Patent Application
20150198298
The present disclosure relates generally to creating a light fixture from individual light modules and more particularly to systems, methods, and devices for creating a floodlight fixture from individual floodlight modules.
Floodlights are used in many different applications. Such floodlights may be used, for example, in commercial applications and residential applications. Floodlights may also be used in industrial applications and other harsh environments, including but not limited to military applications, onboard ships, assembly plants, power plants, oil refineries, and petrochemical plants. When a floodlight is used in such harsh environments, the floodlight must comply with one or more standards and/or regulations to ensure safe and reliable operation. With the development of lighting technologies (e.g., light emitting diode (LED)) that offer alternatives to incandescent lamps, floodlights using such lighting technologies are becoming more common.
In general, in one aspect, the disclosure relates to a light fixture having a first light module, a second light module, and at least one first bracket. The first light module can include at least one first coupling feature, a first power source, and at least one first electrical receiver providing access to the first power source. The second light module can include at least one second coupling feature, a second power source, and at least one second electrical receiver providing access to the second power source. The at least one first bracket of the light fixture can include a first portion and a second portion, where the first portion mechanically couples to the at least one first coupling feature of the first light module, and where the second portion mechanically couples to the at least one second coupling feature of the second light module.
In another aspect, the disclosure can generally relate to an assembly system for a light fixture. The assembly system can include at least one first bracket having a first portion and a second portion, where the first portion is configured to mechanically couple to at least one first coupling feature of a first light module, and where the second portion is configured to mechanically couple to at least one second coupling feature of a second light module. The first light module can include a first power source, and the second light module can include a second power source.
These and other aspects, objects, features, and embodiments will be apparent from the following description and the appended claims.
The drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, as the exemplary embodiments may admit to other equally effective embodiments. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the exemplary embodiments. Additionally, certain dimensions or positionings may be exaggerated to help visually convey such principles. In the drawings, reference numerals designate like or corresponding, but not necessarily identical, elements.
The example embodiments discussed herein are directed to systems, apparatuses, and methods associated with assembly systems for modular light fixtures. While the Figures shown and described herein are directed to floodlights, the disclosed embodiments are also applicable to one or more other types of light fixtures (e.g., spotlights, nightlights, emergency egress lights, high-bay light fixtures). Generally, the floodlight, which is used with example assembly systems, can be called a light fixture herein, where the light fixture includes at least two light modules. Example embodiments can be used in one or more of a variety of environments, indoors or outdoors, where the light fixture can be mounted and exposed. Example environments can include, but are not limited to, conditions with moisture, humidity, dirt, exhaust fumes, vibrations, potential explosions, and noise.
Example light fixtures can use LED technology. The LED can be one or more of a number of types of LED technology, including but not limited to discrete LEDs, LED arrays, chip-on-board LEDs, edge lit LED panels, and surface mounted LEDs. One or more LEDs can be mounted on a light board, and one or more light modules of a LED light fixture can include one or more light boards. Example light fixtures can also be used with different types of light sources using one or more of a number of types of sockets into which the light sources are electrically and mechanically coupled. Examples of a socket can include, but are not limited to, an Edison screw base of any diameter (e. g., E26, E12, E14, E39), a bayonet style base, a bi-post base, a bi-pin connector base, a wedge base, and a fluorescent tube base. A light source can electrically and mechanically couple to the socket and can be of a light source type that corresponds to the socket. Examples of light source types can include, but are not limited to, incandescent lamps, LEDs, halogen lamps, G10/GU10, G9/GU9, AR111/PAR36, T3, MR-11, and MR-16.
Example light fixtures can be of any size and/or shape. A light fixture can be mounted to a surface (e.g., wall, ceiling, pillar), can be a light module in a light fixture, and/or can be used with any other suitable mounting instrument. Such light fixtures can be used in residential, commercial, and/or industrial applications. Such light fixtures can operate from a manual device (e.g., on/off switch, dimming switch, pull chain), a photocell, a timer, and/or any other suitable mechanism.
The assembly system and associated light fixture (or components thereof, such as individual light modules) described herein can be made of one or more of a number of suitable materials to allow the light fixture, when used with example assembly systems, to meet certain standards and/or regulations while also maintaining durability in light of the one or more conditions under which the example light fixture can be exposed. Examples of such materials can include, but are not limited to, aluminum, stainless steel, fiberglass, glass, plastic, and rubber. Light fixtures described herein, when used with example assembly systems, can be rated for one or more of a number (or range) of light color (CCT), light accuracy (CRI), voltages, and/or amperes. Example light fixtures described herein should not be considered limited to a particular CCT, CRI, voltage, and/or amperage rating.
