US 20090080189A1
`
`(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2009/0080189 A1
`(43) Pub. Date:
`Mar. 26, 2009
`Wegner
`
`(5-4)
`
`OPTIC COUPLER FOR LIGHT EMITTING
`DIODE FIXTURE
`
`(75)
`
`Inventor:
`
`Scott David Wegner. Peachtree
`City. GA (US)
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`F211" 1/02
`r'21V17/04
`
`(2006.01)
`(2006.01)
`
`Correspondence Address:
`KING & SPALDING LLP
`1180 PEAC‘HTREE STREET
`ATLANTA, GA 30309-3521 (US)
`
`(73)
`
`Assignee:
`
`Cooper Technologies Company.
`Houston. TX (US)
`
`(21)
`
`Appl. No.:
`
`12/235,141
`
`(22)
`
`Filed:
`
`Sep. 22. 2008
`
`Related US. Application Data
`
`(60)
`
`Provisional application No. (SO/994.792. filed on Sep.
`21. 2007. provisional application No. 61/010549.
`filed on Jan. 9. 2008. pmvisional application No.
`61/065.914. filed on Feb. 15. 2008. provisional appli-
`cation No. 61/090391. filed on Aug. 20. 2008.
`
`(52) U.S.CI. .................................... 362/235;362/249.02
`
`(57)
`
`Ansrmcr
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`A recessed light fixture includes an LED module. which
`includes a single LED package that is configured to generate
`all light emitted by the recessed light fixture. For example. the
`LED package can include multiple LEDs mounted to a com-
`mon substrate. The LED package can be coupled to a heat
`sink for dissipating heat from the LEDs. The heat sink can
`include a core member frotn which fins extend. Each fin can
`
`include one or more straight and/or curved portions. A reflec-
`tor housing maybe coupled to the heat sink and configured to
`receive a reflector. The reflector can have any geometry. such
`as a bell-shaped geometry including two radii of curvature
`that join together at an inflection point. An optic coupler can
`be coupled to the reflector housing and configured to cover
`electrical connections at the substrate and to guide light emit-
`ted by the LED package.
`
`M
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`

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`Patent Application Publication Mar. 26, 2009 Sheet 1 of 12
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`US 2009/0080189 A1
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`FIG. 1
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`Patent Application Publication
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`Mar. 26, 2009 Sheet 3 of 12
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`US 2009/0080189 A1
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`Patent Application Publication Mar. 26, 2009 Sheet 4 0f 12
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`Patent Application Publication Mar. 26, 2009 Sheet 6 0f 12
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`tion Mar. 26, 2009 Sheet 7 0f 12
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`Patent Application Publication Mar. 26, 2009 Sheet 8 0f 12
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`US 2009/0080189 A1
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`FIG. 13
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`Patent Application Publication Mar. 26, 2009 Sheet 9 of 12
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`US 2009/0080189 A1
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`1400
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`METHOD FOR INSTALLING
`AN LED MODULE IN AN EXISTING.
`
`NON-LED FIXTURE
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`1470
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`TTTLE 24
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`NO
`COMPLAINT
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`9
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`
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`CUT WIRES IN THE EXISTING FIXTURE,
`REMOVING AN EDISON BASE FROM
`THE FIXTURE
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`CUT WIRES ON AN EDISON BASE
`ADAPTER TO REMOVE AN EDISON
`SCREW-IN PLUG
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`CONNECT THE WIRES FROM THE
`EDISON BASE ADAPTER TO THE
`
`EXISTING FIXTURE, AND PLUG WIRING
`FROMEEHSEOINEgAlIggaIIJJIAEPgHEEO THE
`
`MOUNT THE EDISON BASE
`ADAPTER TO A BRACKET 0N
`THE LED MODULE
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`FIG. 14
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`1475
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`1420
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`7425
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`RELEASE THE SOCKET FROM
`THE EXISTING FIXTURE
`
`SCREW AN EDISON BASE
`ADAPTER INTO THE SOCKET
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`PLUG WIRING FROM THE
`LED MODULE INTO THE
`EDISON BASE ADAPTER
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`MOUNT THE EDISON BASE ADAPTER
`AND SOCKET TO A BRACKET ON
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`THE LED MODULE
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`1430
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`7435
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`SOUEEZE TORSION SPRINGS ON THE
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`LED MODULE TOGETHER
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`1440
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`1445
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`INSTALL BRACKET ENDS OF THE
`TORSION SPRINGS IN THE
`RECESSED HOUSING
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`ROUTE WIRES INTO FIXTURE AND
`PUSH LED MODULE FLUSH
`TO CEILING SURFACE
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`

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`Patent Application Publication Mar. 26, 2009 Sheet 10 of 12
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`US 2009/0080189 A1
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`15203
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`FIG. 15
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`Patent Application Publication Mar. 26, 2009 Sheet 11 of 12
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`US 2009/0080189 A1
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`330i
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`FIG. 18
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`Patent Application Publication Mar. 26, 2009 Sheet 12 of 12
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`US 2009/0080189 A1
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`M
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`1900f
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`FIG. 19
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`2005
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`2005
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`2015
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`2010
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`FIG. 20
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`US 2009/0080189 A1
`
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`Mar. 26, 2009
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`OPTIC COUPLER FOR LIGHT EMITTING
`
`
`
`
`DIODE FIXTURE
`
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`RELATED APPLICATIONS
