Lighting system with integrated power supply and light source

Abstract

The lighting system comprises a power supply configured to receive an AC input signal and generate a rectified signal; an optical driver configured to generate a drive signal to drive a light source based on the rectified signal; and a housing configured to enclose the power supply and the optical driver, and comprising a heatsink base configured to be mounted on a heatsink mount.

Description

[Technical Field]

[0001] Cross-reference of (one or more) related applications This application is a U.S. Provisional Application No. 63 / 488,972 ("Lighting System with Integrated Power Source and Light Source") filed on March 7, 2023, and a U.S. Provisional Application No. 63 / 490,630 ("Compact, Vertically Stacked, Integrated Lighting Engine") filed on March 16, 2023. U.S. Provisional Application No. 63 / 490,638 ("Integrated Engine with Conductive Substrate and Improved Noise Performance"), U.S. Provisional Application No. 63 / 490,640 ("Integrated Optical Engine with Conductive Substrate and Improved Noise Performance"), U.S. Provisional Application No. 63 / 490,646 ("Integrated Optical Engine with Base Heat Sink and Improved Heat Transfer"), U.S. Provisional Application No. 63 / 490,650 ("Integrated Optical Engine with Base Heat Sink Plate and Improved Noise Performance"), U.S. Provisional Application No. 63 / 490,740 ("Improved Triac Load"), filed on March 16, 2023. We claim priority and benefits of U.S. Provisional Application No. 63 / 492,940 ("Integrated Optical Engine with High-Speed, Low-Power Startup Circuit") filed March 29, 2023, U.S. Provisional Application No. 63 / 493,281 ("Integrated Optical Engine with Low-Power Standby Mode") filed March 30, 2023, U.S. Provisional Application No. 63 / 589,948 ("Compact Optical Engine with Wide AC Input Range and Adjustable Hue and Brightness") filed October 12, 2023, and U.S. Provisional Application No. 63 / 619,264 ("Compact Optical Engine with Integrated LED Array") filed January 9, 2024, the entire contents of which are incorporated herein by reference.

[0002] One aspect of the present invention relates to an optical driver. [Background technology]

[0003] Light-emitting diodes (LEDs) are electronic devices that convert electrical energy (generally in the form of electric current) into light. The light intensity of an LED is primarily based on the magnitude of the drive current. LED light sources can reproduce warm colors by optically mixing light from white LEDs with light from other colored LEDs, such as amber LEDs, and by controlling the drive current so that the light combination changes from white light to a more yellowish / more orange white light. In the prior art, such LED light sources that mix light from colored LEDs use separate drivers to control the different LEDs individually. However, such solutions incur additional costs and require complex control schemes. Furthermore, in the prior art, the (one or more) drivers, power supply circuits, and LED light sources are housed in separate device housings and connected to each other via electrical cables. For this reason, such lighting systems may be unsuitable for applications with strict spatial constraints. [Overview of the project] [Problems that the invention aims to solve]

[0004] The information disclosed in this background technology section is intended to enhance the understanding of the invention and therefore may include information that does not constitute prior art already known to those skilled in the art. [Means for solving the problem]

[0005] Embodiments of the present invention relate to a dimmable and / or color-tunable optical engine having an integrated power supply, color temperature mixing, wireless functionality (for example, enabling wireless dimming and color mixing) and an integrated light source (for example, an integrated array such as an LED array) in a single compact multilayer housing. Thus, the optical engine receives an AC signal from a wall through two wires and generates the desired light temperature and intensity while keeping all the components necessary to convert the AC signal into a desired light output within a single self-contained fixture package.

[0006] In some embodiments, the optical engine has a multilayer structure having multiple PCB layers (e.g., multiple printed circuit board layers) that provide additional surface area for the mounting components. This structure allows the optical engine to place optical channels (e.g., LED channels), a microprocessor, power electronics circuits, and control circuits on a multilayer PCB design that remains compact and can be fitted into existing fixtures. In some embodiments, the multilayer optical engine is configured to modify the intensity of the emitted light to reproduce an optical temperature following a blackbody curve, as well as to adjust the color mixing of the optical channels.

[0007] According to some embodiments of the present disclosure, a lighting system is provided comprising: a power supply configured to receive an AC input signal and generate a rectified signal; an optical driver configured to generate a drive signal based on the rectified signal; a light source configured to emit light based on the drive signal; and a housing configured to enclose the power supply, the optical driver, and the light source, the housing having a housing opening through which light from the light source passes to reach the outside.

[0008] In some embodiments, the housing has a heatsink base configured to be attached to a heatsink mount, the heatsink base configured to dissipate heat from the lighting system and direct it to the heatsink mount.

[0009] In some embodiments, the housing includes a base plate configured to be thermally coupled to a heatsink mount, a case cover defining a housing opening, and a base post configured to connect the base plate and the case cover.

[0010] In some embodiments, the case cover has an inner tapered portion that defines a housing opening, and the inner tapered portion encloses the light source in a planar manner.

[0011] In some embodiments, the lighting system further comprises a tapered reflector positioned within a housing opening and configured to reflect light from a light source illuminating the inside of the case cover outwards; a lens coupled to the case cover and configured to focus the light from the light source; and a cap configured to be fixedly coupled to the case cover and the lens.

[0012] In some embodiments, the base post extends between the base plate and the case cover within the internal space of the housing.

[0013] In some embodiments, the base post has a hollow interior configured to house fasteners for coupling the lighting system to a heatsink mount.

[0014] In some embodiments, the rear of the base plate and the base post are electrically grounded.

[0015] In some embodiments, the base plate has a first printed circuit board (PCB) having a metal layer on the rear side of the base plate, and the light source has a plurality of light-emitting diodes (LEDs) arranged on the base plate and positioned corresponding to the housing opening.

[0016] In some embodiments, one of several components of at least one of the power supply or optical driver is mounted on the upper side of a base plate facing the housing opening.

[0017] In some embodiments, the lighting system further comprises a second layer offset vertically from a base plate by base posts, the second layer comprising a second printed circuit board (PCB) and having PCB openings corresponding to housing openings, and one of a plurality of components of at least one of a power supply or an optical driver is mounted on the underside of the second layer facing the base plate.

[0018] In some embodiments, one of the plurality of components of at least one of the power supply or the optical driver is attached on the upper side of a second layer facing away from the base plate.

[0019] In some embodiments, the second layer overlaps the base plate in a plane.

[0020] In some embodiments, the component attached to the base plate is electrically connected to the component attached to the second layer via an electrical connector.

[0021] In some embodiments, the lighting system further includes a decoupling capacitor connected between the reference ground of the optical driver and the heat sink base of the housing, and the decoupling capacitor has a capacitance of about 4.7 μF.

[0022] In some embodiments, the decoupling capacitor is on the upper side of the base plate of the housing and has an electrode coupled to a wire extending through a via in the base plate to contact the rear side of the base plate.

[0023] In some embodiments, the light source includes a three-channel unsaturated light-emitting diode (LED).

[0024] In some embodiments, the power supply is configured to receive a direct input AC signal from the wall through two electric wires, and the AC input signal is between 90 VAC and 305 VAC.

[0025] In some embodiments, the optical driver is configured to receive at least one of a dimming signal and a CCT signal and further generate a drive signal based on at least one of the dimming signal and the CCT signal.

[0026] In some embodiments, the optical driver is configured to receive dimming signals from a dimmer via dimming control lines and CCT signals from a CCT controller via CCT control lines.

[0027] In some embodiments, the light output of the light source has an intensity of 5000 lumens or less, and the housing has a substantially cylindrical shape with a diameter of 65 mm or less and a height of 30 mm or less.

[0028] In some embodiments, the housing has an outer diameter of 65 mm, the housing opening has an inner diameter of 32 mm, and the light source is configured to include three channels of unsaturated light-emitting diodes (LEDs) and generate 2500 lumens of light.

[0029] According to some embodiments of the present disclosure, a lighting system is provided comprising: a power supply configured to receive an AC input signal and generate a rectified signal; an optical driver configured to generate a drive signal based on the rectified signal; a light source configured to emit light based on the drive signal; and a housing configured to enclose the power supply, the optical driver, and the light source, having a housing opening through which light from the light source passes to reach the outside, and configured to be thermally coupled to a heatsink mount.

[0030] According to some embodiments of the present disclosure, a lighting system is provided, comprising: a power supply configured to receive an AC input signal and generate a rectified signal; an optical driver configured to generate a drive signal to drive a light source based on the rectified signal; and a housing configured to include the power supply and the optical driver, and comprising a heatsink base configured to be mounted on a heatsink mount, the heatsink base being configured to dissipate heat from the lighting system and guide it to the heatsink mount.

[0031] According to some embodiments of the present disclosure, a lighting system is provided comprising: a power supply configured to receive an AC input signal and generate a rectified signal; an optical driver configured to generate a drive signal based on the rectified signal; a light source configured to emit light based on the drive signal; and a housing configured to enclose the power supply, the optical driver, and the light source, the housing comprising a heat sink base and a pedestal structure protruding from the heat sink base, the pedestal structure being configured to support the light source and being thermally coupled to the light source.

[0032] In some embodiments, the housing has a housing opening through which light from a light source passes to reach the outside, and the housing opening overlaps the base structure in a plane.

[0033] In some embodiments, the heat sink base and pedestal structure are thermally conductive and electrically grounded.

[0034] In some embodiments, the lighting system further includes a thermal pad between the base structure and the light source.

[0035] In some embodiments, the housing has base posts that protrude from the heatsink base.

[0036] In some embodiments, two or more of the heat sink base, pedestal structure, and base post are integrally formed from the same material.

[0037] In some embodiments, the base structure is substantially cylindrical, has a flat top surface, and is centrally located relative to the heat sink base.

[0038] In some embodiments, the lighting system further comprises a base insulator configured to electrically isolate a heat sink base from the optical driver circuitry, having an opening configured to penetrate a base structure, and a wound insulator wound around a base post of a housing, configured to electrically isolate the base post from the optical driver circuitry, wherein the base insulator and the wound insulator are thermally conductive.

[0039] In some embodiments, the lighting system further comprises a first layer which is offset vertically from the heatsink base by a base post and comprises a first printed circuit board (PCB) and has a first layer opening, the pedestal structure passing through the first layer opening, and one of a plurality of components of at least one of a power supply or an optical driver is mounted at least below the first layer facing the heatsink base.

[0040] In some embodiments, one of several components of at least one of the power supply or optical driver is mounted on the upper side of the first layer with its back to the heatsink base.

[0041] In some embodiments, the lighting system further comprises a second layer which is vertically offset from a first layer by a base post and comprises a second PCB and a second layer opening, the second layer being located above a pedestal structure, and one of a plurality of components of at least one of a power supply or an optical driver is mounted on the underside of the second layer facing the first layer.

[0042] In some embodiments, one of several components of at least one of the power supply or optical driver is mounted on the upper side of the second layer, with its back to the first layer.

[0043] In some embodiments, the first layer and the second layer overlap each other in a plane.

[0044] In some embodiments, components attached to the first layer are electrically connected to components attached to the second layer via electrical connectors.

[0045] In some embodiments, the lighting system further has a third layer on a base structure, and the light source is mounted on the third layer and thermally coupled to the base structure.

[0046] In some embodiments, the third layer partially overlaps the first and second layers in a planar plane.

[0047] In some embodiments, components attached to the second layer are electrically connected to components attached to the third layer via electrical connectors.

[0048] In some embodiments, the lighting system includes a case cover that defines a housing opening through which light from a light source passes to reach the outside, and a base post configured to connect a heatsink base to the case cover.

[0049] In some embodiments, the case cover has an inward extension that defines an opening, and the inward extension encloses a light source in a planar manner.

[0050] In some embodiments, the base post extends between the heatsink base and the case cover within the internal space of the housing, and the base post has a hollow interior configured to accommodate fasteners for coupling the lighting system to the heatsink mount.

[0051] In some embodiments, the lighting system further comprises a reflector positioned within a housing opening and configured to reflect light from a light source illuminating the inside of the case cover outwards; a lens coupled to the case cover and configured to focus the light from the light source; and a cap configured to be fixedly coupled to the case cover and the lens.

