of first electrical contact points disposed only on the top surface of the aluminum core substrate.

17 more elements

Dependencies are inferred from the claim text.

LED-based light-generating modules for socket engagement, and methods of assembling, installing and removing same

Life of this patent

LED-based light-generating modules for socket engagement, and methods of assembling, installing and removing same

Life of this patent

Abstract

Claims52