Lighting module having field-replaceable optics, improved cooling, and tool-less mounting features

公开(公告)号:
CA3125954A1
公开(公告)日:
2022-01-23
申请号:
CA3125954
申请日:
2021-07-23
授权日:
-
受理局:
加拿大
专利类型:
发明申请
简单法律状态:
审中
法律状态/事件:
实质审查
IPC分类号:
F21V21/04 | F21V29/70 | H05B45/30 | F21S8/02 | F21V3/00 | F21V5/04 | F21V7/00 | F21V17/16
战略新兴产业分类:
电子核心产业
国民经济行业分类号:
C4350 | C3874 | C4090 | C3879
当前申请(专利权)人:
DMF, INC.
原始申请(专利权)人:
DMF, INC.
当前申请(专利权)人地址:
1118 EAST 223RD STREET,CARSON,CA,US
工商统一社会信用代码:
-
工商登记状态:
-
工商注册地址:
-
工商成立日期:
-
工商企业类型:
-
发明人:
KOPITZKE, FREDERICK WILLIAM | GUNSOLLEY, NOLAN | LOTFI, AMIR | CHEN, BENJAMIN PIN-CHUN
代理机构:
-
代理人:
BORDEN LADNER GERVAIS LLP
摘要:
A lighting module includes a heat sink with a sidewall and a partition defining two cavities, a LED light source disposed in one cavity to emit light, a driver module disposed in the other cavity with driver circuitry to provide electrical power to the light source, and an optical assembly to provide a desired emission profile. The optical assembly is field- changeable and includes a cover lens with snap-fit connectors to facilitate removal and replacement. The optical assembly further includes either a reflector coupled to the cover lens or an optical lens coupled to the heat sink via an optic holder. In some examples, the driver circuitry facilitates dimming of the light source. The heat sink also dissipates heat generated by the light source and the driver circuitry to maintain desired operating temperatures and thereby facilitate increased light output.
技术问题语段:
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技术功效语段:
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权利要求:
CLAIMS 1. A lighting module (1000), comprising: a heat sink (1100), comprising: a sidewall (1110) having a first opening (1102a) and a second opening (1104a); and a partition (1120) joined to the sidewall, the partition and the sidewall together defining a first cavity (1102) that is accessible through the first opening and a second cavity (1104) that is accessible through the second opening, the partition comprising: a recessed section (1130) defining a recess (1131) within the first cav- ity: and a tapered section (1121) joined to the recessed section and a portion of the sidewall located proximate to the first opening; a LED light source (1300), disposed in the recess of the first cavity and coupled to the recessed section of the partition, to emit light; and a driver module (1200) disposed in the second cavity and coupled to the heat sink, the driver module comprising: a driver housing (1230) coupled to the heat sink and enclosing the second cav- ity of the heat sink, the driver housing defining a driver cavity (1231); and driver circuitry (1210), disposed within the driver cavity of the driver housing, to supply electrical power to the LED light source, wherein the lighting module has an exterior width dimension ( ON ext, 1, W ext,2) ranging be- tween about 3 inches and about 3-7/8 inches. 2. The lighting module of claim 1, wherein the lighting module has an exterior height di- mension (hex) ranging between about 1 inch and about 2-1/2 inches. 3. The lighting module of claim 1, wherein: the sidewall of the heat sink further comprises a plurality of snap-fit openings (1126); and the lighting module further comprises: 6. Date Recue/Date Received 2021-07-23 an optical assembly (1500), disposed within the first cavity of the heat sink and directly coupled to the heat sink, to redirect the light emitted by the LED light source, the optical assembly comprising: a cover lens (1510) having a plurality of snap-fit connectors (1516) coupled to the plurality of snap-fit openings and enclosing the first opening of the heat sink, the cover lens being removable from the heat sink when the plu- rality of snap-fit connectors is actuated. 4. The lighting module of claim 3, wherein each snap-fit connector of the plurality of snap-fit connectors disengages from a corresponding snap-fit opening of the plurality of snap- fit openings when a force having a magnitude of about 25 pounds is applied to the snap-fit hook. 5. The lighting module of claim 3, wherein: the optical assembly further comprises at least one of an optical lens or a reflector dis- posed between the LED light source and the cover lens; and the optical assembly redirects the light such that the light transmitted through the cover lens has a beam angle greater than or equal to 8 degrees. 6. The lighting module of claim 3, wherein the optical assembly further comprises: a reflector (1540), directly coupled to the cover lens via a snap-fit connection, having a reflector sidewall (1542) defining a first reflector opening (1546) to receive the light emitted by the LED light source and a second reflector opening (1544) through which the light exits the reflector. 