`
`
`
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`[0001] This application claims priority under 35 U.S.C. §
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`
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`119 to US. Provisional Patent Application No. 60/994,792,
`
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`
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`titled “Light Emitting Diode Downlight Can Fixture,” filed
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`Sep. 21, 2007, US. Provisional Patent Application No.
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`61/010,549, titled “Diverging Reflector for Light Emitting
`
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`Diode or Small Light Source,” filed Jan. 9, 2008, US. Provi-
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`sional Patent Application No. 61/065,914, titled “Dimmable
`
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`
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`LED Driver,” filed Feb. 15, 2008, and US. Provisional Patent
`
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`
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`Application No. 61/090,391, titled “Light Emitting Diode
`
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`Downlight Can Fixture,” filedAug. 20, 2008. In addition, this
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`application is related to co-pending US. patent application
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`, titled “Diverging Reflector,” filed Sep. 22,
`Ser. No.
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`
`
`2008, US. patent application Ser. No.
`, titled “Ther-
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`
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`mal Management for Light Emitting Diode Fixture,” filed
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`Sep. 22, 2008, US. patent application Ser. No.
`, titled
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`“Light Emitting Diode Recessed Light Fixture,” filed Sep. 22,
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`2008, and US. Design Pat.ApplicationNo. 29/305,946, titled
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`“LED Light Fixture,” filed Mar. 31, 2008. The complete
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`disclosure of each of the foregoing priority and related appli-
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`cations is hereby fully incorporated herein by reference.
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`TECHNICAL FIELD
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`[0002] The invention relates generally to recessed lumi-
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`naires, and more particularly, to a light emitting diode down-
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`light can fixture for a recessed luminaire.
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`BACKGROUND
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`generally require complex electrical and thermal manage-
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`ment systems. Therefore, traditional recessed light fixtures
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`have not used LED light sources. Accordingly, a need cur-
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`rently exists in the art for a recessed light fixture that uses an
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`LED light source.
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`SUMMARY
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`[0008] The invention provides a recessed light fixture with
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`an LED light source. The light fixture includes a housing or
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`“can” within which an LED module is mounted. The LED
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`module includes a single LED package that generates all or
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`substantially all the light emitted by the recessed light fixture.
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`For example, the LED package can include one or more LEDs
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`mounted to a common substrate. Each LED is an LED die or
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`LED element that is configured to be coupled to the substrate.
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`The LEDs can be arranged in any of a number of different
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`configurations. For example, the LEDs can be arranged in a
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`round-shaped area having a diameter of less than two inches
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`or a rectangular-shaped area having a length of less than two
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`inches and a width of less than two inches.
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`[0009] The LED package can be thermally coupled to a
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`heat sink configured to transfer heat from the LEDs. The heat
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`sink can have any of a number of different configurations. For
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`example, the heat sink can include a core member extending
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`away from the LED package and fins extending from the core
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`member. Each fin can include a curved, radial portion and/or
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`a straight portion. For example, each fin can include a radial
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`portion that extends from the core member, and a straight
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`portion that further extends out from the radial portion. In this
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`configuration, heat from the LEDs can be transferred along a
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`path from the LEDs to the core member, from the core mem-
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`ber to the radial portions of the fins, from the radial portions
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`of the fins to their corresponding straight portions, and from
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`the corresponding straight portions to a surrounding environ-
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`ment. Heat also can be transferred by convection directly
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`from the core member and/or the fins to one or more gaps
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`between the fins. The LED package can be coupled directly to
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`the core member or to another member disposed between the
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`LED package and the core member.
