Patent Application
20250189116
This disclosure relates generally to a luminaire assembly, and more particularly to an integrated housing of a high-lumen light-emitting diode (LED) luminaire assembly located in a harsh and hazardous environment.
Lighting features designed for use in harsh and hazardous environments often require a specific focus on heat management in the operation of the lighting fixtures. Such lighting fixtures may include many high-output LEDs operating in combination and can produce excessively high temperatures, for example, for hazardous location usage where ambient temperature is already relatively high. The peak operating temperatures of the lighting components must be managed to prevent system malfunction or damage. Moreover, the lighting assembly must be resistant to dust, humidity, vapors, gas, or other corrosive or non-corrosive substances present in the ambient environment to provide reliable operation, longevity of the physical components, and safety. To meet these operational requirements, conventional LED luminaire assemblies typically employ lighting housings that are bulky, heavy, and difficult and expensive to manufacture in order for the luminaire assemblies to safely and reliably operate in a harsh and hazardous environment. Further, bulky and heavy assemblies may be difficult to carry, install, replace, and perform maintenance on. There is a need for lighting features that are simultaneously rated for operation in such environments while being lightweight, durable, less expensive to manufacture, and aesthetically pleasing.
This disclosure presents a compact and light luminaire lighting assembly for harsh and hazardous environments as well as other industrial and commercial spaces. A new integrated housing is designed that accommodates LED elements, circuit boards, drivers, and other electronic and electric components and is optimized for better thermal performance for higher ambient temperatures. For example, the single housing may accommodate LEDs and electronic boards on one side and drivers and other electrical and electronic components on the other side separated by a conducting mounting plate. This advantageously reduces the packaging size and weight of the product, making the luminaire assembly more cost-effective for manufacturing as less material is required and more desirable for confined installation sites, and provides better thermal flow path and heat dissipation. The assembly according to this disclosure also provides the added benefits of case of mounting, cleaning, servicing, and handling through a combination of features disclosed herein.
In one embodiment, a light-emitting diode (LED) luminaire assembly is provided, which comprises an integrated housing having a mounting plate mounted horizontally within the integrated housing and divides the integrated housing into an upper and lower internal cavity. A driver is mounted to the mounting plate within the upper internal cavity and configured to provide electricity to an LED assembly. The integrated housing also includes multiple fins extending radially outward from the integrated housing. Heat from the driver is dissipated through the mounting plate and fins. A driver cover is coupled to the integrated housing to form the upper internal cavity. The LED assembly is coupled to the integrated housing to form the lower internal cavity.
In particular embodiments, the integrated housing further comprises a handle. In particular embodiments, the handle extends from two or more fins of the plurality of fins. In particular embodiments, two or more of the plurality of fins are separated from one another by a through spacing. In particular embodiments, two or more of the plurality of fins are separated from one another by a leg spacing to provide an anti-rollover feature. The separation of the fins in the leg spacing is greater than the separation of the fins in the through spacing. In particular embodiments, the integrated housing comprises two anti-rollover features that are positioned 90 degrees apart from each other. In particular embodiments, the mounting plate is made of heat-conducting material. In particular embodiments, the mounting plate has a rim configured with a plurality of cut-outs. In particular embodiments, the driver cover is coupled to the integrated housing via a hinge. In particular embodiments, a maximum opening angle of the driver cover relative to the integrated housing is 128 degrees. In particular embodiments, heat from the LED assembly is dissipated through the plurality of fins. In particular embodiments, the integrated housing further comprises an occupancy sensor. In particular embodiments, the luminaire assembly further comprises one or more Internet of the Things (IoT) boards mounted within the lower internal cavity of the integrated housing. In particular embodiments, an inner surface of the integrated housing comprises a step for coupling the mounting plate to the integrated housing.