7. The lighting module of claim 3, wherein the optical assembly further comprises: an optic holder (1560) directly coupled to the heat sink via a tool-less coupling mecha- nism, the optic holder being coupled to the heat sink separately from the cover lens; and an optical lens (1550) directly coupled to the optic holder and disposed between the LED light source and the cover lens. Date Recue/Date Received 2021-07-23 8. The lighting module of claim 7, wherein the tool-less coupling mechanism comprises: at least one twist and lock receiver (1124) disposed on the heat sink; and at least one twist and lock connector (1564) disposed on the optic holder and engaged to the at least one twist and lock receiver, the at least one twist and lock connector disengaging the at least one twist and lock re- ceiver when the optic holder is rotated relative to the heat sink thereby enabling removal of the optic holder from the heat sink. 9. The lighting module of claim 1, wherein the driver module further comprises: at least one of a potting material (1202) or an electrically insulating film (1206), dis- posed at least between the driver circuitry and the driver housing, to electrically insulate the driver circuitry. 10. The lighting module of claim 1, wherein the driver module further comprises: a driver insulator (1250), disposed between the driver circuitry and the partition of the heat sink, to provide an electrically insulating barrier between the driver circuitry and the par- tition. 11. The lighting module of claim 1, wherein: the driver circuitry generates first heat during operation of the lighting module, the first heat being dissipated primarily through the driver housing and the sidewall of the heat sink; the LED light source generates second heat during operation of the lighting module, the second heat being dissipated primarily through the partition and the sidewall of the heat sink; and the driver circuitry and the LED light source being physically separate so as to reduce the first heat heating the LED light source and the second heat heating the driver circuitry. Date Recue/Date Received 2021-07-23 12. The lighting module of claim 1, wherein the driver circuitry receives an AC power in- put that is converted into the electrical power supplied to the LED light source and a DC con- trol signal to adjust a brightness of the light emitted by the LED light source. 13. A lighting module (1000), comprising: a heat sink (1100), comprising: a sidewall (1110) having a first opening (1102a) and a second opening (1104a); and a partition (1120) joined to the sidewall, the partition and the sidewall together defining a first cavity (1102) that is accessible through the first opening and a second cavity (1104) that is accessible through the second opening; a LED light source (1300), disposed in the first cavity and coupled to the partition of the heat sink, to emit light; and a driver module (1200) disposed in the second cavity and coupled to the heat sink, the driver module comprising: a driver housing (1230) coupled to the heat sink and enclosing the second cav- ity of the heat sink, the driver housing defining a driver cavity (1231) and being formed of a metal; driver circuitry (1210), disposed within the driver cavity of the driver housing, to supply electrical power to the LED light source; and at least one of a potting material (1202) or an electrically insulating film (1206), disposed at least between the driver circuitry and the driver housing, to electri- cally insulate the driver circuitry. 14. The lighting module of claim 13, wherein: the lighting module has an exterior height dimension (hex) ranging between about 1 inch and about 2-1/2 inches; and the lighting module has an exterior width dimension ( ovext,l, Wext,2) ranging between about 3 inches and about 3-7/8 inches. Date Recue/Date Received 2021-07-23 15. The lighting module of claim 13, wherein the partition of the heat sink comprises: a recessed section (1130) defining a recess (1131) within the first cavity to contain and surround the LED light source. 16. The lighting module of claim 13, wherein: the driver circuitry generates first heat during operation of the lighting module, the first heat being dissipated primarily through the driver housing and the sidewall of the heat sink; the LED light source generates second heat during operation of the lighting module, the second heat being dissipated primarily through the partition and the sidewall of the heat sink; and the driver circuitry and the LED light source being physically separate so as to reduce the first heat heating the LED light source and the second heat heating the driver circuitry. 