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`[0010] A reflector housing can be mounted substantially
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`around the LED package. For example, the reflector housing
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`can be coupled to the heat sink and/or the can. The reflector
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`housing can be configured to receive a reflector and to serve as
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`a secondary heat sink for the LED module. For example, the
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`reflector housing can be at least partially composed of a
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`conductive material for transmitting heat away from the LED
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`package. The reflector can be composed of any material for
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`reflecting, refracting, transmitting, or diffusing light from the
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`LED package. For example, the reflector can comprise a
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`specular, semi-specular, semi-diffuse, or diffuse finish, such
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`as gloss white paint or diffuse white paint. The reflector can
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`have any of a number of different configurations. For
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`example, a cross-sectional profile of the reflector can have a
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`substantially bell-shaped geometry that includes a smooth
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`curve comprising an inflection point. Top and bottom portions
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`of the curve are disposed on opposite sides of the inflection
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`point. To meet a requirement of a top-down flash while also
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`creating a smooth, blended light pattern, the bottom portion
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`of the curve can be more diverging than the top portion of the
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`curve.
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`[0011] An optic coupler can be mounted to the reflector
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`housing, for covering electrical connections at the substrate
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`of the LED package and/or for guiding or reflecting light
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`emitted by the LED package. For example, the optic coupler
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`[0003] A luminaire is a system for producing, controlling,
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`and/or distributing light for illumination. For example, a
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`luminaire can include a system that outputs or distributes light
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`into an environment, thereby allowing certain items in that
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`environment to be visible. Luminaires are often referred to as
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`“light fixtures”.
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`[0004] A recessed light fixture is a light fixture that is
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`installed in a hollow opening in a ceiling or other surface. A
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`typical recessed light fixture includes hanger bars fastened to
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`spaced-apart ceiling supports or joists. A plaster frame
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`extends between the hanger bars and includes an aperture
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`configured to receive a lamp housing or “can” fixture.
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`[0005] Traditional recessed light fixtures include a lamp
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`socket coupled to the plaster frame and/or the can fixture. The
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`lamp socket receives an incandescent lamp or compact fluo-
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`rescent lamp (“CFL”) discussed above. As is well known in
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`the art, the traditional lamp screws into the lamp socket to
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`complete an electrical connection between a power source
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`and the lamp.
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`lighting manufacturers are being
`[0006]
`Increasingly,
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`driven to produce energy eflicient alternatives to incandes-
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`cent lamps. One such alternative was the CFL discussed
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`above. CFLs fit in existing incandescent lamp sockets and
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`generally use less power to emit the same amount of visible
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`light as incandescent lamps. However, CFLs include mer-
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`cury, which complicates disposal of the CFLs and raises
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`environmental concerns.
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`[0007] Another mercury-free alternative to incandescent
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`lamps is the light emitting diode (“LED”). LEDs are solid
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`state lighting devices that have higher energy efliciency and
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`longevity than both incandescent lamps and CFLs. However,
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`LEDs do not fit in existing incandescent lamp sockets and
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`US 2009/0080189 A1
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`Mar. 26, 2009
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`can include a member with a central channel that is aligned
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`pler can have any of a number of different geometries that
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`ofthe electrical connections at the substrate, the portion ofthe
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`optic coupler around the channel can have a substantially
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`square,
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`[0012] The LED module can be used in both new construc-
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`creates a junction box between the member and a top of the
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`can when the LED module is mounted in the can. To install the
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`LED module, a person can electrically couple an Edison base
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`adapter to both the existing, non-LED fixture and the LED
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`module. For example, a person can cut at least one wire to
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`remove an Edison base from the existing fixture, cut at least
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`one other wire to remove an Edison screw-in plug from the
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`Edison base adapter, and connect together the cut wires to
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`electrically couple the Edison base adapter and the existing
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`fixture. Alternatively, a person can release a socket from the
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`existing fixture and screw the Edison base adapter into the
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`socket to electrically couple the Edison base adapter and the
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`existing fixture. The junction box can house the Edison base
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`adapter and at least a portion of the wires coupled thereto.
