Method of and apparatus for enhanced thermal isolation of low-profile LED lighting fixtures

Patent metadata

Field	Value
Publication number	US-9395067-B2
Application number	US-201414507077-A
Country	US
Kind code	B2
Filing date	Oct 6, 2014
Priority date	Oct 7, 2013
Publication date	Jul 19, 2016
Grant date	Jul 19, 2016

Abstract

A LED assembly/structure and a method of manufacturing the same. The LED assembly comprises a housing body, one or more LED light emitting component hosting areas, a power unit hosting compartment, one or more light diffusing elements, and a cover. The housing body of the LED assembly serves as a thermal barrier between the power supply and the LED lighting elements, such that thermal stress is able to be reduced.

First claim

What is claimed is:

1. A method of manufacturing a LED assembly comprising:
a. coupling formed sheet metal to form a housing body, wherein the housing body comprises at least two recesses;
b. coupling at least one LED lighting element with each of the at least two recesses, wherein the housing body comprises at least three pieces of sheet metal including a first piece of sheet metal shaped to form the at least two recesses and a first partial portion of an enclosure for the power supply, a second piece of sheet metal shaped to form the at least two recesses and a second partial portion of the enclosure for the power supply and a third piece of sheet metal including upstanding arms hooked to capture and hold the first and the second pieces of sheet metal;
c. enclosing a power supply; and
d. coupling one or more diffusing lens to each of the LED lighting element.

2. The method of claim 1 , wherein the two recesses are at the two sides of the power supply.

3. The method of claim 1 , wherein each of the two recesses comprises a flat area coupling with the LED lighting element.

4. The method of claim 1 , wherein the method comprises joining the pieces of sheet metal by clipping together without screws.

5. A lighting assembly comprising:
a. a housing body having an enclosed power supply compartment; and
b. a portion of the housing body forming a thermal barrier between the power supply and one or more LED panels, wherein the housing body comprises at least three pieces of sheet metal including a first piece of sheet metal shaped to form at least two recesses and a first partial portion of an enclosure for the power supply, a second piece of sheet metal shaped to form the at least two recesses and a second partial portion of the enclosure for the power supply and a third piece of sheet metal including upstanding arms hooked to capture and hold the first and the second pieces of sheet metal.

6. The lighting assembly of claim 5 , wherein the housing body is formed by attaching formed metal sheets.

7. The lighting assembly of claim 5 , wherein the LED panels is covered by one or more diffusing lens.

8. The lighting assembly of claim 5 , wherein the LED panels are at two sides of the power supply.

9. The lighting assembly of claim 5 , further comprising a cover, wherein the cover covers the power supply compartment holding the power supply.

10. The lighting assembly of claim 5 , wherein the cover is a perforated stamped piece.

11. The lighting assembly of claim 5 , wherein the housing body comprises a thermally reflective coating.

12. The lighting assembly of claim 5 , wherein the lighting assembly couples with a LED greater than 100 Watts.

13. A low-profile LED lighting fixture comprising:
a. a body has a thickness less than 70 mm;
b. two lighting areas located at two sides of the fixture;
c. a concave at each of the two lighting areas; and
d. a diffusing lens covering each of the lighting areas, wherein the body comprises at least three pieces of sheet metal including a first piece of sheet metal shaped to form at least two recesses and a first partial portion of an enclosure for a power supply, a second piece of sheet metal shaped to form the at least two recesses and a second partial portion of the enclosure for the power supply and a third piece of sheet metal including upstanding arms hooked to capture and hold the first and the second pieces of sheet metal.

14. The low-profile LED lighting fixture of claim 13 , further comprising two rows of holes facing each other.

15. The low-profile LED lighting fixture of claim 14 , wherein the holes are heat dissipating holes located around a power supply.

16. The low-profile LED lighting fixture of claim 15 , further comprising a thermal barrier between the power supply and a LED lighting element.

17. The low-profile LED lighting fixture of claim 13 , wherein the body is formed by three pieces of formed sheet metal.

18. The low-profile LED lighting fixture of claim 13 , wherein the diffusing lens is lower than a side wall of the body.

Assignees

• Flextronics Ap Llc

Inventors

• Musser Jordon
• Jones Randall
• Barkhurst Corey

Classifications

• F21Y2105/10

  comprising a two-dimensional [2D] array of point-like light-generating elements · CPC title

• F21Y2115/10

  Light-emitting diodes [LED] · CPC title

• F21V29/15

  Thermal insulation · CPC title

• F21V29/505

  of reflectors · CPC title

• F21V23/009

  the casing being inside the housing of the lighting device · CPC title