[0052] In some embodiments, the light source has three channels of unsaturated light-emitting diodes (LEDs).

[0053] In some embodiments, the light source has a single chip-on-board (COB) light.

[0054] In some embodiments, the power supply is configured to receive an input AC signal directly from the wall through two wires, and the AC input signal is between 90VAC and 305VAC.

[0055] In some embodiments, the optical driver is configured to receive at least one of a dimming signal and a CCT signal, and further to generate a drive signal based on at least one of the dimming signal and the CCT signal.

[0056] In some embodiments, the optical driver is configured to receive dimming signals from a dimmer via dimming control lines and CCT signals from a CCT controller via CCT control lines.

[0057] In some embodiments, the light output of the light source has an intensity of 5000 lumens or less, and the housing has a substantially cylindrical shape with a diameter of 61 mm or less and a height of 30 mm or less.

[0058] In some embodiments, the housing has an outer diameter of 50 mm, the housing opening has an inner diameter of 19 mm, and the light source is configured to include three channels of unsaturated light-emitting diodes (LEDs) and generate 1200 lumens of light.

[0059] In some embodiments, the housing has an outer diameter of 50 mm, the housing opening has an inner diameter of 12 mm, and the light source is configured to include three channels of unsaturated light-emitting diodes (LEDs) and generate 1500 lumens of light.

[0060] In some embodiments, the housing has an outer diameter of 50 mm, the housing opening has an inner diameter of 9 mm, and the light source is configured to include three channels of unsaturated light-emitting diodes (LEDs) and generate 1500 lumens of light.

[0061] According to some embodiments of the present disclosure, a lighting system is provided comprising: a light driver configured to generate a drive signal; a light source configured to emit light based on the drive signal; and a housing configured to enclose the light driver and the light source, the housing comprising: a heat sink base; and a pedestal structure protruding from the heat sink base, wherein the pedestal structure is configured to support the light source and is thermally coupled to the light source.

[0062] In some embodiments, the lighting system further comprises a power supply configured to receive an AC input signal and generate a rectified signal, an optical driver configured to generate a drive signal based on the rectified signal, and a housing configured to further enclose the power supply. [Brief explanation of the drawing]

[0063] The attached drawings illustrate embodiments of the present disclosure together with the specification and serve to explain the principles of the present disclosure together with the specification.

[0064] [Figure 1] Figure 1 shows a lighting system having a multi-channel optical driver according to some embodiments of the present disclosure.

[0065] [Figure 2] Figure 2 shows a schematic diagram of a current control circuit for a multi-channel optical driver according to some embodiments of the present disclosure.

[0066] [Figure 3] Figure 3 shows a schematic diagram of a current control circuit utilizing a VCR according to some embodiments of the present disclosure.

[0067] [Figure 4] Figure 4 shows a schematic diagram of the input stage of a lighting system according to some embodiments of the present disclosure.

[0068] [Figure 5] Figure 5 shows a programming device for a lighting system according to several embodiments of the present disclosure.

[0069] [Figure 6] Figure 6 shows the connections between a programming device, a dimming controller, and a channel controller of a lighting system according to some embodiments of the present disclosure.

[0070] [Figure 7A] Figure 7A shows a perspective view of a lighting system according to several embodiments of the present disclosure.

[0071] [Figure 7B] Figure 7B shows exploded perspective views of lighting systems according to several embodiments of the present disclosure.

[0072] [Figure 7C] Figure 7C shows a cross-sectional view of a lighting system according to several embodiments of the present disclosure.

[0073] [Figure 7D-7E] Figures 7D and 7E show cross-sectional perspective views of lighting systems with two different LED arrays according to some embodiments of the present disclosure.

[0074] [Figure 7F-7G] Figures 7F and 7G show exploded perspective views of two PCB layers of a lighting system with internal electrical components implemented according to some embodiments of the present disclosure.

[0075] [Figure 7H] Figure 7H shows a cross-sectional view of two PCB layers of a lighting system according to some embodiments of the present disclosure.

[0076] [Figure 8A] Figure 8A shows a perspective view of a lighting system according to several embodiments of the present disclosure.

[0077] [Figure 8B] Figure 8B shows exploded perspective views of lighting systems according to several embodiments of the present disclosure.

[0078] [Figure 8C] Figure 8C shows a cross-sectional perspective view of a lighting system according to several embodiments of the present disclosure.

[0079] [Figure 8D] Figure 8D shows a cross-sectional view of a lighting system according to several embodiments of the present disclosure.

[0080] [Figure 8E-8F] Figures 8E and 8F show exploded perspective views of layers of a lighting system to which internal electrical components are mounted according to some embodiments of the present disclosure.

[0081] [Figure 8G] Figure 8G shows a side view of two layers of a lighting system according to some embodiments of the present disclosure.

[0082] [Figure 9A] Figure 9A shows a perspective view of a lighting system according to several embodiments of the present disclosure.

[0083] [Figure 9B] Figure 9B shows exploded perspective views of lighting systems according to several embodiments of the present disclosure.

[0084] [Figure 9C] Figure 9C shows a cross-sectional perspective view of a lighting system according to several embodiments of the present disclosure.

[0085] [Figure 9D] Figure 9D shows a cross-sectional view of a lighting system according to several embodiments of the present disclosure.

[0086] [Figures 9E-9F] Figures 9E and 9F show exploded perspective views of layers of a lighting system with internal electrical components implemented according to some embodiments of the present disclosure.

[0087] [Figure 9G] Figure 9G shows a partial side view of the layers of a lighting system according to several embodiments of the present disclosure. [Modes for carrying out the invention]

[0088] The following details are intended to describe embodiments of a compact, integrated, multilayer lighting system provided in accordance with the present invention, and do not represent the only form in which the invention is constructed or utilized. This specification describes the features of the invention in relation to the illustrated embodiments. However, it should be understood that the same or equivalent functions and structures may also be achieved by different embodiments intended to encompass the spirit and scope of the invention. As shown elsewhere in this specification, the same element number is intended to indicate the same element or feature.

[0089] An aspect of one embodiment of the present disclosure relates to an integrated multilayer lighting system in a single fixture having an integrated light source with wireless functionality, color temperature mixing, and spatial priority without sacrificing functionality. In some embodiments, the integrated lighting system is a multilayer structure having multiple printed circuit board (PCB) layers that provide additional surface area for mounting components. The resulting lighting system can reproduce the color temperature of an ideal blackbody radiator while simultaneously arranging color channels, microprocessors, power electronics circuits, and control circuits on a multilayer PCB design that remains compact and fits into an existing lighting fixture. In some examples, the integrated lighting system has a very compact design with a diameter of 61 mm or less and a height of 30 mm or less. The integrated lighting system may operate over a wide input range of about 90 VAC to about 305 VAC at a frequency of about 50 to 60 Hz. Under such inputs, the integrated lighting system may be capable of outputting up to 5000 lumens in various CCT settings.

[0090] According to some embodiments, a compact multilayer design of the lighting system maximizes the space for installing through-hole components. In some examples, the use of one or more ring-shaped PCBs allows color channels to be mounted on the first layer without interference from a second layer or higher.

[0091] Figure 1 shows a lighting system 1 having a multi-channel optical driver 30 according to some embodiments of the present disclosure.

[0092] According to some embodiments, the lighting system 1 includes an input source 10, a plurality of color channels (e.g., a plurality of LED channels) 20, 22, 24, and a multi-channel optical driver 30 for supplying power to the color channels 20, 22, 24 and controlling their brightness / intensity.

[0093] The input source 10 may include, for example, an alternating current (AC) power supply capable of operating at voltages of 100Vac, 120Vac, 240Vac, 277Vac, or higher. The input source 10 may also include a dimmer electrically driven by the AC power supply. The dimmer modifies the input AC signal (e.g., cuts / chops a portion of it) according to the dimming level before transmitting the input AC signal to the lighting driver 30, thereby variably reducing the power supplied to the lighting driver 30 and the color channels 20, 22, 24. In some examples, the dimmer is a triac or ELV dimmer and may chop the leading edge or leading end of the AC input signal. According to some examples, the dimmer interface may be a rocker switch, tap switch, slide switch, rotary switch, etc.

[0094] In some embodiments, the multiple color channels include a first channel (e.g., a green channel) 20, a second channel (e.g., a blue channel) 22, and a third channel (e.g., a red channel) 24. Each channel may include one or more light-emitting diodes (LEDs) of the corresponding color (e.g., red, green, or blue). In some embodiments, the first to third color channels 22 to 24 represent RGB colors, but embodiments of the present disclosure are not limited thereto, and the multiple channels may include any suitable number of color channels. Furthermore, embodiments of the present disclosure are not limited to LEDs, and in some examples, other solid-state lighting devices may be employed.

[0095] In some embodiments, the multi-channel optical driver 30 includes an input rectifier (e.g., an input rectifier circuit) 40, a power supply 50 (also called a power supply circuit), an output rectifier 60, a filter 70, a plurality of current control circuits 80-1 to 80-3, and a channel controller 100.

[0096] The input rectifier 40 can provide an output of the same polarity regardless of the polarity of the AC signal from the input source 10. In some examples, the input rectifier 40 may include a full-wave rectifier circuit using a center-tapped transformer, a full-wave bridge circuit with four diodes, a half-wave bridge circuit, or a polyphase rectifier. The input AC signal may be approximately 90 to 305 VAC at 50 to 60 Hz.

[0097] The power supply circuit 50 converts the rectified AC signal generated by the input rectifier 40 into a drive signal to supply power to the multiple color channels 20, 22, and 24. In some embodiments, the power supply circuit 50 has a voltage converter 52 that maintains (or attempts to maintain) a constant DC bus voltage at the output section while drawing a current (by a PFC controller / circuit 56) that is in phase with and at the same frequency as the line voltage. A transformer 54 in the power supply circuit 50 generates a desired output voltage from the DC bus. In some examples, the power supply circuit 50 may have a PFC circuit (or PFC controller) 56 for improving (e.g., increasing) the power factor of the load of the input source 10 and reducing the total harmonic distortion (THD) of the optical driver 30.

[0098] According to some embodiments, the multi-channel optical driver 30 drives multiple color channels 20, 22, 24 to generate an optical temperature that follows a blackbody curve. Thereafter, the multi-channel optical driver 30 may perform, for example, a color mixture of red, blue, and green light to achieve a desired optical temperature. In some embodiments, the multi-channel optical driver 30 determines the color temperature based on dimmer settings, time of day, or a combination thereof.

[0099] In some embodiments, the drive current for each of the multiple color channels 20, 22, and 24 may be derived from the same secondary winding 54b of the transformer 54. Although the multiple color channels 20, 22, and 24 are driven by the same winding, the channel current of each color channel is independent of the other color channels. This independent control of the channel current is made possible by using separate / different current control circuits 80 for each color channel 20 / 22 / 24.

[0100] According to some embodiments, the color channels 20, 22, and 24 share a common output rectifier (e.g., a diode) 60 and a filter (e.g., a capacitor) 70, which convert the AC drive signal output from the secondary winding 54a of the transformer 54 into DC channel currents to drive the color channels 20, 22, and 24. The anode of the output rectifier 60 may be connected (e.g., directly connected) to the output terminal of the power supply circuit 50.

[0101] According to several embodiments, each of the multiple current control circuits 80-1 to 80-3 is configured to adjust the channel current of the corresponding color channels 20 / 22 / 24 based on a drive signal from the power supply circuit 50 and the corresponding filtered reference signal (e.g., pulse-width modulation (PWM) signal) from the channel controller 100 and the filter circuit 90. By controlling the color intensity (measured in lumens) of each of the red, blue, and green colors output from the color channels 20, 22, and 24, the channel controller 100 can not only enable dimming but also adjust the color mixing of channels 20, 22, and 24 to reproduce light temperatures (in Kelvin (K)) that follow a blackbody curve. The channel controller 100 determines the color mixing for each color temperature (e.g., the intensity of red, blue, and green light) based on a lookup table that provides the light intensities of the different color channels. Tabular color mixing can accurately follow a blackbody curve.