In one or more example embodiments, a light fixture, when used with example assembly systems, is subject to meeting certain standards and/or requirements. For example, the International Electrotechnical Commission (IEC) publishes ratings and requirements for LED floodlights. Specifically, the IEC publishes IP (which stands for Ingress Protection or, alternatively, International Protection) Codes that classify and rate the degree of protection provided against intrusion of solid objects, dust, and water in mechanical casings and electrical enclosures. One such IP Code is IP66, which means that a LED floodlight having such a rating is dust tight and protects against powerful water jets (in this case, 100 liters of water per minute under a pressure of 100 kN/m2 at a distance of 3 meters) for a duration of at least 3 minutes.
The IEC also publishes temperature ratings for electrical equipment. For example, if a device is classified as having a T4 temperature rating, then the surface temperature of the device will not exceed 135° C. Other entities (e.g., the National Electrical Manufacturers Association (NEMA), the National Electric Code (NEC), Underwriters' Laboratories, Inc. (UL)) may also publish standards and/or requirements for LED floodlights.
Example embodiments of light fixtures may meet one or more of a number of standards set by one or more of a number of authorities. Examples of such authorities include, but are not limited to, the National Electric Code (NEC), the Canadian Electric Code (CEC), the IEC, the NEMA, Underwriter's Laboratories (UL), the Standards Council of Canada, Conformité Européenne (CE), and the Appareils destinés à être utilisés en Atmosphères Explosives (ATEX). Examples of such standards include, but are not limited to, Class I, division 2, groups A, B, C, and/or D; Class I, Zone 2; Class II, groups E, F, and/or G; Class III simultaneous presence; Marine and/or Wet locations; Type 4X; IP66; and Ex nA Zone z2.
In addition, the light modules of the light fixtures described herein are rectangular in shape. In other words, each assembly and/or member of the example light modules of the light fixtures shown and described herein are substantially rectangular. One or more assemblies and/or members of an example light modules of a light fixture can have any of a number of other shapes, including but not limited to circular, oval, hexagonal, square, and triangular.
A user as described herein may be any person that interacts, directly or remotely, with light fixtures using example assembly systems. Specifically, a user may install, maintain, operate, and/or interface with a light fixture. Examples of a user may include, but are not limited to, an engineer, an electrician, an instrumentation and controls technician, a mechanic, an operator, a consultant, a contractor, and a manufacturer's representative.
Example embodiments will now be described in detail with reference to the accompanying figures, in which example embodiments of light fixtures using assembly systems are shown. Light fixtures using assembly systems may, however, be embodied in many different forms and should not be construed as limited to the example embodiments set forth herein. Rather, these example embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of light fixtures using assembly systems to those of ordinary skill in the art. Like, but not necessarily identical, elements (also sometimes called assemblies, members, or components) in the various figures are denoted by like reference numerals for consistency.
Terms such as “first,” “second,” “top,” “center,” “width,” “height,” “bottom,” “back,” “front,” and “side” are used merely to distinguish one component (or part of a component or state of a component) from another. Such terms are not meant to denote a preference or a particular orientation, and are not meant to limit embodiments of light fixtures using assembly systems. In the following detailed description of the example embodiments, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.
Referring to
In certain example embodiments, each light module 100 has multiple electrical receivers (e.g., electrical receiver 193, electrical receiver 194). An electrical receiver can be an aperture in the housing of the light module 100. In addition, or in the alternative, an electrical receiver can include part (e.g., male, female) of a connector plug. In any case, at least one of the electrical receivers of a light module 100 can receive a cable (a bridge cable, a power cable) to allow the cable to be mechanically (and, in some cases, electrically) coupled to the power source 260 of the light module 100. When there are multiple electrical receivers for a light module 100, one electrical receiver (e.g., electrical receiver 193) can be called a first electrical receiver 193, and another electrical receiver (e.g., electrical receiver 194) can be called a second electrical receiver 194. The first electrical receiver 193 can receive a cable (allow a cable to be disposed therein) so that the cable can be mechanically and, in some cases, electrically, coupled to the power source 260. In such a case, the other end of the cable can be mechanically and, in some cases, electrically, coupled to an external power source.