17. The lighting module of claim 13, wherein: the sidewall further defines at least one snap-fit opening (1126); and the lighting module further comprises: an optical assembly (1500), coupled to the heat sink, to redirect the light emit- ted by the LED light source, the optical assembly comprising: a cover lens (1510) having a plurality of snap-fit connectors (1516) coupled to the plurality of snap-fit openings and enclosing the first opening of the heat sink, the cover lens being removable from the heat sink when the plu- rality of snap-fit connectors is actuated; and a reflector (1540), directly coupled to the cover lens via a snap-fit con- nection such that the reflector is removable together with the cover lens, hav- ing a reflector sidewall (1542) defining a first reflector opening (1546) to re- ceive the light emitted by the LED light source and a second reflector opening (1544) through which the light exits the reflector. 18. The lighting module of claim 13, wherein: Date Recue/Date Received 2021-07-23 the sidewall further defines at least one snap-fit opening (1126); and the lighting module further comprises: an optical assembly (1500), coupled to the heat sink, to redirect the light emit- ted by the LED light source, the optical assembly comprising: a cover lens (1510) having a plurality of snap-fit connectors (1516) coupled to the plurality of snap-fit openings and enclosing the first opening of the heat sink, the cover lens being removable from the heat sink when the plu- rality of snap-fit connectors is actuated; an optic holder (1560) directly coupled to the heat sink via a tool-less coupling mechanism, the optic holder being coupled to the heat sink separately from the cover lens; and an optical lens (1550) directly coupled to the optic holder and disposed between the LED light source and the cover lens. 19. The lighting module of claim 13, wherein the driver circuitry receives an AC power input that is converted into the electrical power supplied to the LED light source and a DC control signal to adjust a brightness of the light emitted by the LED light source. 20. A lighting module (1000), comprising: a heat sink (1100), comprising: a sidewall (1110) having a first opening (1102a) and a second opening (1104a); and a partition (1120) joined to the sidewall, the partition and the sidewall together defining a first cavity (1102) that is accessible through the first opening and a second cavity (1104) that is accessible through the second opening; a LED light source (1300), disposed in the first cavity and coupled to the heat sink, to emit light; and a driver module (1200) disposed in the second cavity and coupled to the heat sink, the driver module comprising: Date Recue/Date Received 2021-07-23 a driver housing (1230) having a driver sidewall (1232) and a driver base (1234) that together define a driver cavity (1231), the driver base enclosing the second cavity of the heat sink; and driver circuitry (1210), disposed within the driver cavity of the driver housing, to receive an AC power input and a DC control signal, the driver circuitry converting the AC power input to a DC power output to power the LED light source, the driver circuitry adjusting the DC power output based on the DC control signal so as to adjust a brightness of the light emitted by the LED light source. 21. The lighting module of claim 20, further comprising: an electrical cable (1024), electrically coupled to the driver circuitry and passing through an opening (1246) of the driver base, to supply the AC power input and the DC con- trol signal, the cable having a keyed electrical connector (1026). 22. The lighting module of claim 20, further comprising: a first ground cable (1014) disposed in the at least one cavity and electrically coupled to the driver circuitry and a portion of the heat sink; and a second ground cable (1012) electrically coupled to the portion of the heat sink and passing through an opening (1246) of the driver base so as to electrically ground the lighting module to an external ground. 23. The lighting module of claim 20, wherein: the driver housing is formed of a metal; and the driver module further comprises: at least one of a potting material (1202) or an electrically insulating film (1206), disposed at least between the driver circuitry and the driver housing, to electri- cally insulate the driver circuitry. 