[0102] The dimming level may be determined based on a dimming setting from a dimming controller 200, which may communicate electrically with the channel controller 100, as shown in Figure 1. However, embodiments of this disclosure are not limited thereto. For example, the dimming controller 200 may be a triac (TRIAC) or low-voltage (ELV) dimmer in the input source 10. In some examples, a dimming level of 100% may correspond to an output light intensity of approximately 5000 lumens.

[0103] Figure 2 shows a schematic diagram of a current control circuit 80 of a multi-channel optical driver 30 according to some embodiments of the present disclosure.

[0104] Referring to Figure 2, in some embodiments, the current control circuit 80 is electrically coupled to the secondary side 55b of the power supply circuit 50. The current control circuit 80 is coupled between the output section of the power supply circuit 50 and the corresponding color channels 20 / 22 / 24, and is electrically connected in series with the corresponding color channels 20 / 22 / 24 to a sense resistor (R SENSE )82 has a sense resistor 82. The sense resistor 82 controls the channel current (I) of the corresponding color channels 20 / 22 / 24. CHANNEL It is configured to enable sensing of ).

[0105] In some embodiments, the current control circuit 80 controls the output voltage of the power supply circuit 50 (for example, its V IN The input is detected, and the channel current (e.g., I) is sensed via the sense resistor 82. SENSE The regulator 84 (also called a buck regulator, buck converter, or step-down converter) is configured to detect the input, receive a reference signal (e.g., a PWM signal) corresponding to color channels 20 / 22 / 24 from the channel controller 100, and adjust the channel current based on the detected / received signal. The regulator 84 has (V IN Input and I SENSEThe current in the color channels 20 / 22 / 24 is detected by measuring the voltage drop across the sense resistor 82 (via the input). In some embodiments, the channel current flowing through the color channels 20 / 22 / 24 is returned to ground via a regulator 84 (via the LX input). The regulator 84 has a switch (e.g., a metal-oxide-field-effect transistor (MOSFET)) that can switch the channel current on / off based on the detected output voltage, the detected channel current, and a reference signal. The current control circuit may have an inductor 86 coupled between the color channels 20 / 22 / 24 and the regulator 84, and a regulator 84 positioned in the current path of the channel currents 20 / 22 / 24, so that the regulator (e.g., a buck regulator) 84 can generate a stabilized current. Thus, by controllably switching the channel current on / off, the regulator 84 may perform buck control of the channel current.

[0106] In some embodiments, a hybrid DC / PWM signal is applied to the regulator 84 to achieve the advantages of both DC and PWM dimming while maintaining accurate dimming down to 1% while reducing channel current ripple. In some embodiments, the hybrid DC / PWM signal is a pseudo-sawtooth wave that is recognized as a valid DC voltage when operating above the regulator's cutoff voltage (which may support dimming of approximately 5% or more) and as a PWM signal after entering the cutoff operating region of the regulator 84 (which may support dimming of less than 5%).

[0107] According to some embodiments, to generate a pseudo-sawtooth signal, the channel controller 100 first generates a reference signal in the form of a PWM signal (e.g., a square PWM signal) that oscillates between two discrete values and has an adjustable / variable pulse width or duty cycle. Next, this PWM signal is filtered by the low-pass filter 92 of the filter circuit 90 to generate a pseudo-sawtooth signal, which is a smoothly varying analog signal having a triangular or substantially triangular waveform. The low-pass filter 92 may be a first-order RC filter as shown in FIG. 2, but embodiments of the present application are not limited thereto, and the low-pass filter 92 may be any suitable filter such as a higher-order filter or an RLC filter. Generating a pseudo-sawtooth waveform using a PWM signal and a filter does not require a digital-to-analog converter (DAC) for each color channel, thereby avoiding an increase in the cost of the optical driver.

[0108] The operating mode of the regulator 84 is determined by the cut-off voltage related to the V SET input, whereby when the voltage of the V SET input drops below the cut-off voltage, the regulator 84 is cut off. While the voltage of the reference signal is above the cut-off voltage, the regulator 84 continuously adjusts the channel current according to the effective DC value of the sawtooth signal of the V SET input. However, when the voltage of the sawtooth signal drops below the cut-off voltage, the regulator 84 is configured to be in an off state (e.g., to disable the switch 88), thereby cutting off the first channel current.

[0109] However, embodiments of the present disclosure are not limited to the output stages of the embodiments of FIGS. 1-2. For example, some embodiments of the present disclosure may utilize a voltage control resistor (VCR) to control the voltage supplied to the optical channel instead of using a regulator at the output stage.

[0110] FIG. 3 shows a schematic diagram of a current control circuit 80a that utilizes a VCR according to some embodiments of the present disclosure.

[0111] Referring to Figure 3, in some embodiments, the current control circuit 80a controls the channel current (I) of the corresponding color channels 20 / 22 / 24. CHANNEL The system includes a current sensor 82a configured to detect and generate a detection signal, an error amplifier (also called a comparator) 86a configured to receive the detection signal from the current sensor 82a and a reference signal (VREF) from the channel controller 100 and generate a feedback signal (also called an error signal / gate signal) based on the difference between the reference signal and the sensor signal, and a voltage-controlled resistor (VCR, e.g., a linear path element) 88a, wherein the VCR 88a is configured to adjust the corresponding channel current by dynamically adjusting the resistance of the VCR 88a based on the feedback signal from the error amplifier 86a.

[0112] In some embodiments, the current sensor 82 is coupled between the output section of the power supply circuit 50 and the corresponding color channels 20 / 22 / 24 and is electrically connected in series with the corresponding color channels 20 / 22 / 24 to a detection resistor (R SENSE The current sensor 82a also has a current detection circuit 84a configured to detect the current in color channels 20 / 22 / 24 by measuring the voltage drop across the sensor resistor 83a and to generate a detection signal provided to the error amplifier 86a (for example, the negative input terminal of the error amplifier 86a).

[0113] In some embodiments, VCR88a is electrically connected in series with the sensing resistor 83a and the color channels 20 / 22 / 24. In some embodiments, VCR88a is a field-effect transistor (FET), such as a junction field-effect transistor (JFET) or a metal-oxide-semiconductor field-effect transistor (MOSFET), which operates in a quasi-saturated region (e.g., linear / ohmic region) and functions as a variable resistor whose resistance is controlled by the gate voltage.

[0114] According to some embodiments, a feedback signal from the error amplifier 86a controls the resistance of the VCR 88a to adjust the channel current to a desired value corresponding to a reference signal. The current control circuit 80a dynamically adjusts the resistance of the VCR 88a in response to instantaneous changes in the channel current, so that the current control circuit 80a adjusts the channel current to a desired level determined by the corresponding reference signal.

[0115] According to some embodiments, the channel controller 100 generates a reference signal for each of the multiple color channels 20, 22, and 24 based on the desired color intensity of the channel. For example, when the color channels include a green color channel 20, a blue color channel 22, and a red color channel 24, the channel controller generates a first reference signal corresponding to the desired green intensity to be transmitted to a first current control circuit 80a associated with the green color channel 20, a second reference signal corresponding to the blue intensity to be transmitted to a second current control circuit 80a associated with the blue color channel 22, and a third reference signal corresponding to the red intensity to be transmitted to a third current control circuit 80a associated with the red color channel 24.

[0116] Referring to Figure 3, in some embodiments, the power supply circuit 50 monitors the state of the VCR 88a of the current control circuit 80-1a and adjusts the output voltage (i.e., the output voltage of the secondary winding 54b) to reduce or minimize the voltage drop across the VCR 88a. In some examples, the current control circuit 80-1a corresponds to (e.g., associated with) the green color channel 20.

[0117] In some examples, a feedback signal (also called a correction signal) from the error amplifier 86a controlling the green color channel 20 is transmitted to the power supply circuit. In some embodiments, the feedback signal is supplied to a PFC control circuit 56, which may perform power factor correction for the power supply circuit 50.

[0118] In some embodiments, when the error amplifier 86a of the current control circuit 80-1a decides to increase the drive current of the green color channel 20 (for example, when increasing the intensity of green light), the corresponding feedback signal transmitted to the primary side 55a notifies the power supply circuit 50-1 to increase the output voltage in order to ensure sufficient drive voltage for the green color channel 20 (and consequently for the blue color channel 22 and red color channel 24). Conversely, when the error amplifier 86a of the current control circuit 80-1a decides to decrease the drive current of the green color channel 20 (for example, when decreasing the intensity of green light), the corresponding feedback signal notifies the power supply circuit 50-1 to decrease the output voltage in order to prevent excessive power loss by the VCR 88a.

[0119] Therefore, by properly controlling the voltage headroom, the power supply circuit 50 can supply sufficient drive voltage and current to drive all independent color channels, while simultaneously reducing or minimizing excessive power loss due to the VCR. The multi-channel optical driver 30-1 controls the headroom of all channels using only a single feedback / control loop from one main color channel (e.g., the green color channel) rather than multiple different feedback loops. This greatly simplifies the control logic of the optical driver 30-1, leading to a reduction in the overall cost and size of the system.

[0120] According to some embodiments, the components of the optical driver 1 / 2 are packaged within a multilayer lighting system having a multilayer printed circuit board design in which two or more printed circuit board (PCB) layers are stacked vertically and coupled by connectors / separators. The components of the lighting system 1 / 2 are mounted on the top surface of the bottom PCB (e.g., the main PCB) or on the top and bottom surfaces of the remaining PCB substrate layers (e.g., the sub-substrate layers). These layers may be added or removed to make space for mounting all the components of the lighting system 1 / 2.

[0121] Figure 4 shows a schematic diagram of the input stage of lighting system 1 according to some embodiments of the present disclosure.

[0122] In some embodiments, the input rectifier 40 of the lighting system 1 includes a first metal oxide varistor (MOV) 42, a capacitor (e.g., a bulk capacitor 43) coupled in parallel between two input AC lines, a common-mode (CM) choke 44, a bridge rectifier 45, a differential choke 46, and a second MOV 47 coupled between the input lines to the converter 52.

[0123] MOVs 43 and 47 may contribute to suppressing differential spikes (which are the parts of an energy surge where most of the energy is concentrated). The MOVs exhibit very high resistance (and are substantially open circuits) when the input voltage is below a threshold (e.g., 320V), but exhibit very low resistance when the input voltage exceeds the threshold, effectively creating a short circuit that returns current to the AC line and prevents current from flowing into other parts of the lighting system circuit. Therefore, the MOVs can suppress large current surges caused by differential lighting surges. Figure 4 shows MOVs positioned on both sides of a bridge rectifier 45, but embodiments of the present disclosure are not limited thereto, and the input rectifier may have a single MOV on only one side of the bridge rectifier 45. According to some examples, one or more of the MOVs 42 and 47 may be replaced with transient voltage suppression diodes (TVSDs).

[0124] The CM choke 44 may function as an EMI filter that suppresses common-mode electrical surges and sufficiently reduces or prevents the inflow or outflow of fast transient phenomena to the lighting system 1. The CM choke 44 may have two inductors (one for each AC line) that share the same core. A differential-mode choke 46, which may be present on only one of the two input lines, can contribute to the suppression of differential-mode electrical surges.

[0125] According to some embodiments of the present disclosure, the input stage of the lighting system 1 includes an input voltage detector 400, an active load 402, a negative injection circuit 404, and a pulse generator 406.

[0126] The input voltage detector 400 is configured to detect the voltage level of the haversine signal at the input of the converter 52. For example, the input voltage detector 400 may determine whether the input voltage is approximately 120V, approximately 277V, or greater. When the detected voltage is approximately 120V, the input voltage detector activates the active load 402 coupled to the input AC line (for example, between the CM choke 44 and the bridge rectifier 45). The active load 402 is primarily a resistive load that improves the performance of a triac dimmer that may be coupled to the input of the lighting system 1. Since the triac dimmer is not used with input voltages above 120VAC, the input voltage detector 400 deactivates the active load 402 when the detected voltage is above 120V.

