IJSZOO60262545AJ
`
`(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2006/0262545 A1
`(43) Pub. Date: NOV. 23, 2006
`
`Piepgras et al.
`
`64)
`
`(75)
`
`LED-BASED LIGHT-GENERATING
`MODULES FOR SOCKET ENGAGEMENT,
`AND METHODS OF ASSEMBLING,
`INSTALLING AND REMOVING SAME
`
`Inventors: Colin Piepgras. Swampscott. MA (US):
`Tomas Mollnow. Somerville. MA (US):
`Michael Blackwell. Milton. MA (US);
`Brian (Themel. Marblehead. MA (US):
`Frederick M. Morgan. Quincy. MA
`(US); Kevin McCormick. (US);
`Michael A. Bass, legal representative.
`Boston. MA (US)
`
`Correspondence Address:
`WOLF GREENFIELD & SACKS, I’C
`FEDERAL RESERVE PLAZA
`600 ATLANTIC AVENUE
`BOSTON, MA 02210-2206 (US)
`
`(73)
`
`Assignee: Color Kinetics Incorporated. Boston.
`MA
`
`01)
`
`App]. No.:
`
`11/419,998
`
`02)
`
`Filed:
`
`May 23. 2006
`
`Related U.S. Application Data
`
`(60)
`
`Provisional application No. 60/683587. filed on May
`23. 2005. Provisional application No. 60/729370.
`
`filed on Oct. 24. 2005. Provisional application No.
`60/756321. filed on Jan. 6. 2006. Provisional appli-
`cation No. 60/745353. filed on Apr. 21. 2006.
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`(2006.01)
`F21 V 29/00
`(2006.01)
`B60Q 1/06
`(52) US. Cl.
`............................................ 362/373: 36fl800
`
`(57)
`
`ABSTRACT
`
`Modular lighting fixtures that allow convenient installation
`and removal of [FD-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 soflit. in new or existing construction scenarios. The
`fixture housing includes a socket configured to facilitate one
`or more ot‘a mechanical. electrical and thermal coupling of
`the light-genemting 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 straightlbm-‘ard replace-
`ment of the light-generating module upon failure. or
`exchange with another module having difiéreitt light-gener-
`ating 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.
`
`100
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`\ 11a
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`
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`USER
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`INTERFACE
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`
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`OPHCAL ELEMENT
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`124
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`130
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`SIGNAL
`SOURCE
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`102
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`CONTROLLER
`
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` _OWER
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`MEMORY
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`PROCESSOR
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`108
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`

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`Patent Application Publication Nov. 23, 2006 Sheet 1 of 71
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`CONTROLLER
`CONTROLLER
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`202
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`CENTRAL
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`LIGHTING
`UNH
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`LIGHTING
`UNIT
`CONTROLLER
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`CONTROLLER
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`LIGHTING
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`Patent Application Publication Nov. 23, 2006 Sheet 37 of 71
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`Pttttttpplication Publication Nov. 23, 2006 Sheet 44 of 71
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`Patent Application Publication Nov. 23, 2006 Sheet 50 of 71
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`Patent Application Publication Nov. 23, 2006 Sheet 53 of 71
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`Patent Application Publication Nov. 23, 2006 Sheet 54 of 71
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`Patent Application Publication Nov. 23, 2006 Sheet 60 of 71
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`US 2006/0262545 A1
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`FIG.65
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`3c
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`o
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`Patent Application Publication Nov. 23, 2006 Sheet 62 of 71
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`US 2006/0262545 A1
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`to
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`FIG.67
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`Patent Application Publication Nov. 23, 2006 Sheet 63 of 71
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`FIG.68
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`Patent Application Publication Nov. 23, 2006 Sheet 64 of 71
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`US 2006/0262545 A1
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`F/G.696'
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`FIG.693
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`FIG.69A
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`o_(D
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`Patent Application Publication Nov. 23, 2006 Sheet 65 of 71
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`Z L
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`Patent Application Publication Nov. 23, 2006 Sheet 66 of 71
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`FIG.773FIG.770
`FIG.71A
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`Patent Application Publication Nov. 23, 2006
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`Sheet 67
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`Patent Application Publication Nov. 23, 2006 Sheet 69 of 71
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`FIG.74
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`tion Nov. 23, 2006 Sheet 70 0f 71
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`FIG.75
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`Patent Application Publication Nov. 23, 2006 Sheet 71 of 71
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`892 \ 894 /
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`896
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`Processor
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`894
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`852
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`FIG. 76
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`US 2006/0262545 A1
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`Nov. 23, 2006
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`LED-BASED LIGHT-GENERATING MODULES
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`FOR SOCKET ENGAGEMENT, AND METHODS
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`OF ASSEMBLING, INSTALLING AND REMOVING
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`SAME
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`CROSS-REFERENCES TO RELATED
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`APPLICATIONS
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`[0001] This application claims priority under 35 U.S.C. §
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`119(e) to the following US. Provisional Applications:
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`[0002]
`Ser. No. 60/683,587, entitled “LED Modules for
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`Low Profile Lighting Applications,” filed on May 23, 2005;
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`[0003]
`Ser. No. 60/729,870, entitled “Spider Interconnect
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`and Hospital Gown Socket Concept,” filed on Oct. 24, 2005;
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`[0004]
`Ser. No. 60/756,821, entitled “Spider Interconnect
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`and Hospital Gown Socket Concept,” filed on Jan. 6, 2006;
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`and
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`[0005]
`Ser. No. 60/745,353, entitled “Modular Lighting
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`Assembly Methods and Apparatus,” filed on Apr. 21, 2006.