In one embodiment, an integrated housing for use with a light-emitting diode (LED) luminaire assembly is provided, which comprises a mounting plate mounted horizontally within the integrated housing and divides the integrated housing into an upper and lower internal cavity, a driver configured to provide electricity to an LED assembly and mounted to the mounting plate within the upper internal cavity, and a plurality of fins extending radially outward from the integrated housing. Heat from the driver is dissipated through the mounting plate and the plurality of fins.
In particular embodiments, the integrated housing further comprises a handle. In particular embodiments, the handle extends from two or more fins of the plurality of fins. In particular embodiments, two or more of the plurality of fins are separated from one another by a through spacing. In particular embodiments, two or more of the plurality of fins are separated from one another by a leg spacing to provide an anti-rollover feature. The separation of the fins in the leg spacing is greater than the separation of the fins in the through spacing.
In one embodiment, a method of manufacturing a light-emitting diode (LED) luminaire assembly is provided, which comprises: providing an integrated housing, the integrated housing comprising a plurality of fins extending radially outward from the integrated housing; coupling a mounting plate horizontally within the integrated housing such that the mounting plate divides the integrated housing into an upper and lower internal cavity; mounting a driver to the mounting plate within the upper internal cavity, the driver being configured to provide electricity to an LED assembly, wherein heat from the driver is dissipated through the mounting plate and the plurality of fins during operation; coupling a driver cover to the integrated housing to form the upper internal cavity; and coupling the LED assembly to the integrated housing to form the lower internal cavity.
Embodiments in accordance with this disclosure will now be described by reference to the accompanying drawings, in which:
Reference will now be made in detail to the examples which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Directional references such as “up”, “down”, “right”, and “left” are for ease of reference to the figures and not intended to limit the scope of this disclosure.
Various types of lighting fixtures utilizing LEDs have been developed for numerous types of commercial and industrial environments. More specifically, LED light fixtures have been developed for lighting tasks in harsh and hazardous environments, such as being designed to be explosion-protected. In harsh and hazardous environments, such lighting fixtures are often constructed to be, for example and not by way of limitation, shock-resistant and vibration-resistant with no filament or glass to break, for immediate start with instant full illumination, no lifetime reduction due to switching cycles, and reduced disposal costs. Dealing with heat dissipation requirements or thermal management is a problem area for LED light fixtures. Heat dissipation is difficult in part because high-luminance LED light fixtures typically have numerous LEDs operating at once in relatively small spacing from one another. Further, lighting fixture electronics (e.g., drivers, boards, etc.) are also contained with the lighting fixture and further emit heat. As a result, complex structures for LED module mounting and heat dissipation have, in many instances, been deemed necessary, which in turn adds complexity and cost to the fixtures.
Further, some known LED fixtures use heat sinks that are coupled to the fixtures and engineered to provide a path for heat to travel and remove heat from the fixtures to ensure a longer life, better lumen output, and accurate color temperature. Many of these typical LED lighting fixtures in hazardous environments are high-luminance light fixtures and generate a large amount of heat in use. Dissipating heat for LED light fixtures is typically accomplished with heat sinks that are costly for manufacturing and add system footprint as these heat sinks are stacked on the fixtures.
Luminaire assemblies that operate within hazardous environments further present a risk of explosion via ignition of surrounding gas or vapor, dust, fibers, or the like. Such hazardous environments may arise, for example, in petroleum refineries, petrochemical plants, grain silos, wastewater, treatment facilities, or other industrial facilities, wherein volatile conditions are produced in the ambient environment and present a heightened risk of fire or explosion. An occasional or continuous presence of airborne ignitable gas, ignitable vapors, ignitable dust, or otherwise flammable substances presents substantial concerns regarding safe and reliable operation of such facilities overall, including but not limited to, safe operation of the lighting fixtures within predetermined temperature limits that, if exceeded, could produce ignition sources for possible fire or explosion. As such, any lighting fixtures installed in these hazardous locations must reliably operate at a safe temperature with respect to the surrounding atmosphere. Conventional LED lighting fixtures include extensive heat sink features for dissipating heat, which may considerably complicate the lighting fixture assembly and render the manufacturing cost undesirably high. As a result, there is a need to design the lighting fixture to integrate with the heat sink to optimize the dissipation of heat in the assembly such that the lighting fixture can consistently operate at a safe temperature.