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`[0013] These and other aspects, features and embodiments
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`of the invention will become apparent to a person of ordinary
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`skill in the art upon consideration of the following detailed
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`description of illustrated embodiments exemplifying the best
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`mode for carrying out the invention as presently perceived.
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`[0014]
`For a more complete understanding of the present
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`invention and the advantages thereof, reference is now made
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`to the following description, in conjunction with the accom-
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`panying figures briefly described as follows. The patent or
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`application file contains at least one drawing executed in
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`color. Copies of this patent or patent application publication
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`with color drawing(s) will be provided by the Oflice upon
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`request and payment of the necessary fee.
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`FIG. 1 is an elevational top view of hanger bars, a
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`plaster frame, a can, and a junction box of a recessed lighting
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`fixture, in accordance with certain exemplary embodiments.
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`[0016]
`FIG. 2 is an elevational cross-sectional side view of
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`the recessed lighting fixture of FIG. 1, in accordance with
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`certain exemplary embodiments.
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`[0017]
`FIG. 3 is an elevational side view of an LED module
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`of a recessed lighting fixture, in accordance with certain
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`exemplary embodiments.
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`[0018]
`FIG. 4 is an elevational top view of the LED module
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`of FIG. 3, in accordance with certain exemplary embodi-
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`ments.
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`[0019]
`FIG. 5 is an elevational cross-sectional side view of
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`the LED module of FIG. 3, in accordance with certain exem-
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`plary embodiments.
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`[0020]
`FIG. 6 is a perspective side view ofthe LED module
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`of FIG. 3, in accordance with certain exemplary embodi-
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`ments.
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`[0021]
`FIG. 7 is an elevational bottom view of the LED
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`module of FIG. 3, in accordance with certain exemplary
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`embodiments.
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`[0022]
`FIG. 8 is a perspective exploded side view of the
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`LED module of FIG. 3, in accordance with certain exemplary
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`embodiments.
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`[0023]
`FIG. 9 is an elevational cross-sectional top view of a
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`heat sink of the LED module of FIG. 3, in accordance with
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`certain exemplary embodiments.
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`[0024]
`FIG. 10 illustrates a thermal scan of the heat sink of
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`the LED module of FIG. 3, in accordance with certain exem-
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`plary embodiments.
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`[0025]
`FIG. 11 is a perspective side view of a reflector
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`housing of the LED module of FIG. 3, in accordance with
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`certain exemplary embodiments.
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`[0026]
`FIG. 12 is a perspective side view of a reflector
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`being inserted in the reflector housing of FIG. 11, in accor-
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`dance with certain exemplary embodiments.
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`[0027]
`FIG. 13 is a perspective side view of a trim ring
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`aligned for installation with the reflector housing of FIG. 11,
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`in accordance with certain exemplary embodiments.
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`[0028]
`FIG. 14 is a flow chart diagram illustrating a method
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`for installing the LED module of FIG. 3 in an existing, non-
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`LED fixture, in accordance with certain exemplary embodi-
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`ments.
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`[0029]
`FIG. 15 is a perspective side view of the LED mod-
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`ule of FIG. 3 connected to a socket of an existing, non-LED
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`fixture via an Edison base adapter, in accordance with certain
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`exemplary embodiments.
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`[0030]
`FIG. 16 is an elevational side view of the Edison
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`base adapter ofFIG. 15, in accordance with certain exemplary
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`embodiments.
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`[0031]
`FIG. 17 is a perspective top view of an optic coupler
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`of the LED module of FIG. 3, in accordance with certain
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`exemplary embodiments.
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`FIG. 18 is a perspective bottom view of the optic
`[0032]
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`coupler of FIG. 17, in accordance with certain exemplary
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`embodiments.
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`[0033]
`FIG. 19 is a perspective top view of an optic coupler
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`of the LED module of FIG. 3, in accordance with certain
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`alternative exemplary embodiments.
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`[0034]
`FIG. 20 is an exaggerated depiction of a profile of
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`the reflector, in accordance with certain exemplary embodi-
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`ments.
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`DETAILED DESCRIPTION OF EXEMPLARY
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`EMBODIMENTS
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`[0035] The following description of exemplary embodi-
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`ments refers to the attached drawings, in which like numerals
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`indicate like elements throughout the several figures. FIG. 1 is
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`an elevational top view of hanger bars 105, a plaster frame
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`110, a can-shaped receptacle for housing a light source (a
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`“can”) 115, and a junction box 120 of a recessed lighting
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`fixture 100, according to certain exemplary embodiments.
