EP4056888A1 - Improved downlight - Google Patents

Improved downlight Download PDF

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Publication number
EP4056888A1
EP4056888A1 EP22167447.6A EP22167447A EP4056888A1 EP 4056888 A1 EP4056888 A1 EP 4056888A1 EP 22167447 A EP22167447 A EP 22167447A EP 4056888 A1 EP4056888 A1 EP 4056888A1
Authority
EP
European Patent Office
Prior art keywords
housing
assembly according
downlight
downlight assembly
solid state
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22167447.6A
Other languages
German (de)
English (en)
French (fr)
Inventor
Andrew Johnson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Aurora Ltd
Original Assignee
Aurora Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Aurora Ltd filed Critical Aurora Ltd
Publication of EP4056888A1 publication Critical patent/EP4056888A1/en
Pending legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S8/00—Lighting devices intended for fixed installation
    • F21S8/02—Lighting devices intended for fixed installation of recess-mounted type, e.g. downlighters
    • F21S8/026—Lighting devices intended for fixed installation of recess-mounted type, e.g. downlighters intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V21/00—Supporting, suspending, or attaching arrangements for lighting devices; Hand grips
    • F21V21/02—Wall, ceiling, or floor bases; Fixing pendants or arms to the bases
    • F21V21/04—Recessed bases
    • F21V21/047—Mounting arrangements with fastening means engaging the inner surface of a hole in a ceiling or wall, e.g. for solid walls or for blind holes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V23/00—Arrangement of electric circuit elements in or on lighting devices
    • F21V23/003—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array
    • F21V23/004—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array arranged on a substrate, e.g. a printed circuit board
    • F21V23/006—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array arranged on a substrate, e.g. a printed circuit board the substrate being distinct from the light source holder
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/502—Cooling arrangements characterised by the adaptation for cooling of specific components
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/04—Refractors for light sources of lens shape
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00—Reflectors for light sources
    • F21V7/04—Optical design
    • F21V7/041—Optical design with conical or pyramidal surface
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2105/00—Planar light sources
    • F21Y2105/10—Planar light sources comprising a two-dimensional array of point-like light-generating elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]

