In-grade light fixture

Patent metadata

Field	Value
Publication number	US-2016377280-A1
Application number	US-201614989086-A
Country	US
Kind code	A1
Filing date	Jan 6, 2016
Priority date	Jun 23, 2015
Publication date	Dec 29, 2016
Grant date	—

Abstract

An in-grade light fixtures having hermetically sealed components that enable water and air to pass through the fixture to effectuate cooling without degrading the fixture components.

First claim

1 . A light fixture comprising an LED module comprising:
an LED module housing formed by a can and a heat sink, wherein the heat sink is hermetically sealed to the can and comprises a mounting surface exposed within the LED module housing and an external portion that extends exterior to the can; and a plurality of LEDs positioned on the mounting surface of the heat sink.

2 . The light fixture of claim 1 , wherein the heat sink is soldered to the can.

3 . The light fixture of claim 1 , wherein the LED module further comprises a reflector assembly positioned above the plurality of LEDs.

4 . The light fixture of claim 3 , wherein the reflector assembly comprises a plurality of apertures through which light emitted by the plurality of LEDs may pass.

5 . The light fixture of claim 3 , wherein the LED module further comprises a lens positioned over the reflector assembly and hermetically sealed onto the LED module housing to render the LED module impermeable to air and water.

6 . The light fixture of claim 1 , further comprising:
a fixture housing defining an interior cavity and having at least one projection that extends into the interior cavity; and a support ring supported on the fixture housing by the at least one projection, wherein the support ring comprises a flange that supports the LED module within the fixture housing and openings that extend entirely through the support ring so as to be in fluid communication with the interior cavity of the fixture housing.

7 . The light fixture of claim 6 , further comprising:
a power module hermetically sealed within the fixture housing and connected to the LED module.

8 . The light fixture of claim 7 , wherein a connector is provided on the external portion of the heat sink and wherein the light fixture further comprises a cable that extends from the power module and that comprises a plug positioned on an end of the cable for engaging the connector on the heat sink so as to connect the LED module to the power module.

9 . The light fixture of claim 6 , wherein the fixture housing further comprises apertures that extend through the fixture housing so as to be in fluid communication with the interior cavity of the fixture housing such that air and water can pass through the openings in the support ring and into the interior cavity of the fixture housing and exit the interior cavity of the fixture housing via the apertures in the fixture housing.

10 . The light fixture of claim 6 , further comprising a finishing piece mounted on the fixture housing over the support ring and comprising at least one aperture extending through the finishing piece and in fluid communication with the interior cavity of the fixture housing.

11 . A method of forming an light fixture comprising an LED module comprising:
forming an LED module housing by casting a heat sink onto a can, the heat sink forming a bottom surface of the can and also forming a mounting surface in an interior region of the can, wherein the heat sink is hermetically sealed to the can; and mounting a plurality of LEDs on the mounting surface of the heat sink within the interior region of the can.

12 . The method of forming the light fixture of claim 11 , wherein mounting the plurality of LEDs on the mounting surface of the heat sink comprises mounting the plurality of LEDs directly on the mounting surface of the heat sink without a printed circuit board interposed between the LEDs and the mounting surface so as to provide a direct path for dissipation of heat generated by the plurality of LEDs.

13 . The method of forming the light fixture of claim 11 , further comprising positioning a reflector assembly above the mounting surface, the reflector assembly including a plurality of apertures through which light emitted by the plurality of LEDs may pass.

14 . The method of forming the light fixture of claim 13 , further comprising hermetically sealing a lens onto the LED module housing, over the reflector assembly, to prevent air and water from entering the interior region of the can of the LED module housing.

15 . The method of forming the light fixture of claim 11 , further comprising:
molding a custom plug to engage with a connector on a lower portion of the heat sink.

16 . A light fixture comprising:
a fixture housing comprising openings that extend through the fixture housing so as to be in fluid communication with an interior cavity of the fixture housing; an LED module housing positioned within the interior cavity of the fixture housing, the LED module housing comprising a can and a heat sink, the heat sink being hermetically sealed to the can and comprising a mounting surface exposed within the LED module housing and an external portion that extends exterior to the can; and a plurality of LEDs positioned on the mounting surface of the heat sink.

17 . The light fixture of claim 16 further comprising a power module positioned within the fixture housing, the power module being hermetically sealed to render the power module impermeable to air and water.

18 . The light fixture of claim 17 further comprising a cord extending between the power module and a connector on an outer surface of the heat sink, the cord including a custom molded plug for engaging with the connector.

19 . The light fixture of claim 16 further comprising a lens hermetically sealed onto the LED module housing to render the LED module impermeable to air and water.

20 . The light fixture of claim 17 , further comprising a hermetically sealed junction box positioned within a junction box cavity in the fixture housing, wherein a cord extends between the hermetically sealed junction box and the power module.

Assignees

• Abl Ip Holding Llc

Inventors

• Acampora Kenneth J
• Martinez Jesus
• Jim Guang

Classifications

• F21Y2115/10

  Light-emitting diodes [LED] · CPC title

• F21S8/022

  intended to be recessed in a floor or like ground surface, e.g. pavement or false floor · CPC title

• F21V31/005 Primary

  Sealing arrangements therefor · CPC title

• F21V29/77

  with essentially identical diverging planar fins or blades, e.g. with fan-like or star-like cross-section · CPC title

• F21W2131/10

  Outdoor lighting · CPC title