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`FIG. 2 is an elevational cross-sectional side view of the
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`hanger bars 105, plaster frame 110, can 115, and junction box
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`120 of the recessed lighting fixture 100 of FIG. 1, in accor-
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`dance with certain exemplary embodiments. With reference
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`to FIGS. 1 and 2, the hanger bars 105 are configured to be
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`mounted between spaced supports or joists (not shown)
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`within a ceiling (not shown). For example, ends of the hanger
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`

`

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`US 2009/0080189 A1
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`Mar. 26, 2009
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`bars 105 can be fastened to vertical faces of the supports or
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`joists by nailing or other means.
`In certain exemplary
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`embodiments, the hanger bars 105 can include integral fas-
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`teners for attaching the hanger bars 105 to the supports or
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`joists, substantially as described in co-pending US. patent
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`application Ser. No. 10/090,654,
`titled “Hanger Bar for
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`Recessed Luminaires with Integral Nail,” and US. patent
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`application Ser. No. 12/122,945,
`titled “Hanger Bar for
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`Recessed Luminaires with Integral Nail,” the complete dis-
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`closures of which are hereby fully incorporated herein by
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`reference.
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`[0036] The distance between the supports orjoists can vary
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`to a considerable degree. Therefore, in certain exemplary
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`embodiments,
`the hanger bars 105 can have adjustable
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`lengths. Each hanger bar 105 includes two inter-fitting mem-
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`bers 105a and 10519 that are configured to slide in a telescop-
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`ing manner to provide a desired length of the hanger bar 105.
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`A person of ordinary skill in the art having the benefit of the
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`present disclosure will recognize that many other suitable
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`means exist for providing adjustable length hanger bars 105.
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`For example, in certain alternative exemplary embodiments,
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`one or more of the hanger bars described in US. Pat. No.
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`6,105,918, titled “Single Piece Adjustable Hanger Bar for
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`Lighting Fixtures,” the complete disclosure of which is
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`hereby fully incorporated herein, may be utilized in the light-
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`ing fixture 100 ofFIG. 1.
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`[0037] The plaster frame 110 extends between the hanger
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`bars 105 and includes a generally rectangular, flat plate 11011
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`with upturned edges 11019. For example, the flat plate 11011
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`can rest on a top surface of the ceiling. The junction box 120
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`is mounted to a top surface 110110 of the flat plate 11011. The
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`junction box 120 is a box-shaped metallic container that
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`typically includes insulated wiring terminals and knock-outs
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`for connecting external wiring (not shown) to an LED driver
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`(not shown) disposed within the can 115 of the light fixture
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`100 or elsewhere within the light fixture 100.
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`the plaster
`[0038]
`In certain exemplary embodiments,
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`frame 110 includes a generally circular-shaped aperture 1100
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`sized for receiving at least a portion of the can 115 there-
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`through. The can 115 typically includes a substantially dome-
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`shaped member configured to receive an LED module (not
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`shown) that includes at least one LED light source (not
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`shown). The aperture 1100 provides an illumination pathway
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`for the LED light source. A person of ordinary skill in the art
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`having the benefit of the present disclosure will recognize
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`that, in certain alternative exemplary embodiments, the aper-
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`ture 1100 can have another, non-circular shape that corre-
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`sponds to an outer profile of the can 115.
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`[0039]
`FIGS. 3-8 illustrate an exemplary LED module 300
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`of the recessed lighting fixture 100 of FIG. 1. The exemplary
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`LED module 3 00 can be configured for installation within the
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`can 115 ofthe lighting fixture 100 ofFIG. 1. The LED module
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`300 includes an LED package 305 mounted to a heat sink 310.
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`The LED package 305 may be mounted directly to the heat
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`sink 310 or with one or more other components mounted
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`in-between the LED package 305 and the heat sink 310.
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`[0040] The LED package 305 includes one or more LEDs
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`mounted to a common substrate 306. The substrate 306
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`includes one or more sheets of ceramic, metal, laminate,
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`circuit board, mylar, or another material. Each LED includes
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`a chip of semi-conductive material that is treated to create a
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`positive-negative (“p-n”) junction. When the LED package
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`305 is electrically coupled to a power source, such as a driver
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`315, current flows from the positive side to the negative side
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`of each junction, causing charge carriers to release energy in
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`the form of incoherent light.