[0127] In contrast, the input voltage detector 400 deactivates the negative injection circuit 404 when the input voltage is 120V, and activates the negative injection circuit 404 when the input voltage is higher than 120V (for example, 277V or higher).

[0128] When sampling the voltage to the reference pin (REF) of the PFC controller 56, the inductor current of the converter 52 is limited by the sampling voltage supplied to REF of the PFC controller 56, so it is desirable that the waveform shape of the rectified input voltage VREC is maintained. According to some embodiments, a negative injection circuit 404, which is also electrically connected to the reference pin REF of the PFC controller 56, contributes to maintaining the voltage signal input to the reference pin REF. This allows the lighting driver 30 to maintain an appropriate power factor and low total harmonic distortion (THD) of the input line current.

[0129] Without the negative feedback circuit 404, a problem may arise where the input filter capacitor, which is incorporated into the converter 52 to hold the voltage, cannot be fully discharged because the load does not supply enough current when driving the optical driver at a low load. The input filter capacitor plays a role in holding the voltage, and it is desirable that it be fully discharged before the next cycle of the rectified voltage.

[0130] According to some embodiments, the downshifting of the sampled rectified signal by the negative injection circuit 404 enables efficient driving of the optical driver 30 by making the inductor current of the converter 52 in phase with the sampled rectified voltage and maintaining it at the same fundamental frequency, thereby achieving a high power factor and low total harmonic distortion (THD).

[0131] Furthermore, when the optical driver 30 operates at a low output level, the on-time of the PFC controller may decrease and the high-frequency switching of the converter 52 may increase. This increase in high-frequency switching induces an increase in common-mode noise input to the reference pin REF of the PFC controller 56. Sampling rectified output voltage V REC By injecting a negative voltage into the reference pin REF to shift the frequency, the inductor current of the converter 52 can be made in phase with the sampling rectifier voltage and kept at the same fundamental frequency, thereby ensuring that the optical driver 30 operates efficiently. This may reduce the high-frequency switching of the converter 52, and as a result, reduce common-mode noise.

[0132] As described above, the negative injection voltage -VDC supplied by the negative injection circuit 404 to the reference pin of the PFC controller 56 shifts the sampled rectified signal downward. This results in a shifted haversine signal input to the reference pin, where the trough reaches zero or near zero (e.g., as close to zero as possible). Shifting the sampled haversine signal to zero or near zero ensures a high power factor (PF) and low total harmonic distortion (THD). If the trough does not reach near zero, the PFC controller 56 may not be able to properly maintain the inductor current in phase with the sampled voltage signal and at the same fundamental frequency. The amount of negative voltage injection may be automatically adjusted by detecting the AC voltage and / or AC current input to the driver input. Furthermore, the circuit plays a role in reducing common-mode noise input to the multiplier pin.

[0133] In some embodiments, the pulse generation circuit 406 generates a rectified input line voltage V to generate a rectified signal. REC The pulse generation circuit 406 is coupled to the output of the rectifier 40 via a first voltage divider having a first resistor R1 and a second resistor R2 that attenuate the signal. The pulse generation circuit 406 utilizes this rectified signal to generate a pulse signal (e.g., a pulse-width modulation (PWM) signal) corresponding to the signal received by the rectifier 40, which may be a chopped waveform from a dimmer (e.g., a triac dimmer or a 0-10V dimmer). Thus, the pulse signal indicates the dimming level of the lighting (e.g., a dimming level set by the user via a phase-cut dimmer). For this purpose, the pulse generation circuit 406 supplies this signal to the PWM input of the channel controller 100, which may determine the dimming level set by the user with a phase-cut dimmer and adjust the light output intensity of the optical channels 20 / 22 / 24 accordingly.

[0134] Figure 5 shows a programming device 300 for a lighting system 1 according to some embodiments of the present disclosure. Figure 6 shows the connections between the programming device 300, dimming controller 200, and channel controller 100 for a lighting system 1 according to some embodiments of the present disclosure.

[0135] Referring to Figures 5-6, in some embodiments, the CCT value and dimming level of the lighting system 1 may be set or programmed into memory by a programming device 300 that can initiate the programming mode of the lighting system 1. During normal operation, the lighting system 1 may rely on programmed values ​​to set / determine the CCT and / or dimming level of the output light. In some examples, the programming device 300 may be connected to and interact with a dimming controller 200 of the programmable lighting system 1 via lead wires 302 or block connector 304.

[0136] Since lighting system 1 is a self-contained lighting engine whose only external connections are two AC input lines and leads / connectors to the programming device 300, it is desirable to electrically isolate the dimming controller 200 from the rest of the circuitry within lighting system 1. Therefore, in some embodiments, the dimming controller transmits the dimming level and CCT value programming values ​​to the channel controller 100 via one or more optocouplers. By maintaining this electrical isolation, lighting system 1 can also satisfy the EMI requirements imposed on devices directly connected to wall AC outlets.

[0137] According to several embodiments, the compact lighting system 1 includes a power supply that converts alternating current to direct current, and a light source (e.g., LEDs) within a single compact package having a circular aperture. The lighting system 1 is fully configurable and can be programmed (on a production line or in operation) to produce any light output color and any light intensity (e.g., 3 kilolumens or 4 kilolumens). The lighting system 1 has an onboard transceiver that allows for reprogramming at any time (e.g., after installation). This eliminates the need to produce and manufacture different lighting for different applications, significantly reducing inventory and improving product profitability. In some examples, the lighting system 1 is intended to be an alternative to chip-on-board (COB) lighting, which has a high-density LED panel (i.e., high density LEDs in a small area) and the ability to emit a powerful, uniform beam (e.g., a conical beam). COB, and by extension the lighting system 1 of this disclosure, can be used for aesthetic purposes in architectural design or for lighting in general lighting applications. Commercially available COBs have standard sizes, and this lighting system 1 must conform to them. In some embodiments, the physical characteristics of the housing of the lighting system 1 (e.g., evaporator, form factor, dimensions, etc.) conform to the Zhaga standard defined by the Zhaga Consortium (https: / / www.zhagastandard.org).

[0138] The input to System 1 is an AC signal supplied by a neutral wire from the wall and a single power line (i.e., there is no ground wire). Lighting System 1 may receive an AC input of approximately 90VAC to approximately 305VAC (considered high voltage). System 1 performs voltage conversion (AC-DC) and generates the desired light output. This is in contrast to conventional technology, where the lighting engine takes a DC voltage input and relies on an external power supply to convert the AC from the wall to DC voltage. By integrating the AC-DC voltage converter power supply into the same package as the lighting driver, System 1 eliminates the need for an additional power supply, thereby reducing costs and simplifying installation. However, as a result of this integration, Lighting System 1 faces significant challenges related to high voltage requirements, power line quality requirements, thermal issues, and insulation requirements, which related technologies do not need to consider or address. Therefore, embodiments of the present disclosure include features and solutions that significantly mitigate or completely eliminate the aforementioned concerns.

[0139] As described above, one of the challenges that lighting system 1 must overcome is meeting power line quality requirements that require it to withstand lightning surges of approximately 2500V on the AC lines at the input of lighting system 1, which are the only high-voltage inputs to the unit. The surges that lighting system 1 can withstand include differential surges between the two AC lines and common-mode surges between one of the AC lines and ground. Both types of surges may be suppressed, at least in part, by MOV 42 and 47 of rectifier 40 (see, for example, Figure 4).

[0140] Furthermore, lighting system 1 must meet essential safety requirements regarding insulation. Therefore, lighting system 1 strategically employs insulation to avoid arc discharge between components that could damage or destroy components, and to ensure safety even if a user touches the unit.

[0141] Conventional lighting engines do not include high-energy surge suppression capabilities (including only low-level electrostatic discharge). This is because, in conventional technology, the AC-DC power supply is located outside the lighting unit, and the quality requirements of the power line are left to the external power supply and not addressed by the optical engine. Furthermore, since conventional optical engines operate at low voltage, user safety issues are minimal or nonexistent. The following describes in detail the intelligent packaging and use of insulating materials for components that enable all necessary components of lighting system 1 to meet additional power line surge and isolation requirements.

[0142] Furthermore, since the heat source (e.g., LED) is integrated into the same small housing / package as all other components, thermal considerations are extremely important in the lighting system 1. If the generated heat is not properly dissipated, the temperature rise inside the light source and internal components may adversely affect the operation of the lighting system 1. Therefore, in some embodiments, the lighting system 1 utilizes a metal heatsink as a back surface that can efficiently transfer the heat generated inside to the outside (e.g., via a heatsink fixture attached to the back of the lighting system 1).

[0143] Furthermore, since the lighting system 1 can be directly connected to a wall AC outlet, it is necessary to meet stringent EMI requirements (such as Class B and FCC / global requirements for radiated emissions), including preventing noise injection into the AC input line and the addition of extra harmonics or distortion, and limiting radiated noise to the outside of the lighting system package / enclosure. The main switch 53 (see, for example, Figure 4) in the converter 52, controlled by the PFC controller 56, switches at high speed (e.g., at about 200 kHz) and supplies power during normal operation, and generates a large amount of broadband noise (e.g., common-mode noise) and ringing throughout the lighting circuit 1. Since the circuit of the light driver 30 is located on a metal backplate and insulated by a thin insulating layer, this structure acts as a large capacitor that can direct much of this noise (e.g., common-mode noise) to the ground plane of the metal backplate and, consequently, to the rest of the internal circuit. Therefore, embodiments of the present disclosure address this problem through various techniques, as described below.

[0144] Figure 7A shows a perspective view of lighting system 1-1 according to some embodiments of the present disclosure. Figure 7B shows an exploded perspective view of lighting system 1-1 according to some embodiments of the present disclosure. Figure 7C shows a cross-sectional view of lighting system 1-1 according to some embodiments of the present disclosure. Figures 7D and 7E show cross-sectional perspective views of lighting system 1-1 with two different LED arrays according to some embodiments of the present disclosure. Figures 7F and 7G show exploded perspective views of two PBC layers on which the internal electrical components of lighting system 1-1 are mounted according to some embodiments of the present disclosure. Figure 7H shows a cross-sectional view of two PBC layers of lighting system 1-1 according to some embodiments of the present disclosure.

[0145] Referring to Figure 7A, lighting system 1-1 is a dimmable AC-input white LED engine with a wide light-emitting surface (LES) and high lumen output, suitable for general lighting applications. In some embodiments, lighting system 1-1 may be a cylindrical luminaire having a diameter of about 65 mm, but the diameter is not limited to that and may be about 61 mm or less. The flat top surface may have an aperture (e.g., a circular lens) with an LES of about 32 mm. Lighting system 1-1 may be capable of producing a high light output of about 2500 lumens or up to 5000 lumens across the entire CCT setting range. In some examples, lighting system 1-1 may utilize 3-channel unsaturated (fusion) LEDs to achieve precise blackbody line (BBL) adjustment.

[0146] Referring to Figure 7B, the lighting system 1-1 has a two-layer structure including a first layer (e.g., a first printed circuit board (PCB) layer or substrate PCB layer) 702 and a second layer (e.g., a second PCB layer) 704, wherein the second layer 704 is bonded to the first layer 702 by two or more base posts 706 and is offset vertically from the first layer 702. The first layer 702 may have a single-layer PCB (e.g., a single metal layer), and the second layer 704 may have a PCB with one or more layers (e.g., metal layers). In some embodiments, the first layer 702 has a metal layer on its back / backside (facing away from the second layer 704), and the metal layer may function as a heat sink for components mounted on the upper side (facing the second layer 704).

[0147] In some embodiments, the first layer 702 has a first constituent region at its periphery and a first optical region in its center, and the second layer 704 has a second constituent region that overlaps the first constituent region of the first layer 702 in a plane and a first aperture that overlaps the first optical region of the first layer 702 in a plane. The first constituent region may surround the first optical region, and the second constituent region may surround the first aperture. Electronic components may be arranged on the upper side of the first layer 702 (most or all of the first constituent region) and on one or both sides of the second layer 704 (within the second constituent region).