24. The lighting module of claim 20, wherein the partition comprises: Date Recue/Date Received 2021-07-23 a recessed section (1130) defining a recess (1131) within the first cavity to contain and surround the LED light source: and a tapered section (1121) joined to the recessed section and a portion of the sidewall lo- cated proximate to the first opening. 25. The lighting module of claim 20, wherein: the sidewall further defines at least one snap-fit opening (1126); and the lighting module further comprises: an optical assembly (1500), coupled to the heat sink, to redirect the light emit- ted by the LED light source, the optical assembly comprising: a cover lens (1510) having a plurality of snap-fit connectors (1516) coupled to the plurality of snap-fit openings and enclosing the first opening of the heat sink, the cover lens being removable from the heat sink when the plu- rality of snap-fit connectors is actuated; and a reflector (1540), directly coupled to the cover lens via a snap-fit con- nection such that the reflector is removable together with the cover lens, hav- ing a reflector sidewall (1542) defining a first reflector opening (1546) to re- ceive the light emitted by the LED light source and a second reflector opening (1544) through which the light exits the reflector. 26. The lighting module of claim 20, wherein: the sidewall further defines at least one snap-fit opening (1126); and the lighting module further comprises: an optical assembly (1500), coupled to the heat sink, to redirect the light emit- ted by the LED light source, the optical assembly comprising: a cover lens (1510) having a plurality of snap-fit connectors (1516) coupled to the plurality of snap-fit openings and enclosing the first opening of the heat sink, the cover lens being removable from the heat sink when the plu- rality of snap-fit connectors is actuated; Date Recue/Date Received 2021-07-23 an optic holder (1560) directly coupled to the heat sink via a tool-less coupling mechanism, the optic holder being coupled to the heat sink separately from the cover lens; and an optical lens (1550) directly coupled to the optic holder and disposed between the LED light source and the cover lens. 27. A lighting module (1000), comprising: a heat sink (1100), comprising: a sidewall (1110) having a first opening (1102a) and a second opening (1104a); and a partition (1120) joined to the sidewall, the partition and the sidewall together defining a first cavity (1102) that is accessible through the first opening and a second cavity (1104) that is accessible through the second opening; a LED light source (1300), disposed in the first cavity and coupled to the heat sink, to emit light; and a driver module (1200) disposed in the second cavity and coupled to the heat sink, the driver module comprising: a driver housing (1230) having a driver sidewall (1232) and a driver base (1234) that together define a driver cavity (1231), the driver base enclosing the second cavity of the heat sink; and driver circuitry (1210), disposed within the driver cavity of the driver housing, to receive an AC power input from a triac-based dimmer, the driver circuitry converting the AC power input to a DC power output to power the LED light source, the driver circuitry adjusting the DC power output based on the AC power input from the triac-based dimmer, the driver circuitry comprising: a switched capacitor circuit to change an output capacitance across the DC power output, as a function of time, to mitigate perceivable flicker in the light emitted by the LED light source. 28. The lighting module of claim 27, wherein: Date Recue/Date Received 2021-07-23 the driver housing is formed of a metal; and the driver module further comprises: at least one of a potting material (1202) or an electrically insulating film (1206), disposed at least between the driver circuitry and the driver housing, to electri- cally insulate the driver circuitry. 29. The lighting module of claim 27, wherein the partition comprises: a recessed section (1130) defining a recess (1131) within the first cavity to contain and surround the LED light source: and a tapered section (1121) joined to the recessed section and a portion of the sidewall lo- cated proximate to the first opening. 30. The lighting module of claim 27, wherein: the sidewall further defines at least one snap-fit opening (1126); and the lighting module further comprises: an optical assembly (1500), coupled to the heat sink, to redirect the light emit- ted by the LED light source, the optical assembly comprising: a cover lens (1510) having a plurality of snap-fit connectors (1516) coupled to the plurality of snap-fit openings and enclosing the first opening of the heat sink, the cover lens being removable from the heat sink when the plu- rality of snap-fit connectors is actuated; and a reflector (1540), directly coupled to the cover lens via a snap-fit con- nection such that the reflector is removable together with the cover lens, hav- ing a reflector sidewall (1542) defining a first reflector opening (1546) to re- ceive the light emitted by the LED light source and a second reflector opening (1544) through which the light exits the reflector. 