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`[0041] The wavelength or color of the emitted light
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`depends on the materials used to make the LED package 305.
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`For example, a blue or ultraviolet LED can include gallium
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`nitride (“GaN”) or indium gallium nitride (“InGaN”), a red
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`LED can include aluminum gallium arsenide (“AlGaAs”),
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`and a green LED can include aluminum gallium phosphide
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`(“AlGaP”). Each of the LEDs in the LED package 305 can
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`produce the same or a distinct color of light. For example, the
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`LED package 305 can include one or more white LED’s and
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`one or more non-white LEDs, such as red, yellow, amber, or
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`blue LEDs, for adjusting the color temperature output of the
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`light emitted from the fixture 100. A yellow or multi-chro-
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`matic phosphor may coat or otherwise be used in a blue or
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`ultraviolet LED to create blue and red- shifted light that es sen-
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`tially matches blackbody radiation. The emitted light
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`approximates or emulates “white,” incandescent light to a
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`human observer. In certain exemplary embodiments,
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`emitted light includes substantially white light that seems
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`slightly blue, green, red, yellow, orange, or some other color
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`or tint. In certain exemplary embodiments, the light emitted
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`from the LEDs in the LED package 305 has a color tempera-
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`ture between 2500 and 5000 degrees Kelvin.
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`[0042]
`In certain exemplary embodiments, an optically
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`transmissive or clear material (not shown) encapsulates at
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`least a portion of the LED package 305 and/or each LED
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`therein. This encapsulating material provides environmental
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`protection while transmitting light from the LEDs. For
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`example, the encapsulating material can include a conformal
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`coating, a silicone gel, a cured/curable polymer, an adhesive,
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`or some other material known to a person of ordinary skill in
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`the art having the benefit of the present disclosure. In certain
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`exemplary embodiments, phosphors are coated onto or dis-
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`persed in the encapsulating material for creating white light.
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`In certain exemplary embodiments, the white light has a color
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`temperature between 2500 and 5000 degrees Kelvin.
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`[0043]
`In certain exemplary embodiments, the LED pack-
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`age 305 includes one or more arrays of LEDs that are collec-
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`tively configured to produce a lumen output from 1 lumen to
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`5000 lumens in an area having less than two inches in diam-
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`eter or in an area having less than two inches in length and less
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`than two inches in width. In certain exemplary embodiments,
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`the LED package 305 is a CL-L220 package, CL-L230 pack-
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`age, CL-L240 package, CL-L102 package, or CL-L190 pack-
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`age manufactured by Citizen Electronics Co., Ltd. By using a
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`single, relatively compact LED package 305, the LED mod-
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`ule 300 has one light source that produces a lumen output that
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`is equivalent to a variety of lamp types, such as incandescent
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`lamps, in a source that takes up a smaller volume within the
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`fixture. Although illustrated in FIGS. 7 and 8 as including
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`LEDs arranged in a substantially square geometry, a person of
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`ordinary skill in the art having the benefit of the present
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`disclosure will recognize that the LEDs can be arranged in
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`any geometry. For example, the LEDs can be arranged in
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`circular or rectangular geometries in certain alternative exem-
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`plary embodiments.
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`[0044] The LEDs in the LED package 305 are attached to
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`the substrate 306 by one or more solderj oints, plugs, epoxy or
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`bonding lines, and/or other means for mounting an electrical/
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`optical device on a surface. Similarly, the substrate 306 is
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`mounted to a bottom surface 31011 ofthe heat sink 310 by one
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`or more solder joints, plugs, epoxy or bonding lines, and/or
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`

`

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`US 2009/0080189 A1
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`Mar. 26, 2009
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`other means for mounting an electrical/optical device on a
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`surface. For example, the substrate 306 can be mounted to the
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`heat sink 310 by a two-part arctic silver epoxy.
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`[0045] The substrate 306 is electrically connected to sup-
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`port circuitry (not shown) and/or the driver 315 for supplying
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`electrical power and control to the LED package 305. For
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`example, one or more wires (not shown) can couple opposite
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`ends of the substrate 306 to the driver 315, thereby complet-
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`ing a circuit between the driver 315, substrate 306, and LEDs.
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