[0148] In some embodiments, the integrated multilayer lighting system 1-1 has a light source 710 having a plurality of light-emitting diodes (LEDs) coupled to a first layer 702 and arranged in a first light region corresponding to a first aperture of a second layer 704. The first aperture of the second layer 704 allows light generated by the light source 710 to pass through the second layer 704 without obstruction and illuminate the target environment. The light source 710 may have one or more green LEDs in a green color channel 20, one or more blue LEDs in a blue color channel 22, and one or more red LEDs in a red color channel 24. In some examples, the LEDs 710 are unsaturated LEDs that play a role in providing more vivid and consistent color to the illuminated object compared to saturated LEDs. Unlike saturated LEDs, which may have certain light bands missing from the visible light spectrum, unsaturated LEDs emit light evenly across the entire spectrum and consistently fill in gaps in the light spectrum that may not be filled by saturated LEDs.

[0149] In some embodiments, the lighting system 1-1 has a housing 711 that houses / encompasses and protects components within the lighting system 1-1, such as a power supply 50, an optical driver 30, and a light source 710, from the external environment. The housing 711 may have a base plate, which may be a first layer 702, a case cover 712, and a base post 706 configured to connect the base plate 702 and the case cover 712. The case cover 712 may have an inner tapered portion (e.g., an inner wall or an inward / inward extension) 713 in the center that defines a housing opening (e.g., an inner tapered opening) that can function as an optical tunnel that guides light generated by the LED 710 outwards. The inner tapered portion 713 has an inner diameter that increases vertically outwards (e.g., towards the lens 716) as it moves away from the light source 710. The lower edge 713a of the tapered portion 713 having the minimum inner diameter encloses the light source 710 in plane (i.e., the light source 710 fits completely within the opening of the housing 711 in plane). A reflector (e.g., a tapered reflector such as a metal reflector) 714 is positioned within the case / housing opening (e.g., the inner tapered portion 713) to reflect outward the light from the light source 710 that has entered the inner surface of the tapered portion 713 of the case cover 712, ensuring that the light generated by the light source 710 is not absorbed by the inner wall of the case / housing opening. This can improve (e.g., increase) the light extraction efficiency of the illumination system 1-1. As shown in Figure 7B, the reflector 714 may have one or more lips 714a that can be fitted into corresponding notches in the case cover 712 to hold the reflector 714 in place relative to the case cover 712. The lens (e.g., a glass lens) 716 is fitted into a peripheral notch (or stepped portion) 713b of the case cover 712 and is held above the light source 710 by a cap (e.g., a ring-shaped retaining cap) 718, the cap 718 is configured to be fixedly attached (e.g., fastened or screwed) to the top of the case cover 712 via one or more screws 719.

[0150] The base post 706 may extend vertically within the internal space of the housing 711 from the base plate 702 to the top of the case cover 712. The base post 706 not only connects the case cover 712 to the base plate 702 but also supports a second layer 704 above the base plate 702. In some embodiments, the base post 706 has a hollow interior through which a fastener can pass to connect the lighting system 1-1 to a heatsink mount (e.g., a fixture heatsink) 750, and the heatsink mount may be a passive heat exchanger or an active heat exchanger (e.g., including a fan).

[0151] Since the light source 710 can generate a large amount of heat within the tightly enclosed space of the lighting fixture 1-1, thermal management is an important consideration for the proper and stable operation of the lighting system 1-1.

[0152] To improve heat dissipation from the light source 710, the first layer 702 has a metal core layer on its back surface opposite to the light source 710. The metal core layer is both thermally conductive and electrically conductive and is configured to be attached to a heat sink mount 750. The metal core layer provides electrical grounding to the light source 710 and other electrical components of the first layer 702 and is configured to transfer (e.g., dissipate) the heat generated by the light source 710 during operation to the lighting system 1-1. The metal core layer may be a metal plating extending continuously or substantially continuously across the entire bottom surface of the first layer 702 and having sufficient thickness to maintain the temperature of the light source 710 within a desired temperature range, for example, about 30°C to about 40°C. Without the heat dissipation properties of the metal core layer 106, the LED 710 could operate at significantly higher temperatures (e.g., about 20°C to 30°C higher), which could cause changes in LED characteristics and undesirable changes in the color and intensity of the light output of the lighting system 1-1. In some examples, the metal core layer comprises a material that is both thermally conductive and electrically conductive (e.g., having sufficiently low thermal resistance and electrical sheet resistance), such as aluminum, copper, and / or similar materials. The metal core layer may also function as a safety ground for the lighting system 1-1.

[0153] The lighting system 1-1 includes a plurality of first components coupled to a first layer 702 and located in a first component region, and a plurality of second components coupled to a second layer 704 and located in a second component region. According to some embodiments, the plurality of first components include surface-mount electrical components, and the plurality of second components include through-hole mounted electrical components. In some examples, the first component 208 may not include through-hole components to avoid using plated / insulating vias, which could increase the cost of the lighting system 1-1, in order to insulate the through-hole pins of such components from the grounded metal core layer 206.

[0154] The first components may be located (e.g., soldered) on the upper surface (i.e., the forward-facing side) of the first layer 702 opposite the metal core layer and electrically coupled to one another by a plurality of wires. The second components are located on at least one of the rear side of the second layer 704 (facing the upper side of the first layer 702) and the upper side (i.e., the forward-facing side) of the second layer 704 (facing the lower side of the second layer 704) and are connected to one another via traces wired on the top and / or bottom of the second layer 704. The second components located on the opposite side of the second substrate 210 may be electrically connected via one or more electrical vias within the second layer 704.

[0155] Referring to Figures 7F-7H, in some examples, the multiple first components mounted on the first layer 702 may include a channel regulator 80, an input voltage detector 400, a pulse generator 406, and a channel controller 100. The multiple second components mounted on the second layer 704 may include a rectifier 40 (and components such as an input bulk capacitor 43, a CM choke 44, and a differential choke 46), an active load 402, a negative injection circuit 404, a PFC controller 56, a converter 52 (including a switch 53), a bus rectifier 70, a dimming controller 200, and one or more associated optocouplers. Thus, the noisy high-voltage and high-speed switching components of the lighting system 1-1 may be mounted on the second layer 704, isolated from the quiet, low-voltage elements of the lighting system 1-1 via an air gap between the first layer 702 and the second layer 704. Since the primary switch 53 of the converter 52 may generate heat during normal operation, a heatsink (e.g., a copper heatsink) may be placed on it to aid in heat dissipation and improve thermal management.

[0156] In some embodiments, to further improve vertical space utilization, one or more second components, such as differential chokes, may be mounted on one side of an intermediate substrate (e.g., a choke holder) 46a that is offset and fixed to the bottom surface of the second layer 704. This allows other components (e.g., small resistors and capacitors of the active load 402) to be mounted on the opposite side of the intermediate substrate 46a, resulting in further space savings and a higher component density within the confined packaging of the lighting system 1-1.

[0157] Since an air layer exists between the first layer 702 and the second layer 704, larger second components (e.g., 43, 44, 46, 53, 54, 70, 705) may be attached to the back surface of the second layer 704 facing the first layer 702 in order to improve space utilization. Furthermore, by arranging these components, which are part of the main heat sources of the lighting system 1-1 (excluding the light source 710), in close proximity to the metal backplate of the first layer (and thus the fixture heat sink mount 750), heat dissipation and thermal management are improved. A thermal gap pad may be placed between the bottom surface of these components and the components of the lower layer and / or the first layer, thereby further improving heat dissipation through the back metal plate. The thermal gap plate may have low thermal resistance (which is thermal conductivity), but is an electrical insulator that prevents unintended electrical connections between the components of the first layer 702 and the components of the second layer 704. Furthermore, the adhesive properties of the thermal gap pad contribute to improving the stability and structural integrity of the two layers 702 and 704 (because they are held in place by the two base posts 706).

[0158] In some examples, a second component attached to the second layer 704 may be electrically connected to a first component of the first layer 702 via one or more electrical connectors / links 703.

[0159] In some embodiments, the channel controller 100 has an internal wireless transceiver (e.g., having Bluetooth® and / or WiFi® functionality) which enables the lighting system 1-1 to be remotely dimmed or generally programmed. Thus, as shown in Figures 7F-7H, an antenna 101 of appropriate length may be coupled to the first layer 702 (e.g., via antenna pins and connectors) and extend over the second layer 704.

[0160] As described above, in the embodiments of Figures 7A-7H, the conductors on the upper surface of the first layer 702 (e.g., wiring patterns, other metal components, and lead wires), together with the underlying insulating layer and back metal plate, form a large capacitor that attracts most of the noise (e.g., common-mode noise) generated by the lighting system 1 (e.g., by the primary switch 53) to the metal backplate and other components of the lighting system 1, which function as a heat sink and safety ground based on impedance. Substantially, the backplate acts like a magnet for common-mode noise. It is desirable to reorient the impedance so that the noise returns from the ground plate to the main switch 53 in the converter 52, where most of the noise originates. Therefore, according to some embodiments, the lighting system 1-1 further includes a strategically placed decoupling capacitor (e.g., about 4.7 μF) electrically connected between the safety ground of the backplate of the first layer 702 and the local ground (e.g., driver ground) of the circuit of the lighting system 1-1. The decoupling capacitor provides a capacitive return path for high dV / dt common noise to return to the primary switch 53 of the converter 52. Since the backplate of the first layer 702 may be grounded during installation and the input AC voltage to the lighting system may reach several hundred VAC, there may be a large voltage difference between the safety ground (e.g., earth ground) and the driver ground. Furthermore, during surges (e.g., lightning surges), this voltage difference may reach 2-3 kV. For this reason, the decoupling capacitor 720 may have a high voltage rating and be able to withstand a 4 kV surge. Therefore, the decoupling capacitor 720 may be a physically large component.

[0161] In some embodiments, to efficiently electrically couple a decoupling capacitor 720 (i.e., a surface-mount safety capacitor), this large capacitor 720 is positioned near a ground post 706 connected to an aluminum / copper plate on the back of the first layer 702. In some examples, the electrodes of the decoupling capacitor 720 may be soldered to a base post 706 that is metal and connected to a backplate. However, creepage / clearance requirements around the solder (e.g., 2.5 mm) may consume valuable space on the first layer 702, and soldering during the manufacturing process may be a difficult / cost operation. In other examples, this connection may be established via a via passing through the first layer 702, but this may impose similar creepage limitations around the via and complicate the wiring routing of layer 702. Therefore, in some embodiments, the electrodes of the decoupling capacitor 720 are connected to a wire that protrudes / projects into a hole 706a through which the base post 706 passes, and the wire is pulled down along a vertical path as the post 706 pushes through the hole 706a. Therefore, the wire can be routed vertically along the side of the support column 706 and along the hole 706a and connected to the aluminum / copper backing. Thus, a good electrical connection can be established between the cap electrode and the conductive backplate. The other electrode of the decoupling / safety capacitor 720 is connected to the driver ground, which is returned to the main switch 53 of the second layer 704 via a vertical pin / link connecting the first layer 702 and the second layer 704 to each other. This creates a preferred path for noise (decoupling path), that is, it provides the lowest impedance path for noise to return from the backplate to the primary switch 53. The decoupling / safety capacitor 720 blocks the DC current path, and its capacitance is small enough that the AC leakage current is also small.

[0162] In some embodiments, the base post 706 is insulated from earth (e.g., safety earth). For example, the base post 706 may be formed of an insulating material to prevent components of the lighting system 1-1 from being accidentally connected to electrical earth. In some examples, the base post 706 may be formed of a conductive material and safety earthed. In such examples, it is desirable to insulate the post from other parts of the lighting system circuit. Therefore, the housing 711 may have an insulating post cover (e.g., a plastic post cover) that covers and insulates the base post 706 and prevents other electrical components from making physical and electrical contact with the base post 706. In some examples, the insulation of the post is achieved by wrapping insulating tape around the post. However, these are merely examples, and other suitable means of insulating the conductive base post 706 from the lighting system circuit may be employed.