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`[0006] Each of the foregoing applications hereby is incor-
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`porated herein by reference.
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`FIELD OF THE DISCLOSURE
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`[0007] The present disclosure relates generally to modular
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`lighting apparatus and methods of assembly, installation and
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`replacement of such apparatus. In various aspects, methods
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`and apparatus according to the disclosure facilitate ease of
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`manufacture, installation and replacement of modular light-
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`ing apparatus components as well as thermal efficiency
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`during operation. In one aspect, such lighting apparatus and
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`methods employ LED-based light sources to provide visible
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`in a variety of environments and for a variety of
`light
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`lighting applications.
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`BACKGROUND
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`[0008] LED-based lighting fixtures are employed for a
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`variety of illumination applications.
`In some cases,
`the
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`lighting fixture may include a controller, one or more
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`LED-based light sources, and may further include one or
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`more components to facilitate heat dissipation, in one incor-
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`porated unit. To replace any one element of such an incor-
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`porated unit may require either replacement of the entire
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`lighting fixture or repair by a skilled technician. Addition-
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`ally, physically exchanging new LED-based light sources
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`for the existing LED-based light sources can be difficult if
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`different LED-based lighting assemblies are desired, or if the
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`existing LED-based source(s) fail.
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`[0009] Recessed lighting is a popular lighting option for
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`both new construction and remodeling. With recessed light-
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`ing, the majority of a lighting fixture is disposed substan-
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`tially behind or recessed into an architectural surface or
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`feature, such as a ceiling (or wall, or soffit). The lighting
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`fixture typically includes a housing (sometimes commonly
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`referred to as a “can”), a bulb such as an incandescent,
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`fluorescent or halogen bulb, and some means for electrically
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`connecting the fixture to a source of operating power. With
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`new construction, the fixture is typically supported by han-
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`gars attached to joists. When remodeling,
`to reduce the
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`amount of ceiling (or other architectural surface) that is
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`removed, the fixture may be inserted through a ceiling hole
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`and attached to the drywall forming the ceiling, wherein the
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`ceiling hole provides a light exit aperture for light generated
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`by the fixture’s bulb.
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`SUMMARY
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`[0010] Various embodiment of the present disclosure are
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`directed to modular lighting fixtures that allow convenient
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`installation and removal of LED-based light-generating
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`modules as well as controller modules that may be employed
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`to control the light-generating modules. In one example, a
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`modular lighting fixture includes a housing that is config-
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`ured to be recessed into or otherwise disposed behind an
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`architectural surface such as ceiling, wall, or soffit, in new or
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`existing construction scenarios. The fixture housing includes
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`a socket configured to facilitate one or more of a mechanical,
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`electrical and thermal coupling of the light-generating mod-
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`ule to the fixture housing. The ability to easily engage and
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`disengage the LED-based light-generating module with the
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`socket, without removing the fixture housing itself, allows
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`for straightforward replacement of the light-generating mod-
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`ule upon failure, or exchange with another module having
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`different light-generating characteristics. Modular lighting
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`controllers (also referred to as “controller modules”) for
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`such fixtures also may be easily installed in or removed from
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`the fixture housing, in some instances via the same access
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`route by which the light-generating module is installed and
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`removed.
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`[0011] Thus, according to various aspect of the disclosure,
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`modular lighting fixtures are provided in which a single
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`housing may accommodate different LED-based light-gen-
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`erating modules that may be switched in and out of the
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`housing. In this regard, light-generating modules according
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`to various embodiments of the present disclosure may mimic
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`the ease of installation and replacement of conventional
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`incandescent, fluorescent or halogen light bulbs in that a new
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`light-generating module can be inserted into the housing
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`without changes to the fixture. A new light-generating mod-
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`ule may be inserted, for example, when a previous light-
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`generating module stops working or an improved or differ-
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`ent light-generating module is desired.