Definitions

  • the present invention relates to downlight luminaires. It is particularly applicable, but in no way limited, to fire rated downlight luminaires.
  • Copper (k value 400) and silver (k value 429) are both better conductors of heat than aluminium but are more expensive and are not commonly used in heat sinks in fire rated downlights.
  • mild steel which is the material generally used to construct the fire rated housing or can of a downlight is a relatively poor conductor of heat, having a k value in the order of 43 to 53 depending on the percentage of carbon in the steel. Because of this low k value, heat sinks for use in downlight luminaires are never made from mild steel.
  • a high powered LED solid state lighting element in order to have a good working life, a high powered LED solid state lighting element must be in positioned in good thermal contact with a heat sink made from a material with good thermal conductivity that is to say with a thermal conductivity constant k of above about 100 W/(m.k), and preferably a finned aluminium heat sink.
  • a heat sink made from a material with good thermal conductivity that is to say with a thermal conductivity constant k of above about 100 W/(m.k), and preferably a finned aluminium heat sink.
  • Such heat sinks are referred to in this context as conventional heat sinks. This has an impact on the cost of a downlight because a separate heat sink must be provided, which costs money, uses up valuable natural resources, and adds to the cost of and time taken for assembly in the manufacturing process.
  • the housing is made from a material having a melting point in excess of 1000° C.
  • the fire rated housing further comprises an outwardly extending flange at or towards the front side of the downlight housing.
  • This flange enables the downlight to be fixed in a partition surface, such as in a ceiling.
  • the solid state lighting element comprises a plurality of LEDs.
  • the heat generated is spread over a much larger surface area of the rear wall of the housing, improving the life expectancy and the light efficiency of the LED unit.
  • the plurality of LEDs are mounted on a printed circuit board (PCB), which is preferably a metal printed circuit board (MPCB) and more preferably the metal PCB includes aluminium.
  • PCB printed circuit board
  • MPCB metal printed circuit board
  • the printed circuit board is attached directly to the inside face of the rear end wall of the housing.
  • thermally conductive interface is provided between the PCB and the rear end wall of the housing.
  • Suitable thermally conductive interfaces are, by way of example, thermally conductive grease, thermally conducting pads, graphite foil, or thermally conductive acrylic film.
  • control circuitry and components required to power and control the solid state lighting element comprise one or more components selected from the group of components comprising power supply components, dimmer control components, control IC components, and other electronic components.
  • the downlight assembly further comprises a reflector adapted to direct light from the solid state lighting element out of the front of the housing.
  • the assembly may also include a lens adapted to focus the light emitted by the solid state lighting element.
  • control circuitry and components required to power and control the solid state lighting element are accommodated in an annular space provided around the lens or reflector.
  • control circuitry and components required to power and control the solid state lighting element are thermally isolated as well as electrically isolated from the housing, and are preferably substantially located in a bottom cover and preferably the additional electronic components are substantially covered by a top cover.
  • the housing comprises steel, more preferably mild steel and the housing can advantageously be pressed out of a sheet of mild steel, to keep manufacturing costs down, and preferably the housing comprises a substantially tubular body having a front side and a rear side and at least one side wall.
  • the housing can thus be formed as a pressing, for example from sheet material.
  • the only aperture required in the rear wall of the pressing is to allow cable entry to the solid state lighting element and any associated control gear.
  • other ventilation apertures may be provided in the rear end wall or side wall(s) of the housing to assist in heat dissipation. If these apertures are small they do not impair the fire rating of the assembly in fire tests.
  • a downlight assembly comprising:-
  • 'LED lighting module' refers to a functioning LED light engine and its associated control circuitry, such as a power supply, dimmer, and/or control IC or electronics.
  • control circuitry such as a power supply, dimmer, and/or control IC or electronics.
  • 'LED module' refers to one or more LED light engines mounted on a suitable PCB, with or without any associated control circuitry.
  • FIG. 1 this shows an exploded view of the components for a fire rated downlight assembly 10 which has no external or separate conventional heat sink other than a metal housing and which does not rely on intumescent material to achieve the desired fire rating.
  • the assembly comprises a fire rated housing 11, an LED module 12, a reflector 13, a diffuser 14 and a seal 15 to retain the diffuser in place.
  • the housing is in effect a closed shallow can with an outwardly extending flange 16 around the front face of the can.
  • the rear of the can is closed off by a rear wall 17, as shown in Figure 2B .
  • the assembly includes spring loaded arms 18, 19 supported by brackets 20, 21 which are attached to the can by rivets 22.
  • a cord grip 23 is attached to the outside of the rear wall of the housing, with a small aperture (not shown) in the rear wall of the can to allow cable entry to the LED module and any associated control gear. This one small cable entry aperture does not affect the fire rating of the can.
  • the LED module is attached directly to the inside face of the rear end wall of the can, such that light from the LED's is directed out of the front open face of the can or housing.
  • the housing is fire resistant
  • the housing is preferably made from metal with a melting point in excess of 900° C, and more preferably in excess of 1000° C.
  • Steel is a suitable material and mild steel is particularly suitable as its melting point is over 1400° C and it can be readily and cheaply pressed into the desired shape.
  • Fire resistance standards for fire rated ceilings for the United Kingdom are set out in BS EN 1365-2:2014. This requires that a fire resistant member must be able to withstand a specified temperature for a specified period of time.
  • the specified temperature is around 1000°C so any metal that can withstand temperatures of that order could be used in the manufacture of a fire rated housing. It will be appreciated that other countries may specify different temperatures in their fire resistance standards.
  • the present example shows a housing pressed out of one piece of metal, the housing can be formed from two, or more components welded or otherwise firmly fixed together.
  • the LED PCB and thus the LED module 12 must be in good thermal contact with the inside of the rear end wall 17 of the housing 11.
  • This good thermal contact may be enhanced by means of thermally conductive interface materials such as thermally conductive grease, a thermally conducting pad or pads, graphite foil, thermally conductive acrylic film, or thermally conductive nano composites or polymers. It will be understood that any suitable thermally conductive material can be used for this purpose.
  • the inside face of the rear end wall 17 of the housing 11 is substantially planar to facilitate heat transfer over the whole surface area of the back of the LED PCB.
  • the necessary power supply, dimmer and control IC are located in a remote driver unit (not shown).
  • Embodiments are shown in Figures 3 to 8 inclusive in which the power supply, dimmer and/or control IC or electronics are located within the housing.
  • a 3 x 3 array of 9 LEDs are located on a PCB situated on the rear wall 37 of a housing 31 and may be in good thermal contact with the rear wall 37 if desired. Alternatively these components may be thermally insulated from the housing if required.
  • Power supply, dimmer and other control IC and other electronic components are located in a separate annular space around the LED PCB and around the outside of the lens 33.
  • These other components are in one embodiment preferably mounted on one or more PCBs separate from and spaced away from the LED PCB.
  • a solid substantially frustoconical lens 33 of conventional format directs light from the LEDs out of the front of the housing by total internal reflection.
  • This arrangement creates an annular cavity 44 in which these additional components can be accommodated.
  • a similar annular cavity is formed when a reflector plate 13 is used as shown in Figure 1 .
  • FIG 8 shows the components in exploded diagram format that comprise the type of downlight assembly shown in Figures 3 to 7 .
  • a housing pressed from steel includes a front flange 46.
  • An LED module 42 on a PCB is fixed to the inside of the rear wall of housing 41 with a thermally conducting paste between the two surfaces.
  • Set around the LED PCB is a bottom cover 54 for the power, control and driver components, which can be seen on their own PCB as 55 in Figure 8 .
  • a top cover 56 is fitted over the driver components and optionally a lens, not shown, occupies the space within the top cover.
  • the assembly is completed by a diffuser 44 and a seal 45.
  • FIG. 11 A sectional view of a downlight assembly of this type installed in a ceiling is shown in Figure 11 , and the housing and LED module alone are shown in Figure 12 . Corresponding views of a downlight assembly with a remote driver (not shown) are shown in Figures 9 and 10 .
  • control components are located in a substantially annular space around or behind a lens or a reflector, or both, is applicable to other downlight assemblies, not just those described above and in the foregoing examples. That is to say, most lenses and reflectors are substantially frustoconical in shape and this tends to leave a substantially annular space around the base of the lens or reflector. This space can be advantageously used to accommodate a wide range of electrical and electronic components.
  • the downlight assembly according to the present invention is devoid of any outer housing and there is no outer housing around or associated with the housing described.
  • the housing described is therefore located in free airspace when properly installed behind some partition surface, such as a ceiling.