[0163] In some examples, the first layer 702 may be substantially circular, and the second layer 704 may be annular. Furthermore, the first layer 702 and the second layer 704 may have the same or substantially the same diameter, but embodiments of the present disclosure are not limited thereto, and the first layer 702 and the second layer 704 may have any suitable shape and size to fit within a compact housing or existing wall mounting fixture.

[0164] Therefore, as described above, the multilayer structure design of lighting system 1-1 provides additional surface area for vertically mounting the various components of the light driver 30, thereby enabling lighting system 1 to achieve a more compact design and a smaller installation area compared to the design of related technologies.

[0165] Figure 8A shows a perspective view of lighting system 1-2 according to some embodiments of the present disclosure. Figure 8B shows an exploded perspective view of lighting system 1-2 according to some embodiments of the present disclosure. Figure 8C shows a cross-sectional perspective view of lighting system 1-2 according to some embodiments of the present disclosure. Figure 8D shows a cross-sectional view of lighting system 1-2 according to some embodiments of the present disclosure. Figures 8E and 8F show exploded perspective views of the layers of lighting system 1-2 to which the internal electrical components are mounted, according to some embodiments of the present disclosure. Figure 8G shows a side view of two layers of lighting system 1-2 according to some embodiments of the present disclosure.

[0166] Lighting system 1-2 may have many components and features that are identical or substantially similar to those of lighting system 1-1. For the sake of brevity, the following description will primarily focus on the differences between lighting system 1-1 and lighting system 1-2, and descriptions of common or substantially similar components and features may not be repeated herein.

[0167] Referring to Figure 8A, lighting systems 1-2 in several embodiments are adjustable AC-input white LED engines with a wide light-emitting surface (LES) and high lumen output suitable for general lighting applications. In some examples, lighting systems 1-2 may be cylindrical luminaires having a diameter of about 50 mm. The flat top surface may have an aperture (e.g., a circular lens) with an LES of about 19 mm. Lighting systems 1-2 may be capable of producing a light output of about 1200 lumens. In some examples, lighting systems 1-2 may utilize 3-channel desaturated (fusion) LEDs to achieve precise blackbody line (BBL) adjustment.

[0168] Referring to Figure 8B, the lighting system 1-2 has a three-layer structure comprising a first layer 802, a second layer 804 coupled to the first layer 802 by two or more base posts 806 and offset vertically, and a third layer 808 coupled to the second layer 804 and offset vertically. Layers 802, 804, and 808 may have printed circuit boards (PCBs) having one or more layers (e.g., metal layers).

[0169] In some embodiments, the housing 811 of the lighting system 1-2 has a heat sink base 801 at the bottom / rear of the lighting system 1-2 with its back to layers 802, 804, and 808, and the heat sink base 801 has a central support (or column) structure 801a projecting from the heat sink base 801 toward the third layer 808. The heat sink base 801 and the support structure 801a integrally form a heat sink for the light source 810 and the components of the lighting system 1-2.

[0170] The base post 806 may extend vertically within the internal space of the housing 811 from the heatsink base 801 to the top of the case cover 812. The base post 806 not only connects the case cover 812 to the heatsink base 801 but also supports the first layer 802 and the second layer 804 above the heatsink base 801 via one or more stepped portions on the outside of the base post 806. In some examples, the base post 806 has a hollow interior through which fasteners can pass to connect the lighting system 1-2 to a heatsink mount (e.g., a fixture heatsink) 850, and the heatsink mount may be a passive heat exchanger or an active heat exchanger (e.g., including a fan).

[0171] In some embodiments, the first layer 802 and the second layer 804 may be annular and have a central opening through which the base 801a can pass. The first layer 802 and the second layer 804 may be offset perpendicularly to the heat sink base 801, thereby allowing components to be attached to both sides of each of the first layer 802 and the second layer 804.

[0172] In some embodiments, the integrated multilayer lighting system 1-2 includes a light source 810 coupled to a third layer 808 which is supported and thermally connected by a heatsink base 801a. An opening in the second layer 804 located above the third layer 808 allows light generated by the light source 810, which may have multiple light-emitting diodes (LEDs), to pass through the second layer 804 without obstruction and illuminate the target environment. The light source 810 may have one or more green LEDs in a green color channel 20, one or more blue LEDs in a blue color channel 22, and one or more red LEDs in a red color channel 24. In some examples, the LEDs 810 are unsaturated LEDs that serve to provide more vivid and consistent colors to the illuminated object compared to saturated LEDs.

[0173] The housing 811 has a case cover 812 that houses / encloses the components together with the heat sink base 801 and protects them from the external environment. The case cover 812 may have an inward extension 813 in the center that defines an opening (or case / housing opening) which can function as a light tunnel that guides the light generated by the light source 810 outwards. A reflector (e.g., a metal reflector) 814 is placed in the case / housing opening to improve (e.g., increase) the light extraction efficiency of the lighting system 1-2 by ensuring that the light generated by the light source 810 is not absorbed by the inner wall of the case / housing opening. The reflector 814 may be mounted on or in contact with the inner surface of the inward extension 813. The reflector 814 may be cylindrical (see Figures 8B-8D) or tapered inwards. The glass lens 816 is fitted into the notch 813b of the case / housing opening and is held above the light source 810 by a retaining cap (e.g., an annular retaining cap) 818 which is fixed (e.g., screwed) to the upper part of the case cover 812.

[0174] Thermal management is a critical consideration because the light source 810 can generate a significant amount of heat within the tightly enclosed space of the luminaire 1-1. To improve heat dissipation from the light source 810, the third layer 808 on which the light source 810 is mounted is positioned on a thermally conductive and conductive heat dissipation base 801a, which conducts / transfers the heat generated from the light source to the heat dissipation base 801 and the outside (e.g., via a heat dissipation mount / fixture 850). In some examples, a thermally conductive pad 820 may fill the gap between the light source 810 and the top surface of the conductive (grounded) base 801a. As the thickness of the thermal pad 820 increases, the resistance between the back of the light source (e.g., LED) 810 and the base 801a decreases. In some examples, the thickness of the thermal pad 820 is about 2 mm, which is significantly larger than the micron-unit separation distance between the wiring and the metal plate in the solutions (substrate solutions) of the embodiments in Figures 7A-7H. Therefore, the capacitance resulting from the electrically insulating thermal pad 820 between the conductive base 801a and the metal backing of the light source (e.g., LED) is very small (compared to the capacitance resulting from the metal backing and micron-thickness insulator in the first layer 702) and does not affect the circuit operation of the lighting system 1-2. In other words, the noise generated by system 1-2 (e.g., primary switch 53) does not have a meaningful path to safety ground. Therefore, the design of the embodiments in Figures 8A-8G does not require the decoupling capacitor 720 for separating the safety ground and driver ground of the heat sink structure as described above in Figures 7A-7H.

[0175] In some embodiments, two or more of the heat sink base 801, the base structure 801b, and one or more support columns 806 are integrally formed from the same material. For example, the heat sink base 801 and the base structure 801a may be cast from the same material to form a single, integrated / integrated heat sink structure, but embodiments of the present disclosure are not limited thereto. For example, one or more of the heat sink base 801, the base structure 801a, and one or more support columns 806 may be formed separately (e.g., separately cast) and fixed to each other (e.g., via welding or fastening mechanisms). In some examples, the heat sinks 801 and 801a may be made of copper, aluminum, or other suitable materials with sufficiently high electrical and thermal conductivity.

[0176] The metal heat sink base 801 may extend continuously or substantially continuously across the entire bottom surface of the lighting system 1-2, and the base 801a may have a diameter sufficient to maintain the temperature of the light source 810 within a desired temperature range, for example, about 30°C to about 40°C. Without the heat dissipation properties of the metal core layer 106, the LED 810 may operate at significantly higher temperatures (e.g., about 20°C to 30°C higher), which could cause changes in the LED characteristics and undesirable changes in the color and intensity of the light output of the lighting system 1-2. The heat dissipation structures 801 and 801a may also function as safety grounds for the lighting system 1-2.

[0177] In some examples, the base post 806 may be cast from the same material as the heat sink structures 801 and 801a and form an integral structure. However, embodiments of the present disclosure are not limited thereto, and for example, the base post 806 may be formed separately and then fixed to the heat sink structures 801 and 801a.

[0178] The base 801a not only functions as a heat sink but also positions the light source 810 closer to the circular opening 816, thereby allowing the lighting system 1-2 to improve light extraction efficiency and achieve the target 100 lumens / watt from a small opening. The base structure 801a may slightly increase the thermal resistance from the back of the light source 810 to the backplate. Therefore, in some examples, copper, which has a higher thermal conductivity than aluminum, may be used as the casting material to compensate for this additional thermal resistance and to maximize heat transfer from the light source 810 to the back of the heat sink base 801.

[0179] In some examples, one or more components of at least one of the power supply 50 and / or one or more components of the optical driver 30 are mounted on at least the lower side of the first layer 802 facing the heatsink base 801. Furthermore, one or more components of at least one of the power supply 50 or the optical driver 30 are mounted on the upper side of the first layer 802 with their backs to the heatsink base 801. Similarly, one of the multiple components of at least one of the power supply 50 or the optical driver 30 is mounted on the lower side of the second layer 804 facing the first layer 802, and one of the multiple components of at least one of the power supply 50 or the optical driver 30 is mounted on the upper side of the second layer 804 with their backs to the first layer 802.

[0180] In some examples, with the exception of the light source 810, the components mounted on the first layer 802 may be identical or substantially identical to the components mounted on the second layer 704, and the components mounted on the second layer 804 may be identical or substantially identical to the components mounted on the first layer 702. However, taking advantage of the additional space that can be obtained by mounting components on both sides of the second layer 804, in some embodiments, the main switch 53 and other small components may be mounted on the second layer 804. This is shown more clearly in Figures 8E to 8G. In some examples, as shown in Figures 8E and 8G, the antenna 101 may be mounted on the same layer as the channel controller 100, i.e., the second layer 804.

[0181] As illustrated, in some embodiments, the second components attached to the first layer 802, the second layer 804, and the third layer 808 may be electrically connected to one or more electrical connectors / links 803.

[0182] Since the base post 806 is safety-grounded, it is desirable to insulate the post 806 from the rest of the lighting system circuit. Therefore, in some embodiments, the base insulator 830 is placed on the heat sink base 801, and one or more wound insulators 840 may be placed around different sections of the vertical base post 806 to insulate the safety-grounded heat sink (801, 801a, and 806) from the electrical components of the lighting system 1-2. The base insulator 830 has through-openings corresponding to the base 801a and the two base posts 806, and may have circular projections covering the lower sides of the base 801a and the two base posts 806. The wound insulator 840 is secured to the base 801a and the two base posts 806 by tape, ultrasonic welding, heat welding, vacuum sealing, or other suitable mechanism. The base insulator 830 and the wound insulator 840 may be made of a material having high voltage resistance, high temperature resistance (and, for example, self-extinguishing) and electrical insulation properties. Furthermore, the material may be thermally conductive via heat sinks (801, 801a and 806) to improve heat dissipation. However, embodiments of the present disclosure are not limited thereto. For example, the housing 811 may have insulating post covers (e.g., plastic post covers) that cover and insulate the base posts 806 and pedestal 801a and prevent other electrical components from making physical and electrical contact with these elements.

[0183] In some examples, the first layer 802 and the second layer 804 may have annular shapes. Furthermore, the first layer 802 and the second layer 804 may have the same or substantially the same diameter. However, embodiments of the present disclosure are not limited thereto, and the first layer 802 and the second layer 804 may have any suitable shape and size that fits within an existing wall fixture. For example, as shown in Figures 8B-8G, the first layer 802 and the second layer 804 overlap each other in plane. Furthermore, the third layer 808 partially overlaps the first layer 802 and the second layer 804 in plane (for example, the outer edge of the third layer 808 may overlap the inner edges of the first layer 802 and the second layer 804 in plane).