In addition to hazardous locations discussed above, so-called harsh locations also require specific focus in the design of light fixtures used therewith. Harsh locations may entail corrosive elements and the like in the atmosphere that are not necessarily explosive and/or are subject to temperature cycling, pressure cycling, shock and/or mechanical vibration forces that are typically not present in non-harsh operation environments. Of course, some locations in which LED lighting fixtures are desirably employed are both harsh and hazardous by nature, and therefore heavy-duty fixtures are designed to withstand various operating conditions that typical lighting features for other uses could not withstand.
Simpler, more reliable, and more cost-efficient LED luminaire assemblies for harsh and hazardous environments are therefore desired. A further demand is to reduce the weight and/or size of the components, and improve the durability of the lighting fixture in order to reduce the cost of manufacture while making the lighting fixtures more ergonomic for installation, repair, or replacement. Simultaneously, any reduction in size or changes in components must still meet the rigorous demands for harsh and hazardous environments, for example and not by limitation, adequate heat dissipation, corrosion-proof, flame-proof, and the like.
The embodiments disclosed herein present a new LED luminaire assembly that accommodates various lighting components in a single housing with optimized shape and size while meeting the required thermal performance for specific types of harsh and/or hazardous environments. For example, certain embodiments according to this disclosure may offer 30% weight reduction or 35% reduced packaging space. Moreover, components with lower temperature tolerance such as the LED driver may be kept thermally isolated by a unique mounting plate from heat-generating features like the LEDs to ensure proper functioning. Customers may further benefit from the case of mounting in confined spaces, cleaning, servicing, and handling through various novel structures such as a handle, one or more rollover prevention features, streamlined heat dissipation fin designs, and so forth, which will be explained in greater detail below. Other benefits of this disclosure may become apparent to those skilled in the art in light of the description, the figures, and the claims.
In particular embodiments, the luminaire assembly 10 also includes a driver cover 108 mounted to the integrated housing 110 and configured to cover an interior of the integrated housing 110. For example, the driver cover 108 may cover the driver 106 and other sensitive electronics that are housed inside the integrated housing 110 so as to protect them against the environment and enclose the upper internal cavity 706. For example, the edges of the upper internal cavity 706 may be defined by the inner edges of driver cover 108 and integrated housing 110. Additionally, a seal (not shown) such as an O-ring may be positioned along an interface between the driver cover 108 and the integrated housing 110 such that the luminaire assembly 10 is sealed tight against dust, moisture ingression, etc. Alternatively and in particular embodiments, the driver cover 108 may be coupled to the integrated housing 110 via a hinge, a snap-fit, a clipper, adhesive, or other suitable coupling feature that allows the driver cover 108 to be openable relative to the integrated housing 110, providing access to the interior of the integrated housing 110 to, for example, provide maintenance purposes or repairing or replacing the various components within the upper internal cavity 706 (e.g., the driver 106). In particular embodiments, the driver cover 108 may be provided with one or more mounting features located at a top surface of the driver cover 108 such as mounting holes or the like. For example, fasteners like screws may be inserted through the holes to secure the luminaire assembly 10 to a desired mounting site or surface, for example and not by way of limitation, a wall or ceiling within a harsh and hazardous environment.