If the external power source is received from another light module 100, the cable can be called a bridge cable. Such a configuration allows for the daisy-chaining (in series and/or in parallel) of power among light modules 100 in a light fixture. Specifically, one end of the bridge cable can be disposed in the second electrical receiver 193 so that the cable can be mechanically and, in some cases, electrically, coupled to the power source 260 of one light module 100 in a light fixture, and the other end of the bridge cable (such as, for example, bridge cable 690 shown in
In certain example embodiments, a cable gland 149 is disposed within an electrical receiver of a light module 100. For example, as shown in
Alternatively, a plug 208 can be inserted into an electrical receiver if the electrical receiver is not used. For example, as shown in
The one or more coupling features 107 can be disposed at one or more locations on a light module 100. For example, as shown in
The coupling features 107 can include, but are not limited to, a portion of a hinge, an aperture (as shown), a slot, a tab, a detent, and a mating thread. A side bracket 300, a rear bracket 400, a center interface 500, and/or another component of the example assembly system can be coupled to the light module 100 by the direct use of the coupling features 107. In addition, or in the alternative, side bracket 300, the rear bracket 400, the center interface 500, and/or another component of the example assembly system can be coupled to the light module 100 using one or more independent devices that interact with the coupling features 107 disposed on the light module 100. Examples of such devices can include, but are not limited to, a pin, a hinge, a fastening device (e.g., fastening device 629 described below with respect to
The various features (e.g., size, shape, type of light source, color) of the light module 100 can vary. Since a light fixture using example assembly systems includes two or more light modules 100, the features of one light module 100 in a light fixture can be substantially the same as, or different than, the corresponding features of the one or more other light modules 100 in the light fixture.
Example assembly systems described herein include one or more of a number of components. Examples of such components are a side bracket 300, a rear bracket 400, and a center interface 500.
Referring to
Similar to the top portion 310, the bottom portion 330 of the side bracket 300 can include at least one coupling feature 340 that mechanically couples the top portion 310 of the side bracket 300 to a portion of a light module 100. The one or more coupling features 340 of the bottom portion 330 can include, but are not limited to, a portion of a hinge, an aperture (as shown), a slot, a tab, a detent, and a mating thread. The side bracket 300 can be coupled to a portion (e.g., one or more coupling features 107 disposed on a side 111) of a light module 100 by the direct use of the coupling features 340. In addition, or in the alternative, side bracket 300 can be coupled to the light module 100 using one or more independent devices that interact with the coupling features 340 disposed on the bottom portion 330 of the side bracket 300. Examples of such devices can include, but are not limited to, a pin, a hinge, a fastening device, and a spring. One coupling feature 340 of the bottom portion 330 of a side bracket 300 can be the same as, or different than, one or more other coupling features 340 of the side bracket 300.
The middle portion 320 of the side bracket 300 can be disposed at any point along the side bracket 300 between the top portion 310 and the bottom portion 330. For example, as shown in
In certain example embodiments, the side bracket 300 can have one or more features that enhance the strength of the side bracket 300 in supporting one or more light modules 100, the optional mounting assembly 680, and/or one or more other components of the light fixture. For example, as shown in
In certain example embodiments, the side bracket 300 can be made of one or more of a number of suitable materials, including but not limited to steel, titanium, and aluminum. Further, the side bracket 300 can have any suitable shape and/or size (e.g., height, width, thickness) to couple multiple light modules 100 to each other. If an assembly system includes multiple side brackets 300, the shape and/or size of one side bracket 300 can be substantially the same as, or different than, one or more of the other side brackets 300.
In certain example embodiments, the side bracket 300 is made of a single piece, as from a mold or a cast. In such a case, one or more portions (e.g., top portion 310, bottom portion 330) of a side bracket 300 can be linearly aligned (coplanar) with each other. For example, as shown in
Alternatively, one or more portions of the side bracket 300 is made of multiple pieces that are mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to welding, fastening devices (e.g., clamps, brackets, bolts), and compression fittings. In certain example embodiments, the coupling methods used to mechanically couple two or more portions of the side bracket 300 to each other can be adjustable. For example, the adjustable coupling methods can allow the portions of the side bracket 300 to become decoupled from each other. As another example, the adjustable coupling methods can allow the distance between the portions of the side bracket 300 to be adjusted. As yet another example, the adjustable coupling methods can allow the angle formed between the portions of the side bracket 300 to be adjusted.