[0184] Figure 9A shows a perspective view of lighting systems 1-3 according to some embodiments of the present disclosure. Figure 9B shows an exploded perspective view of lighting systems 1-3 according to some embodiments of the present disclosure. Figure 9C shows a cross-sectional perspective view of lighting systems 1-3 according to some embodiments of the present disclosure. Figure 9D shows a cross-sectional view of lighting systems 1-3 according to some embodiments of the present disclosure. Figures 9E and 9F show exploded perspective views of the layers of lighting systems 1-3 to which the internal electrical components are mounted, according to some embodiments of the present disclosure. Figure 9G shows a partial side view of the layers of lighting systems 1-3 according to some embodiments of the present disclosure.

[0185] Lighting system 1-3 may have many components and features that are identical or substantially similar to those of lighting system 1-2. For the sake of brevity, the description of lighting system 1-3 will mainly focus on the differences between lighting system 1-2 and lighting system 1-3, and may not repeat descriptions of common or substantially similar components and features.

[0186] Referring to Figure 9A, lighting system 1-3 is a static white AC input LED engine with a narrow light-emitting surface (LES) and high lumen output. In some examples, lighting system 1-2 may be a cylindrical luminaire having a diameter of approximately 50 mm. The flat top surface may have an aperture (e.g., a circular lens) with an LES of approximately 9 mm or 12 mm. Lighting system 1-3 may be capable of producing a light output of approximately 1500 lumens. In some examples, lighting system 1-3 may utilize a single CCT COB to achieve an even narrower LES and even higher lumen output. Lighting system 1-3 provides high lumens per watt (LPW) but does not have a white color adjustment function.

[0187] The internal structure of lighting system 1-3 may be substantially the same as that of lighting system 1-2, with a few exceptions. For example, lighting system 103 utilizes a COB (e.g., single CCT COB) 910 supported by a base 801a instead of a third layer 808 having surface-mount LEDs 810. A thermal gap pad 820 may also fill the gap between the base 801a and the COB 910. One or more of the first layer 802 and the second layer 804 may have wiring connections to the COB 910.

[0188] In some embodiments, the case cover 912 of the housing 911 has an inner extension 913 that is tapered inward and serves to centrally position and secure the COB 910. The reflector 914 conforms to the shape of the inner extension 913 and is held in place by a lens (e.g., a glass lens) 916. The lens 916 may be fitted into a peripheral cutout (or stepped portion) 913b of the case cover 912. The lens 916 is held in place above the COB 910 by a cap (e.g., a ring-shaped retaining cap) 918 configured to be fixedly attached (e.g., fastened or screwed) to the top of the case cover 912 via one or more screws 719.

[0189] The design of lighting system 1-3 allows for the replacement of the COB910 with any monochromatic array, full-color array, or other suitable LED array. This modification can be achieved by using the same light engine and simply making appropriate modifications to the channel controller firmware. This significantly increases the versatility of the lighting system 1-3 design.

[0190] Therefore, as described above, the multilayer design of lighting systems 1-2 / 1-3 provides additional surface area for vertically mounting the various components of the light driver 30, thereby enabling lighting systems 1-2 / 1-3 to achieve a more compact design and a smaller installation area compared to designs of related technologies.

[0191] In this specification, terms such as “first,” “second,” and “third” are used to describe various elements, components, areas, layers, and / or sections, but it is understood that these elements, components, areas, layers, and / or sections should not be limited by these terms. These terms are used to distinguish one element, component, area, layer, or section from another element, component, area, layer, or section. Accordingly, the first element, component, area, layer, or section described below may be referred to as the second element, component, area, layer, or section without departing from the spirit and scope of the concept of the invention.

[0192] As illustrated, to describe the relationship between one element or feature and another, this specification uses spatially relative terms such as “downward,” “below,” “underside,” “upward,” and “upperside” for convenience of explanation. It should be understood that, in addition to the illustrated orientation, different orientations of the device in use or operation are also encompassed by spatially relative terms. For example, if the illustrated device is turned over, the elements described as “downward,” “below,” and “underside” are positioned “up” relative to other elements or features. Therefore, terms such as “downward,” “below,” and “underside” are interpreted to include both upward and downward orientations. The device may be positioned in other orientations (e.g., rotated 90 degrees or in other orientations), and the spatially relative descriptive terms used herein should be interpreted accordingly. Furthermore, it should be understood that when a layer is described as being “between” two layers, that layer may be the only layer between the two layers, or there may be one or more intervening layers.

[0193] The terms used herein are for the purpose of describing specific embodiments and are not intended to limit the concept of the invention. In this specification, the singular forms “a” and “an” are intended to include the plural form unless the context clearly indicates otherwise. Furthermore, it is understood that the terms “having,” “possessing,” “equipped with,” and / or “equipped with” in this specification identify the presence of a described feature, element, step, operation, component, and / or component, but do not exclude the presence or addition of one or more other features, elements, steps, operations, components, components, and / or groups thereof. In this specification, the term “and / or” includes any combination of one or more related enumeration items. Expressions such as “at least one” placed before a list of elements modify the elements of the entire list, not the individual elements within the list. Furthermore, when the term “possible” is used to describe embodiments of the concept of the invention, it refers to “one or more embodiments of the concept of the invention.” Also, the term “exemplary” is intended to refer to an example or description.

[0194] In this specification, the term “and / or” encompasses any combination that includes one or more of the related enumeration items. For example, the expression “A and / or B” means A, B or A and B. Expressions such as “one or more” and “at least one” qualify the elements of the entire list when placed before a list of elements, not the individual elements within the list. For example, the expressions “one or more A, B and C,” “one or more A, B and C,” and “one or more A, B and C” mean A only, B only, A only, B only, A and B, A and C, and A and B and C, respectively. “At least one of A, B or C,” “at least one of A, B and C,” and “at least one selected from the group consisting of A, B and C” mean A only, B only, C only, both A and B, both A and C, both B and C, or all of A, B, and C.

[0195] When an element or layer is described as "on top of," "connected to," "joined," or "adjacent to" another element or layer, it is understood that it is directly on top of, connected to, joined to, or adjacent to the other element or layer, or that one or more intervening elements or layers may exist. When an element or layer is described as "directly on top of," "directly connected to," "directly joined," or "immediately adjacent to" another element or layer, there are no intervening elements or layers.

[0196] In this specification, the terms “substantially,” “about,” and similar terms are used to express approximation, not degree. They are intended to take into account the inherent variability in measured or calculated values ​​as recognized by those skilled in the art.

[0197] In this specification, the terms "use," "to use," and "used" can be considered synonymous with the terms "utilize," "to use," and "used," respectively.

[0198] Integrated multilayer lighting systems and / or other related devices or components, such as channel controllers, according to some embodiments of the present invention described herein may be implemented using any suitable hardware, firmware (e.g., application-specific integrated circuits), software, or a suitable combination of software, firmware, and hardware. For example, various components of an independent multi-source display device may be formed on a single integrated circuit (IC) chip or on separate IC chips. Furthermore, various components of an LED driver may be mounted on a flexible printed circuit film, tape carrier package (TCP), or printed circuit board (PCB), or formed on the same board. Furthermore, various components of an LED driver may be processes or threads that run on one or more processors in one or more computing devices, execute computer program instructions, and interact with other system components to perform the various functions described herein. Computer program instructions are stored in memory implemented in the computing device using a standard memory device such as random access memory (RAM). Computer program instructions may also be stored in other non-temporary computer-readable media such as a CD-ROM or flash drive. Furthermore, those skilled in the art should recognize that it is possible to integrate or combine the functions of various computing devices into a single computing device and to distribute the functions of a particular computing device to one or more other computing devices without departing from the scope of the embodiments of the present invention.

[0199] Although the present invention has been described in detail with particular reference to embodiments illustrating its specific features, the embodiments described herein are not intended to be exhaustive or to limit the scope of the invention to any specific form disclosed. Experts in the art will understand that various modifications and improvements can be made to the described structures, assembly methods and operating methods without substantially departing from the principles, spirit and scope of the invention as defined in the following claims and equivalents.

Claims

1. A lighting system, A power supply configured to receive an AC input signal and generate a rectified signal, An optical driver configured to generate a drive signal based on the rectified signal, A light source configured to emit light based on the aforementioned drive signal, A housing configured to include the power supply, the optical driver, and the light source, having a housing opening through which light from the light source passes to reach the outside, A lighting system equipped with [specific features / features].

2. The lighting system according to claim 1, wherein the housing comprises a heatsink base configured to be attached to a heatsink mount, and the heatsink base is configured to dissipate heat from the lighting system and guide it to the heatsink mount.

3. The aforementioned housing is A base plate configured to be thermally bonded to the heatsink mount, A case cover defining the housing opening, A base post configured to connect the base plate and the case cover, The lighting system according to claim 1, comprising:

4. The lighting system according to claim 3, wherein the case cover has an inner tapered portion that defines the housing opening, and the inner tapered portion encompasses the light source in a planar manner.

5. A tapered reflector is positioned within the housing opening and configured to reflect outward the light from the light source that irradiates the inside of the case cover, A lens, which is coupled to the case cover and configured to focus the light from the light source, A cap configured to be fixedly attached to the case cover and the lens, The lighting system according to claim 3, further comprising the following:

6. The lighting system according to claim 3, wherein the base post extends between the base plate and the case cover within the internal space of the housing.

7. The lighting system according to claim 6, wherein the base post has a hollow interior configured to house fasteners for connecting the lighting system to the heat sink mount.

8. The lighting system according to claim 3, wherein the rear side of the base plate and the base post are electrically grounded.

9. The base plate comprises a first printed circuit board (PCB) having a metal layer on the rear side of the base plate. The lighting system according to claim 3, wherein the light source comprises a plurality of light-emitting diodes (LEDs) arranged on the base plate and positioned corresponding to the housing opening.

10. The lighting system according to claim 9, wherein one of at least one of the multiple components of the power supply or the optical driver is mounted on the upper side of the base plate facing the housing opening.

11. A second layer is further provided, which is offset vertically from the base plate by the base post, and comprises a second printed circuit board (PCB) and has a PCB opening corresponding to the housing opening. The lighting system according to claim 3, wherein one of at least one of the multiple components of the power supply or the optical driver is mounted on the underside of the second layer facing the base plate.

12. The lighting system according to claim 11, wherein one of at least one of the multiple components of the power supply or the optical driver is mounted on the upper side of the second layer with its back to the base plate.

13. The lighting system according to claim 11, wherein the second layer overlaps the base plate in a planar manner.

14. The lighting system according to claim 11, wherein the components attached to the base plate are electrically connected to the components attached to the second layer via electrical connectors.

15. The optical driver is further provided with a decoupling capacitor connected between the reference ground and the heat sink base of the housing, The lighting system according to claim 1, wherein the decoupling capacitor has a capacitance of approximately 4.7 μF.

16. The lighting system according to claim 15, wherein the decoupling capacitor is located above the base plate of the housing and has electrodes coupled to wires extending through vias of the base plate to contact the rear side of the base plate.

17. The lighting system according to claim 1, wherein the light source comprises three channels of unsaturated light-emitting diodes (LEDs).

18. The power supply is configured to receive an input AC signal directly from the wall through two wires. The lighting system according to claim 1, wherein the AC input signal is between 90VAC and 305VAC.

19. The lighting system according to claim 1, wherein the optical driver is configured to receive at least one of a dimming signal and a CCT signal, and further to generate the drive signal based on at least one of the dimming signal and the CCT signal.

20. The lighting system according to claim 19, wherein the optical driver is configured to receive the dimming signal from a dimmer via a dimming control line and to receive the CCT signal from a CCT controller via a CCT control line.

21. The light output of the aforementioned light source has an intensity of 5000 lumens or less. The lighting system according to claim 1, wherein the housing has a substantially cylindrical shape with a diameter of 65 mm or less and a height of 30 mm or less.

22. The housing has an outer diameter of 65 mm, and the housing opening has an inner diameter of 32 mm. The lighting system according to claim 1, wherein the light source comprises three channels of unsaturated light-emitting diodes (LEDs) and is configured to generate 2500 lm of light.