31. The lighting module of claim 27, wherein: the sidewall further defines at least one snap-fit opening (1126); and the lighting module further comprises: Date Recue/Date Received 2021-07-23 an optical assembly (1500), coupled to the heat sink, to redirect the light emit- ted by the LED light source, the optical assembly comprising: a cover lens (1510) having a plurality of snap-fit connectors (1516) coupled to the plurality of snap-fit openings and enclosing the first opening of the heat sink, the cover lens being removable from the heat sink when the plu- rality of snap-fit connectors is actuated; an optic holder (1560) directly coupled to the heat sink via a tool-less coupling mechanism, the optic holder being coupled to the heat sink separately from the cover lens; and an optical lens (1550) directly coupled to the optic holder and disposed between the LED light source and the cover lens. 32. A lighting module (1000), comprising: a heat sink (1100), comprising: a sidewall (1110) having a first opening (1102a), a second opening (1104a), and a pair of snap-fit openings (1126); and a partition (1120) joined to the sidewall, the partition and the sidewall together defining a first cavity (1102) accessible through the first opening and a second cavity (1104) accessible through the second opening; a LED light source (1300), disposed in the first cavity and coupled to the heat sink, to emit light towards the first opening; a driver module (1200) disposed in the second cavity and coupled to the heat sink, the driver module comprising: a driver housing (1230) coupled to the heat sink and enclosing the second cav- ity of the heat sink, the driver housing defining a driver cavity (1231); and driver circuitry (1210), disposed within the driver cavity of the driver housing, to receive an AC power input and a DC control signal, the driver circuitry converting the AC power input to a DC power output to power the LED light source, the driver circuitry adjusting the DC power output based on the DC control signal so as to adjust a brightness of the light emitted by the LED light source; and Date Recue/Date Received 2021-07-23 an optical assembly (1500), removably coupled to the heat sink, to redirect the light emitted by the LED light source, the optical assembly comprising: a cover lens (1510) having a plurality of snap-fit connectors (1516) coupled to the plurality of snap-fit openings and enclosing the first opening of the heat sink, the cover lens being removable from the heat sink when the plurality of snap-fit connect- ors is actuated, wherein: the lighting module has an exterior height dimension (hext) ranging between about 1 inch and about 2-1/2 inches; and the lighting module has an exterior width dimension ( ovext,l, Wext,2) ranging between about 3 inches and about 3-7/8 inches. 33. The lighting module of claim 32, wherein: the optical assembly further comprises at least one of an optical lens or a reflector dis- posed between the LED light source and the cover lens; and the optical assembly redirects the light such that the light transmitted through the cover lens has a beam angle that is one of 15 degrees, 25 degrees, 40 degrees, 60 degrees, or greater than or equal to 90 degrees. 34. The lighting module of claim 32, wherein the optical assembly further comprises: a reflector (1540), directly coupled to the cover lens via a snap-fit connection, having a reflector sidewall (1542) defining a first reflector opening (1546) to receive the light emitted by the LED light source and a second reflector opening (1544) through which the light exits the reflector. 35. The lighting module of claim 32, wherein the optical assembly further comprises: an optic holder (1560) directly coupled to the heat sink via a tool-less coupling mecha- nism, the optic holder being coupled to the heat sink separately from the cover lens; and an optical lens (1550) directly coupled to the optic holder and disposed between the LED light source and the cover lens. Date Recue/Date Received 2021-07-23
技术领域:
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背景技术:
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发明内容:
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具体实施方式:
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