The rear bracket 400 of the assembly system, an example of which is shown in
The coupling extensions 420 of the rear bracket 400 can be disposed at any point along the rear bracket 400. For example, as shown in
In certain example embodiments, the rear bracket 400 can have one or more features that enhance the strength of the rear bracket 400 in supporting one or more light modules 100 and/or one or more other components of the light fixture. For example, main body 410 of the rear bracket 400 can include one or more stiffening features (e.g., ribs) disposed along some portion of the main body 410. The shape and size of the main body 410, as well as the shape, size, and position of the coupling extensions 420, can allow the rear bracket 400 to be positioned in a specific location relative to, and to be coupled to, one or more components of a light fixture. An example of this is shown below with respect to
The various portions of the rear bracket 400 can be planar (two dimensional) with respect to each other. Alternatively, the rear bracket 400 can be three dimensional. In other words, the main body 410 and/or one or more coupling extensions 420 can be set at an angle relative to itself and/or each other. For example, an apex can run along the width of the main body 410 to create an angle between one portion of the main body 410 and the other portion of the main body 410. The various components of the rear bracket 400 can be made from a single piece (as from a cast) or multiple pieces. When the rear bracket 400 is made of multiple pieces, the pieces can be mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to welding, epoxy, fastening devices (e.g., bolts, brackets), and compressions fittings. One or more of the coupling methods can allow one or more components of the rear bracket 400 to be adjustable, either relative to itself or to another component of the rear bracket 400. For example, a hinge with detents can be disposed along the width of a bottom half and a top half of the main body 410. In such a case, the halves of the main body 410 can be set at various angles relative to each other.
In certain example embodiments, the rear bracket 400 can be made of one or more of a number of suitable materials, including but not limited to steel, titanium, and aluminum. Further, the rear bracket 400 can have any suitable shape and/or size (e.g., height, width, thickness) to couple multiple light modules 100 to each other. If an assembly system includes multiple rear brackets 400, the shape and/or size of one rear bracket 400 can be substantially the same as, or different than, one or more of the other rear bracket 400.
In certain example embodiments, the center interface 500 is optional and is used for aesthetic purposes. Alternatively, the center interface 500 can be a required component of the example assembly system. The center interface 500 of the example assembly system, an example of which is shown in
The front portion 510 can have a height sufficient to cover a gap that exists between two or more adjacent light modules 100 when those light modules 100 are mechanically coupled to each other by one or more components (e.g., two side brackets 300) of the assembly system. The front portion 510 of the center interface 500, when mechanically coupled to one or more light modules 110, can be disposed over the front surface of at least part of a component (e.g., the bezel) of the same and/or a different light module 110. In addition, or in the alternative, the front portion 510 can have a width that is at least slightly greater than the width of one or more light modules 100. The width and/or the height of the center portion 510 of the center interface 500 can be substantially uniform or variable throughout.
The one or more side portions 520 of the center interface 500, when mechanically coupled to one or more light modules 110, can be disposed over a side surface of at least part of a component (e.g., the bezel, a flange of a housing assembly) of the same and/or a different light module 110. In addition, or in the alternative, a side portion 520 can have a width that is at least slightly greater than the width of at least a portion one or more light modules 100. The width and/or the height of the side portion 520 of the center interface 500 can be substantially uniform or variable throughout. If there are multiple side portions 520, the shape and/or size of one side portion 520 can be substantially the same as or different than the other side portions 520.
The one or more rear portions 530 of the center interface 500, when mechanically coupled to one or more light modules 110, can be disposed over a back surface of at least part of a component (e.g., the bezel, a flange of a housing assembly) of the same and/or a different light module 110. The width and/or the height of a rear portion 530 of the center interface 500 can be substantially uniform or variable throughout. If there are multiple rear portions 530, the shape and/or size of one rear portion 530 can be substantially the same as or different than the other rear portions 530.
The center interface 500 can include one or more of a number of coupling features 540 that mechanically couples the center interface 500 to a portion of one or more light modules 100. The one or more coupling features 540 can include, but are not limited to, a portion of a hinge, an aperture (as shown), a slot, a tab, a detent, and a mating thread. The center interface 500 can be coupled to a portion (e.g., one or more coupling features 107 disposed on the rear) of a light module 100 by the direct use of the coupling features 540. In addition, or in the alternative, the center interface 500 can be coupled to the light module 100 using one or more independent devices that interact with the coupling features 540 disposed on a portion (e.g., one or more rear portions 530, as shown in
The front portion 510, the one or more side portions 520, and the one or more rear portions 530 can be formed from a single piece (e.g., folded, taken from a cast or mold) or can be formed from multiple pieces that are mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to welding, epoxy, fastening devices (e.g., bolts, brackets), and compressions fittings. When the center interface 500 is made of multiple pieces, the multiple pieces can be adjusted relative to itself and/or to each other. For example, the front portion 510 can be made of two pieces that are slidably coupled to each other, allowing the width of the front portion 510 (and, thus, the spacing between the rear portions 530) can be adjusted by a user.