In particular embodiments, the integrated housing 110 may comprise one or more fins 112 extending radially outward from the integrated housing 110. The integrated housing 110 may be generally cylindrical and configured to accommodate various electrical and electronic components—e.g., the driver 106—inside the integrated housing 110. In some embodiments, the integrated housing 110 may also house other components such as one or more Internet of Things (IoT) boards that enable communication between, for example and not by way of limitation, the luminaire assembly, control of lighting, smart features, or wireless technologies. An upper rim of the integrated housing 110 may be coupled to the driver cover 108, for example, in a sealed manner as described above, so as to cover the interior of the integrated housing 110. The LED assembly 102 may be attached underneath a bottom of the integrated housing 110 such that the LED assembly 102 is isolated from the driver 106. In particular embodiments, the luminaire assembly 10 also includes a driver cover 108 mounted to the integrated housing 110 and configured to cover an interior of the integrated housing 110. For example, the LED assembly 102 may cover the bottom of the integrated housing 110 to enclose the lower internal cavity 708. For example, the edges of the lower internal cavity 708 may be defined by the inner edges of LED assembly and integrated housing 110.
In particular embodiments, the fins 112 may generally be flat in shape and oriented along the radial direction of the integrated housing 110. As an example and not by way of limitation, the fins 112 may be positioned around the outer circumference of the integrated housing 110 and arranged at one or more predefined spacings from each other. Heat generated by one or more components within the luminaire assembly 10 may be dissipated to air through the spacings, as well as being directed further away from the integrated housing 110 through the fins 112. In particular embodiments, the spacing between adjacent fins 112 may be a through spacing 114, providing an open passage along an axial direction of the integrated housing 110. Specifically, the fins 112 may be designed with no neck or other lateral feature interposing between the fins 112, reducing the cross-sectional area of the luminaire assembly 10 that undesirably collects dust. Conventionally, a heat sink may be designed with complicated fin structures or include rib-like features connecting the fins, which typically extend from the integrated housing and span across the fins circumferentially. This adds complexity to the overall system and makes it difficult for manufacture and maintenance, especially for cleaning, as dust, water, or other particles may accumulate on the heat sink. The embodiments according to this disclosure contrast and improve upon conventional fin designs as it removes the intervening ribs, providing an open spacing between the fins that is easily accessible for cleaning purposes and streamlining the fin design. Configured as such, the fins 112 have the least dust or rain accumulation on the luminaire assembly at the installation site. This allows easy and fast cleaning of the product during maintenance with less amount of effort and water resources.
As further illustrated, in particular embodiments, the spacing between adjacent fins 112 may be a leg spacing 116, providing an open passage along an axial direction of the integrated housing 110. One or more leg spacings 116 may be formed between the fins 112, which separate the adjacent fins 112 at a greater distance (e.g., in a circumferential direction) than the through spacings 114. Similar to the through spacing 114, the leg spacing 116 may extend throughout along the axial direction of the integrated housing 110, e.g., to eliminate any features connecting transversely between the fins 112 that collect dust. In operation, the leg spacing 116 may provide an anti-rollover feature and work as a stand when the luminaire assembly 10 is placed on a flat surface. This reduces or avoids rollover and product falloff. This moreover enhances safety for the operator and avoids damage to the fragile components of the luminaire assembly 10 such as lens, sensor, glass, window, etc. In some embodiments, two leg spacings 116 may be provided, which are separated at 90 degrees apart from each other such that the customer may conveniently place the luminaire assembly 10 in different orientations without the risk of rollover or falloff. In other embodiments, more or less leg spacings 116 may be provided as needed or located differently without departing from the scope of this disclosure.
In particular embodiments, a handle 118 may be formed outside the integrated housing 110, which may be configured as an extension of two or more of the fins 112. As an example and not by way of limitation, the handle 118 may stem from one fin 112 across a leg spacing 116 to another adjacent fin 112 along a circumferential direction. In practice, for example, the handle 118 allows the user to carry the luminaire assembly effortlessly or hook it to a carabiner or other connectors while climbing ladder or elevator prior to installation. In addition to improving the case of handling, by integrating the handle 118 on the integrated housing 110 and connecting between the fins 112, it may also enhance heat dissipation and improve thermal performance as heat generated by the electronic components of the integrated housing 110 may be directed via the handle 118 away from the integrated housing 110 or dissipate to the air in the leg spacing 116 underneath the handle 118. In alternative embodiments, the handle 118 may be comprised of an insulating material, or covered with an insulating material to reduce the temperature of the handle and enable safe handling by workers during installation or maintenance of luminaire assembly 10 in harsh or hazardous environments.