23. A lighting system, A power supply configured to receive an AC input signal and generate a rectified signal, An optical driver configured to generate a drive signal based on the rectified signal, A light source configured to emit light based on the aforementioned drive signal, A housing configured to include the power supply, the optical driver, and the light source, having a housing opening through which light from the light source passes to reach the outside, and configured to be thermally coupled to a heatsink mount, A lighting system equipped with [specific features / features].

24. A lighting system, A power supply configured to receive an AC input signal and generate a rectified signal, An optical driver configured to generate a drive signal to drive a light source based on the rectified signal, A housing configured to include the power supply and the optical driver, comprising a heatsink base configured to be attached to a heatsink mount, wherein the heatsink base is configured to dissipate heat from the lighting system and guide it to the heatsink mount, A lighting system equipped with [specific features / features].

25. A lighting system, A power supply configured to receive an AC input signal and generate a rectified signal, An optical driver configured to generate a drive signal based on the rectified signal, A light source configured to emit light based on the aforementioned drive signal, A housing configured to enclose the power supply, the optical driver, and the light source, comprising a heat sink base and a pedestal structure protruding from the heat sink base, wherein the pedestal structure is configured to support the light source and is thermally coupled to the light source, A lighting system equipped with [specific features / features].

26. The housing has a housing opening through which light from the light source passes to reach the outside. The lighting system according to claim 25, wherein the housing opening overlaps the base structure in a planar view.

27. The lighting system according to claim 25, wherein the heat sink base and the base structure are thermally conductive and electrically conductive and electrically grounded.

28. The lighting system according to claim 25, further comprising a heat pad between the base structure and the light source.

29. The lighting system according to claim 25, wherein the housing comprises a base post protruding from the heat sink base.

30. The lighting system according to claim 29, wherein two or more of the heat sink base, the base structure, and the base post are integrally formed from the same material.

31. The lighting system according to claim 25, wherein the base structure is substantially cylindrical, has a flat top surface, and is positioned centrally with respect to the heat sink base.

32. A base insulator configured to electrically isolate the heat sink base from the optical driver circuit, the base insulator having an opening configured to penetrate the base structure, A wound insulator wound around the base post of the housing, configured to electrically insulate the base post from the optical driver circuit, The lighting system according to claim 25, further comprising the base insulator and the wound insulator being thermally conductive.

33. A first layer is offset vertically from the heat sink base by base posts, and further comprises a first printed circuit board (PCB) and a first layer opening, The base structure passes through the first layer opening, The lighting system according to claim 25, wherein one of a plurality of components of at least one of the power supply or the optical driver is mounted at least below the first layer facing the heat sink base.

34. The lighting system according to claim 33, wherein one of at least one of the multiple components of the power supply or the optical driver is mounted on the upper side of the first layer with its back to the heat sink base.

35. A second layer is further comprising a second layer offset vertically from the first layer by the base post, the second layer comprising a second PCB and having a second layer opening, The second layer is located above the base structure, The lighting system according to claim 33, wherein one of at least one of the multiple components of the power supply or the optical driver is mounted on the underside of the second layer facing the first layer.

36. The lighting system according to claim 35, wherein one of at least one of the multiple components of the power supply or the optical driver is mounted on the upper side of the second layer with its back to the first layer.

37. The lighting system according to claim 35, wherein the first layer and the second layer overlap each other in a plane.

38. The lighting system according to claim 35, wherein the components attached to the first layer are electrically connected to the components attached to the second layer via electrical connectors.

39. The base structure further comprises a third layer, The lighting system according to claim 35, wherein the light source is attached to the third layer and thermally coupled to the base structure.

40. The lighting system according to claim 39, wherein the third layer partially overlaps the first and second layers in a planar manner.

41. The lighting system according to claim 39, wherein the components attached to the second layer are electrically connected to the components attached to the third layer via electrical connectors.

42. A case cover that defines a housing opening through which light from the light source passes to reach the outside, A base post configured to connect the heat sink base and the case cover, The lighting system according to claim 25, comprising:

43. The lighting system according to claim 42, wherein the case cover has an inner extension that defines the opening, and the inner extension encompasses the light source in a planar manner.

44. The base post extends between the heat sink base and the case cover within the internal space of the housing, The lighting system according to claim 42, wherein the base post has a hollow interior configured to house fasteners for connecting the lighting system to a heat sink mount.

45. A reflector is positioned within the housing opening and configured to reflect the light from the light source that irradiates the inside of the case cover outwards, A lens, which is coupled to the case cover and configured to focus the light from the light source, A cap configured to be fixedly attached to the case cover and the lens, The lighting system according to claim 42, further comprising:

46. The lighting system according to claim 25, wherein the light source comprises three channels of unsaturated light-emitting diodes (LEDs).

47. The lighting system according to claim 25, wherein the light source comprises a single chip-on-board (COB) light.

48. The power supply is configured to receive an input AC signal directly from the wall through two wires. The lighting system according to claim 25, wherein the AC input signal is between 90VAC and 305VAC.

49. The lighting system according to claim 25, wherein the optical driver is configured to receive at least one of a dimming signal and a CCT signal, and further to generate the drive signal based on at least one of the dimming signal and the CCT signal.

50. The lighting system according to claim 49, wherein the optical driver is configured to receive the dimming signal from a dimmer via a dimming control line and to receive the CCT signal from a CCT controller via a CCT control line.

51. The light output of the aforementioned light source has an intensity of 5000 lumens or less. The lighting system according to claim 25, wherein the housing has a substantially cylindrical shape with a diameter of 61 mm or less and a height of 30 mm or less.

52. The housing has an outer diameter of 50 mm, and the housing opening has an inner diameter of 19 mm. The lighting system according to claim 25, wherein the light source comprises three channels of unsaturated light-emitting diodes (LEDs) and is configured to generate 1200 lm of light.

53. The housing has an outer diameter of 50 mm, and the housing opening has an inner diameter of 12 mm. The lighting system according to claim 25, wherein the light source comprises three channels of unsaturated light-emitting diodes (LEDs) and is configured to generate 1500 lm of light.

54. The housing has an outer diameter of 50 mm, and the housing opening has an inner diameter of 9 mm. The lighting system according to claim 25, wherein the light source comprises three channels of unsaturated light-emitting diodes (LEDs) and is configured to generate 1500 lm of light.

55. A lighting system, An optical driver configured to generate a drive signal, A light source configured to emit light based on the aforementioned drive signal, A housing configured to enclose the optical driver and the light source, comprising a heat sink base and a pedestal structure protruding from the heat sink base, wherein the pedestal structure is configured to support the light source and is thermally coupled to the light source, A lighting system equipped with [specific features / features].

56. The system further includes a power supply configured to receive an AC input signal and generate a rectified signal, The optical driver is configured to generate the drive signal based on the rectification signal, The lighting system according to claim 55, wherein the housing is configured to further include the power supply.

57. It is an optical driver, An input rectifier configured to rectify the input line voltage in order to generate a rectified input line voltage, An active load coupled to the input rectifier and configured to be selectively in an operating state and a non-operating state, A negative injection circuit coupled to the reference input of the power factor correction (PFC) circuit of the optical driver, wherein the negative injection circuit is configured to inject a negative voltage into the reference input in order to shift the sampling voltage corresponding to the rectified input line voltage sampled by the PFC circuit, and to selectively operate and deactivate, An input voltage detector connected to the output section of the aforementioned input rectifier, Based on the rectified input line voltage, it is determined whether the input line voltage is greater than the first voltage. In response to determining that the input line voltage is not greater than the first voltage, The active load is brought into operation, An input voltage detector configured to deactivate the negative injection circuit, An optical driver equipped with [this feature].

58. The aforementioned input voltage detector is In response to determining that the input line voltage is greater than the first voltage, The active load is rendered inoperable, The optical driver according to claim 57, further configured to activate the negative injection circuit.

59. The optical driver according to claim 57, wherein the active load includes a resistive load and is configured to improve the performance of a triac dimmer connected to the input of the optical driver in response to operation.

60. The optical driver according to claim 57, wherein the first voltage is 120V.

61. The optical driver according to claim 57, wherein determining that the input line voltage is greater than the first voltage indicates that a triac dimmer is not connected to the input of the optical driver.

62. The aforementioned input rectifier is, The system includes a bridge rectifier configured to rectify the input line voltage in order to generate a Haversine signal corresponding to the rectified input line voltage, The optical driver according to claim 57, wherein the active load is selectively coupled to the input of the bridge rectifier.

63. The aforementioned input rectifier is, A first metal oxide varistor (MOV) coupled between the input AC lines of the input section of an optical driver, configured to suppress current surges in the input AC lines, A first common-mode choke coupled between the first MOV and the bridge rectifier, configured to suppress common-mode electrical surges in the input AC line, A second MOV coupled to the output section of the bridge rectifier, the second MOV coupled between the output lines of the input rectifier, A second common-mode choke coupled between the first MOV and the bridge rectifier, the second common-mode choke configured to suppress differential-mode electrical surges at the output of the bridge rectifier, The optical driver according to claim 62, further comprising:

64. A voltage divider coupled to the output of the input rectifier, further comprising a first resistor and a second resistor, configured to attenuate the rectified input line voltage in order to generate a rectified signal, The optical driver according to claim 57, wherein the sampling voltage is the rectified signal.

65. The optical driver according to claim 57, further comprising the PFC circuit configured to reduce the total harmonic distortion (THD) of the optical driver and improve the power factor (PF) of the optical driver.

66. The optical driver according to claim 57, further comprising a converter configured to convert the rectified input line voltage into a drive signal for driving a light source coupled to the optical driver.

67. The optical driver according to claim 57, wherein the input line voltage from which the rectified input line voltage is generated is between 100VAC and 277VAC.

68. It is an optical driver, An input rectifier configured to rectify the input line voltage in order to generate a rectified input line voltage, An active load coupled to the input rectifier and configured to be selectively in an operating state and a non-operating state, A negative injection circuit coupled to the reference input of the power factor correction (PFC) circuit of the optical driver, wherein the negative injection circuit is configured to inject a negative voltage into the reference input in order to shift the sampling voltage corresponding to the rectified input line voltage sampled by the PFC circuit, and to selectively operate and deactivate, An input voltage detector connected to the output section of the aforementioned input rectifier, Based on the rectified input line voltage, it is determined whether the input line voltage is greater than the first voltage. In response to determining that the input line voltage is greater than the first voltage, The active load is rendered inoperable, An input voltage detector configured to operate the negative injection circuit, An optical driver equipped with [this feature].

69. The optical driver according to claim 68, wherein the active load includes a resistive load and is configured to improve the performance of a triac dimmer connected to the input of the optical driver in response to operation.

70. The optical driver according to claim 68, wherein the first voltage is 120V.

71. The optical driver according to claim 68, wherein determining that the input line voltage is greater than the first voltage indicates that a triac dimmer is not connected to the input of the optical driver.

72. The aforementioned input rectifier is, The system includes a bridge rectifier configured to rectify the input line voltage in order to generate a Haversine signal corresponding to the rectified input line voltage, The optical driver according to claim 68, wherein the active load is selectively coupled to the input of the bridge rectifier.

73. The aforementioned input rectifier is, A first metal oxide varistor (MOV) coupled between the input AC lines of the input section of an optical driver, configured to suppress current surges in the input AC lines, A first common-mode choke coupled between the first MOV and the bridge rectifier, configured to suppress common-mode electrical surges in the input AC line, A second MOV coupled to the output section of the bridge rectifier, the second MOV coupled between the output lines of the input rectifier, A second common-mode choke coupled between the first MOV and the bridge rectifier, the second common-mode choke configured to suppress differential-mode electrical surges at the output of the bridge rectifier, The optical driver according to claim 72, further comprising:

74. A voltage divider coupled to the output of the input rectifier, further comprising a first resistor and a second resistor, configured to attenuate the rectified input line voltage in order to generate a rectified signal, The optical driver according to claim 68, wherein the sampling voltage is the rectified signal.

75. The PFC circuit is configured to reduce the total harmonic distortion (THD) of the optical driver and improve the power factor (PF) of the optical driver, The optical driver according to claim 68, further comprising a converter configured to convert the rectified input line voltage into a drive signal for driving a light source coupled to the optical driver.

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