Referring to
In this case, the example assembly system includes two side brackets 300, with one disposed on each side 111 of the two light modules 100, which are stacked vertically with respect to each other. Each side bracket 300 is shaped and sized substantially the same relative to each other. In this example, the top portion 310 of each side bracket is mechanically coupled to a side 111 (in this case, toward the bottom) of the top light module 100, and the bottom portion 330 is mechanically coupled to a side 111 (in this case, toward the bottom) of the bottom light module 100.
As explained above, in certain example embodiments, middle portion 320 of the side bracket 300 can be mechanically coupled to one or more components of the light fixture 600. An example of such a component is the mounting assembly 680. The mounting assembly 680 can include one or more coupling features (hidden from view by fastening devices 688). Each coupling feature can be of the mounting assembly 680 can be disposed on a yoke bracket 686 of the bracket 682 of the mounting assembly 680. The coupling features of the mounting assembly 680 may be configured in any manner appropriate to receive and couple to the coupling features 340 of the side bracket 300, the coupling features 107 on the side 111 of a light module 100, and/or some other component of the light fixture 600. For example, as shown in
The yoke bracket 686 may include one or more features (e.g., slots) that allow a user to rotate, tilt, swivel, or otherwise move the light generated by the light fixture 600 in a particular vertical direction and/or angled position. For example, the yoke bracket 686 in
The example light fixture 600 also includes one rear bracket 400 and one center interface 500. The rear bracket 400 is rectangular in shape, with a coupling extension 420 disposed in each corner of the main body 410. The top two coupling extensions 420 are mechanically coupled to a back side of the top light module 100, and the bottom two coupling extensions 420 are mechanically coupled to a back side of the bottom light module 100. The center interface 500 in this case has two side portions 520 and two rear portions 530, where two coupling features 540 (in this case, apertures) are disposed on each rear portion 530. The top coupling feature 540 of each rear portion 530 is mechanically coupled to back side of the top light module 100, and the bottom coupling feature 540 of each rear portion 530 is mechanically coupled to back side of the bottom light module 100. Each rear portion 530 is positioned (disposed) within the relief feature 350 of each side bracket 300. The front portion 510 of the center interface 500 has a height sufficient to cover the gap 615 that exists between two or more adjacent light modules 100.
The example assembly system of
Example embodiments provide for light fixtures having two or more light modules, where each light module has its own power source. The light fixtures using example assembly systems can have various shapes and sizes. The light modules of example light fixtures can be the same as or different from each other. The light modules of example light fixtures can be fixed or adjustable relative to each other. Example embodiments of the light fixtures described herein are designed to meet one or more of a number of standards and/or regulations to be used in a variety of conditions.
Although the inventions are described with reference to preferred embodiments, it should be appreciated by those skilled in the art that various modifications are well within the scope of the invention. From the foregoing, it will be appreciated that embodiments of the light fixtures using example assembly systems overcome the limitations of the prior art. Those skilled in the art will appreciate that light fixtures using example assembly systems are not limited to any specifically discussed application and that the embodiments described herein are illustrative and not restrictive. From the description of the example embodiments, equivalents of the elements shown therein will suggest themselves to those skilled in the art, and ways of constructing other embodiments of the light fixtures using example assembly systems will suggest themselves to practitioners of the art. Therefore, the scope of the light fixtures using example assembly systems is not limited herein.
The present application is related to a patent application titled “Floodlights With Multi-Path Cooling,” having attorney docket number 13682.118878, filed concurrently with the U.S. Patent and Trademark Office, and hereby incorporated by reference in its entirety. The present application is also related to U.S. patent application Ser. No. 13/436,172 titled “Light-Emitting Diode (LED) Floodlight”, which itself claims priority from U.S. Provisional Patent Application No. 61/470,554, titled “Light-Emitting Diode (LED) Floodlight”. The entire contents of both are hereby incorporated herein by reference.