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`[0012] As indicated above, according to one aspect of the
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`disclosure, a socket or other attachment element facilitates
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`the attachment of a light-generating module to a housing of
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`a lighting fixture. In addition to providing a mechanical
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`connection between the light-generating module and the
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`lighting fixture, the socket also may provide an electrical
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`connection and/or a thermal connection. For example, the
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`socket may include electrical connections that provide drive
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`signals and operating power to a light-generating module
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`when the light-generating module is inserted into or other-
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`wise coupled to the socket. According to another aspect of
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`the disclosure, a socket or other attachment element may
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`facilitate thermal diffusion in at least two manners. First, the
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`socket may be configured to interact with the light-gener-
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`ating module so that the light-generating module achieves a
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`thermal connection with the housing or other component of
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`the lighting fixture. Second, the socket itself may be ther-
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`mally conductive and help to transfer heat to the housing
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`and/or directly to surrounding air (e.g., via a front light-exit
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`face of the light-generating module).
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`[0013] According to another aspect of the disclosure, a
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`removable light-generating module is itself configured to
`
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`
`
`

`

`
`
`US 2006/0262545 A1
`
`
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`
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`Nov. 23, 2006
`
`
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`facilitate heat transfer away from the light sources present in
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`the module. The heat transfer is achieved in some embodi-
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`ments by using a thermally conductive chassis for the
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`light-generating module to facilitate transfer of heat away
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`from a front side (light exit face) of the light-generating
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`module. In some embodiments, a thermally conductive base
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`plate is attached to a rear side of the light-generating module
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`to facilitate transfer of heat to a housing or other part of a
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`lighting fixture, in some cases via the socket.
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`[0014] According to another aspect of the disclosure, the
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`engagement and disengagement of a light-generating mod-
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`ule with the socket of a lighting fixture is accomplished via
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`a simple rotating motion.
`In this regard,
`installing and
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`removing an LED-based light-generating module from a
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`modular lighting fixture may have a familiar feel similar to
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`the process of changing a conventional incandescent light
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`bulb.
`
`[0015]
`In particular, in one exemplary implementation, the
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`socket is configured as a collar with screw-type threads, and
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`the module is configured so as to be attachable to and
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`detachable from a socket via a threaded grip ring that is
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`placed over the module and engages with the threads on the
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`socket via rotation,
`thereby “sandwiching” the module
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`between the grip ring and socket. According to another
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`aspect of the disclosure, a removable light-generating mod-
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`ule includes a number of hexagonally-shaped LED subas-
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`semblies. In some embodiments, the grip ring is rotatable
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`relative to the module so that the orientation of the LED
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`subassemblies is not affected by the rotation of the grip ring
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`(i.e., the module itself does not rotate in the socket as the
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`grip ring is rotated). Additionally, the relative rotation of the
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`grip ring may allow a connector to be directly mounted to
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`light-generating module without concern for the effects of
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`twisting on the connector.
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`[0016]
`In other embodiments, no grip ring is used to
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`secure the light-generating module to the socket, and elec-
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`trical connections between the light-generating module and
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`the socket are achieved through connections of post (or
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`threads) on the light-generating module and corresponding
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`threads (or posts) on the socket. That is to say, electrical
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`contacts may be provided on the engagement elements
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`themselves in some embodiments.
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`[0017] According to another aspect of the disclosure, a
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`controller module may be used in connection with a light-
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`generating module in a lighting fixture implementation.
`
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`According to another aspect of the disclosure, a controller
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`module may have a physical structure that is configured for
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`installation in a specific type of lighting fixture housing. For
`
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`example, a controller module may have one or more rounded
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`edges to facilitate placement or removal of the controller
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`module from a recessed lighting fixture which is not itself
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`removable from an architectural feature such as a ceiling.
`
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`
`[0018]
`In one embodiment, a controller module itself may
`
`
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`have an internal modular construction. More specifically, the
`
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`controller module may be configured for interchangeability
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`of components that are used for receiving input control
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`signals and/or data at a “front-end” input interface (e.g.,
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`coupled to a user interface, control network, sensor, etc.).
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`The controller module further may be configured for inter-
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`changeability of components that are used for outputting
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`control signals and/or data and/or power at a “back-end”
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`interface to the light-generating module. In this
`output
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`regard, the controller module may be flexible in its ability to
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`communicate with various light-generating modules and/or
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`networks, computers, or other controllers without the need
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`for numerous hardware and/or software components being
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`simultaneously present within the controller module. Such a
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`configuration may save on space and/or cost when produc-
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`ing controller modules for modular lighting fixtures and
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`other applications.
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`[0019] According to another aspect, a light-generating
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`module for a modular lighting fixture may be configured
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`with some nominal data storage and processing capability
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`for providing information to a controller associated with the
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`lighting fixture and packaged as a separate controller module
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`of the fixture. For example, the light-generating module may
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`provide information on one or more of the type of light
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`sources present in the light-generating module, their power
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`requirements, operating temperature, operating time or tem-
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`perature history, calibration parameters and the like, so that
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`a separate controller module may provide appropriate drive
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`signals and operating power to the light-generating module.