Additionally, in some embodiments, a cable router 120 may be disposed at the outer circumference of the integrated housing 110. For example, the cable router 120 may extend between two fins 112 and includes a hole for looping safety cable therethrough or facilitating attachment of other suitable wiring features or connectors. Moreover, as illustrated, a sensor assembly 122 may be coupled to the integrated housing 110. The sensor assembly 122 may enclose one or more sensors and/or electronics that are configured to detect and measure movement, area occupancy, lighting levels, ambient temperatures, and so forth. It should be understood that while this disclosure describes and illustrates embodiments of the integrated housing 110 as having particular components such as the cable router and the sensor assembly in a particular manner, such a configuration is not necessarily a requirement. Other embodiments of the integrated housing are also envisioned with or without these features, or with various combinations of these features, and do not depart from the scope of this disclosure.
In particular embodiments, the integrated housing 110 may be integrated and manufactured as one single piece. For example, the integrated housing 110 may integrate the aforementioned individual components such as the fins, the handle, the sensor assembly, etc., into one single piece. In particular embodiments, the integrated housing 110 may be fabricated by casting. Alternatively, the integrated housing 110 may be fabricated by other manufacturing processes such as molding, additive manufacturing, or other suitable methods. In particular embodiments, the integrated housing 110 may be composed of aluminum, such as AL 8360, or may be composed of other thermally conductive material such as copper for performing the desired functions as described herein, for example, the heat dissipation and durability requirements for harsh and hazardous environments.
In particular embodiments, thickness of the base plate 602 and the wall 604 of the integrated housing 110 may be adjusted depending on the desired temperature reduction and thermal performance of the luminaire assembly 10. For example, a reduced thickness may reduce heat transferred from the integrated housing 110 to the surroundings, while an increased thickness may increase heat transferred from the integrated housing 110 to the surroundings. In particular embodiments, the wall 604 may be straight, tapered, stepped, or otherwise shaped to meet different manufacturing requirements or operation parameters.
The aforementioned features, components, and designs, when utilized either individually or in combination, contribute to and provide a luminaire assembly according to this disclosure with reduced weight and height. Specifically, for example, the luminaire assembly 10 as described in detail above may have a weight of around 13 lbs. (7L) and a height of 5 in. Even with the compact size, the luminaire assembly 10 meets thermal requirements for typical harsh and hazardous location use.
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In particular embodiments, method 2000 may begin at step 2010, where an integrated housing is provided. In a manufacturing process of the luminaire assembly 10 as depicted in
Herein, “or” is inclusive and not exclusive, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, “A or B” means “A, B, or both,” unless expressly indicated otherwise or indicated otherwise by context. Moreover, “and” is both joint and several, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, “A and B” means “A and B, jointly or severally,” unless expressly indicated otherwise or indicated otherwise by context.
The scope of this disclosure encompasses all changes, substitutions, variations, alterations, and modifications to the example embodiments described or illustrated herein that a person having ordinary skill in the art would comprehend. The scope of this disclosure is not limited to the example embodiments described or illustrated herein. Moreover, although this disclosure describes and illustrates respective embodiments herein as including particular components, elements, feature, functions, operations, or steps, any of these embodiments may include any combination or permutation of any of the components, elements, features, functions, operations, or steps described or illustrated anywhere herein that a person having ordinary skill in the art would comprehend. Furthermore, reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted to, arranged to, capable of, configured to, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, component, whether or not it or that particular function is activated, turned on, or unlocked, as long as that apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operative. Additionally, although this disclosure describes or illustrates particular embodiments as providing particular advantages, particular embodiments may provide none, some, or all of these advantages.