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Arrangement Of Elements, Cooling, Sealing, Or The Like Of Lighting Devices (AREA)
EP22167447.6A 2015-12-10 2016-12-15 Improved downlight Pending EP4056888A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
GB1521756.5A GB2545242B (en) 2015-12-10 2015-12-10 Improved downlight
PCT/IB2016/057674 WO2017098487A1 (en) 2015-12-10 2016-12-15 Improved downlight
EP16825892.9A EP3387322B1 (en) 2015-12-10 2016-12-15 Improved downlight

Related Parent Applications (2)

Application Number Title Priority Date Filing Date
EP16825892.9A Division EP3387322B1 (en) 2015-12-10 2016-12-15 Improved downlight
EP16825892.9A Division-Into EP3387322B1 (en) 2015-12-10 2016-12-15 Improved downlight

Publications (1)

Publication Number Publication Date
EP4056888A1 true EP4056888A1 (en) 2022-09-14

Family

ID=55274494

Family Applications (2)

Application Number Title Priority Date Filing Date
EP22167447.6A Pending EP4056888A1 (en) 2015-12-10 2016-12-15 Improved downlight
EP16825892.9A Active EP3387322B1 (en) 2015-12-10 2016-12-15 Improved downlight

Family Applications After (1)

Application Number Title Priority Date Filing Date
EP16825892.9A Active EP3387322B1 (en) 2015-12-10 2016-12-15 Improved downlight

Country Status (5)

Country Link
EP (2) EP4056888A1 (zh)
CN (2) CN209355087U (zh)
AU (1) AU2016366819B2 (zh)
GB (1) GB2545242B (zh)
WO (1) WO2017098487A1 (zh)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100259919A1 (en) * 2009-02-11 2010-10-14 Koninklijke Philips Electronics, N.V. LED Downlight Retaining Ring
EP2674671A1 (en) * 2012-06-13 2013-12-18 Panasonic Corporation Light emitting device and lighting fixture
GB2504133A (en) * 2012-07-20 2014-01-22 Aurora Ltd Heat sink assembly
GB2509772A (en) * 2013-01-15 2014-07-16 Kosnic Uk Ltd LED down light
CN104565930A (zh) * 2014-12-31 2015-04-29 东莞高仪电子科技有限公司 一体式可覆盖保温棉的防火灯具
CA2879629A1 (en) * 2014-02-19 2015-08-19 Michael D. Danesh Unified driver and light source assembly for recessed lighting

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100259919A1 (en) * 2009-02-11 2010-10-14 Koninklijke Philips Electronics, N.V. LED Downlight Retaining Ring
EP2674671A1 (en) * 2012-06-13 2013-12-18 Panasonic Corporation Light emitting device and lighting fixture
GB2504133A (en) * 2012-07-20 2014-01-22 Aurora Ltd Heat sink assembly
GB2509772A (en) * 2013-01-15 2014-07-16 Kosnic Uk Ltd LED down light
CA2879629A1 (en) * 2014-02-19 2015-08-19 Michael D. Danesh Unified driver and light source assembly for recessed lighting
CN104565930A (zh) * 2014-12-31 2015-04-29 东莞高仪电子科技有限公司 一体式可覆盖保温棉的防火灯具
GB2533864A (en) * 2014-12-31 2016-07-06 Chao Wen-Hsin Integral type fireproof lamp for covering thermal insulating cotton

Also Published As

Publication number Publication date
EP3387322A1 (en) 2018-10-17
GB2545242B (en) 2018-08-01
CN211600341U (zh) 2020-09-29
GB201521756D0 (en) 2016-01-27
AU2016366819A1 (en) 2018-07-26
CN209355087U (zh) 2019-09-06
WO2017098487A1 (en) 2017-06-15
GB2545242A (en) 2017-06-14
EP3387322B1 (en) 2022-05-25
AU2016366819B2 (en) 2019-04-18

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