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`[0020] According to another aspect of the disclosure, a
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`controller module is configured to receive information, data
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`and or control signals from a light-generating module relat-
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`ing to some operating parameter or characteristic associated
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`with the light-generating module. The controller module
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`may be programmed to alter its outgoing control signals
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`and/or power output to the light-generating module based on
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`the information received from the light-generating module.
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`For example, the light-generating module may indicate to
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`the controller the voltage or current
`levels desired for
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`operation of that particular light-generating module, and the
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`controller may provide the appropriate voltage and current
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`levels based on that information.
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`[0021] According to another aspect of the disclosure, a
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`battery or other auxiliary power source is provided in an
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`LED lighting fixture such that the LED lighting fixture may
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`be used for emergency lighting in addition to its primary
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`lighting purpose.
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`[0022]
`In sum, as discussed in greater detail below, one
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`embodiment of the present disclosure is directed to a light-
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`generating apparatus comprising an LED assembly, a plu-
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`rality of optical components, and a chassis coupled to the
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`LED assembly and including a plurality of chambers in
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`which the plurality of optical components respectively are
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`held. The LED assembly comprises an assembly substrate
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`and a plurality of LED subassemblies coupled to the assem-
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`bly substrate. Each LED subassembly of the plurality of
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`LED subassemblies forms at
`least one of a mechanical
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`connection, an electrical connection, and a first thermal
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`connection to the assembly substrate. The chassis is config-
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`ured such that each optical component of the plurality of
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`optical components is disposed in an optical path of a
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`corresponding one of the plurality of LED subassemblies.
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`[0023] Another embodiment is directed to a light-gener-
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`ating apparatus comprising a thermally conductive chassis
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`through which light exits from the apparatus, an LED
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`assembly to generate the light, and a thermally conductive
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`base plate. The LED assembly is disposed between the
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`thermally conductive base plate and the thermally conduc-
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`tive chassis. The LED assembly and the thermally conduc-
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`tive chassis form a first thermal connection to facilitate first
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`heat dissipation from the LED assembly via the thermally
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`

`

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`US 2006/0262545 A1
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`Nov. 23, 2006
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`conductive chassis. The LED assembly and the thermally
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`conductive base plate form a second thermal connection to
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`facilitate second heat dissipation from the LED assembly Via
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`the thermally conductive base plate.
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`[0024] Another embodiment is directed to a light-gener-
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`ating apparatus comprising a circular chassis and a circular
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`printed circuit board substrate coupled to the circular chas-
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`sis. The circular printed circuit board substrate includes at
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`least one chip-on-board LED module.
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`[0025] Another embodiment is directed to a lighting con-
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`trol apparatus, comprising at least one connection mecha-
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`nism configured to permit a modular
`installation and
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`removal of at
`least a first circuit board including input
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`circuitry configured to receive at
`least one input signal
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`including information relating to lighting, and a second
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`circuit board including output circuitry configured to output
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`at least one lighting control signal that is based at least in
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`part on the information included in the at least one input
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`signal. The at least one connection mechanism provides at
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`least one electrical connection between the first circuit board
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`and the second circuit board when both the first and second
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`circuit boards are coupled to the at least one connection
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`mechanism.
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`[0026] Another embodiment is directed to a modular light-
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`ing fixture, comprising a fixture housing having at least one
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`thermally conductive portion, and a socket mounted to the at
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`least one thermally conductive portion of the fixture hous-
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`ing. The socket is configured to facilitate a thermal conduc-
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`tion path between a light-generating module installed in the
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`socket and the at least one thermally conductive portion of
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`the fixture housing.
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`[0027] Another embodiment is directed to a modular light-
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`ing fixture, comprising a fixture housing having at least one
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`light exit aperture, a socket mounted to the fixture housing
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`and accessible via the at least one light exit aperture, a
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`light-generating module installed in and removable from the
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`socket via the at least one light exit aperture, and a controller
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`module to control the light-generating module. The control-
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`ler module is disposed in the fixture housing and accessible
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`via the at least one light exit aperture to facilitate installation
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`and removal of the controller module.
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`[0028] Another embodiment is directed to a modular light-
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`ing fixture, comprising a fixture housing, a socket mounted
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`to the fixture housing, a light-generating module installed in
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`and removable from the socket, and a controller module to
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`control the light-generating module, the controller module
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`disposed in or proximate to the fixture housing. The light-
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`generating module is configured to provide information to
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`the controller module relating to at least one characteristic of
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`the light generating module, and the controller module is
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`configured to control the light-generating module