This application is based upon and claims the benefit of priority from prior Japanese Patent Applications No. 2008-311217, filed Dec. 5, 2008; No. 2008-311418, filed Dec. 5, 2008; No. 2008-332886, filed Dec. 26, 2008; No. 2008-334065, filed Dec. 26, 2008; and No. 2008-334444, filed Dec. 26, 2008, the entire contents of all of which are incorporated herein by reference.
1. Field of the Invention
The present invention relates to a luminaire using a light-emitting element such as a light-emitting diode as a light source.
2. Description of the Related Art
A light-emitting diode has been increased in the light-emitting efficiency, and used as a light source. A lighting apparatus using a light-emitting diode as a light source has been commercialized as a relatively large lighting apparatus for home and office use. Jap. Pat. Applin. KOKAI Publication No. JP2008-257903 discloses a lighting apparatus comprising square panels having light-emitting diodes arranged in a checkered pattern on a ceiling. Jap. Pat. Applin. KOKAI Publication No. JP2002-117705 discloses a lighting apparatus, in which a main unit is recessed in a ceiling. This lighting apparatus comprises a main unit recessed and fixed to a ceiling, and a panel-like light source unit fixed to the side frame of the main unit with a hinge having a rod. The light source unit comprises a large number of white light-emitting diodes. Jap. Pat. Applin. KOKAI Publication No. JP2001-005409 discloses a displaying apparatus, in which a large number of displaying units using light-emitting diodes as a light source is recessed in the ceiling of arcade.
The above lighting apparatuses are reduced in weight by making a main body a thin panel by using a light-emitting diode as a light source. Since the installation operation of the lighting apparatus on a′ ceiling is required to perform in high places, the operation is difficult. Therefore, it is important to simplify the installation operation. Further, in the lighting apparatus disclosed in Jap. Pat. Applin. KOKAI Publication No. JP2008-257903, as described in paragraph [0011], the panels are installed on the ceiling by using a fixing means such as a screw, which must be removed on maintenance. Thus, the installation operation includes troublesome steps, and the lighting apparatus may not be securely installed.
As for the lighting apparatus shown in Jap. Pat. Applin. KOKAI Publication No. JP2002-117705, according to the description of paragraph [0007] and [0008], the main unit is fixed to a edge of opening on a ceiling by a common method using the elasticity of spring material. Thus, if the main unit assembled with a lighting unit is very heavy, the lighting apparatus may not be securely installed. Particularly, if the lighting apparatus is very large, the equipment may not be supported by sufficient strength. When the equipment is installed on a ceiling, the equipment is fixed to the edge of opening on the ceiling in the state in which the panel-shaped light source unit is previously fixed to the main unit. The installation operation is difficult, because the operation must be performed while supporting a relatively heavy part such as the light-emitting unit. Though a light-emitting diode is adopted as a light source, workability is not improved. Therefore, improvement of the installation operation is required.
Generally, a large-size lighting apparatus uses a large number of light-emitting diodes. A large number of lead wires connecting the light-emitting diodes to a power supply unit are liable to complexly extend. Therefore, it is important that how to connect the lead wires, how to prevent interference between a light-emitting diode and a light source unit, and how to prevent breaking of wire. In the lighting apparatus disclosed in Jap. Pat. Applin. KOKAI Publication No. JP2001-005409, according to the description of paragraph [0007], a large number of lead wires are connected in vertical and horizontal directions. The electrical wires and lead wires of the light-emitting diodes are exposed to the rear side of the light-emitting unit And disturb the installation of the lighting apparatus. Something may contact and damage or break the electrical wires. Owing to the structure, this lighting apparatus is difficult in reducing the size, and the workability in installation is not improved.
Further, in the lighting apparatus described in Jap. Pat. Applin. KOKAI Publication No. JP2001-005409, according to paragraphs [0021] and [0022], two or more panel-shaped lighting units are arranged and fixed to supporting wires. The lighting units are not connected to one another. Thus, clearance is likely to occur between the lighting units. In the lighting apparatus comprising two or more light-emitting units, if a clearance is present between adjacent light-emitting units, light may leak from the clearance. Therefore, the lighting apparatus comprising two or more light-emitting units is required to have a structure causing no clearance between adjacent light-emitting units.
A luminaire according to an embodiment of the invention is securely installed in a part, such as a ceiling, and is simplify the installation operations. The luminaire comprises a light-emitting unit, a main body frame, a support frame, and a lighting unit, for example. The light-emitting unit comprises light-emitting elements. The main body frame supports the light-emitting unit, and is formed rectangular having a hook-shaped engaging piece on one side. The support frame is formed square surrounding the outer periphery of the main body frame, and has a groove-shaped receiving place to engage with the engaging piece of the main body frame, on one internal side. The lighting unit turns on the light-emitting elements.
The light-emitting unit comprises a base substrate, a reflector, and a terminal unit. The base substrate is a plate, on which two or more light-emitting elements are mounted. The reflector is attached on the side of the base substrate, on which the light-emitting elements are mounted, and has a reflection surface formed by slopes surrounding each light-emitting element. The terminal unit is mounted on the base substrate, and connected to the light-emitting elements.
The lighting unit comprises a case, and a lighting circuit. The case is fixed to the support frame, and is suspended from a ceiling with a suspension bolt. The lighting circuit is housed in the case. In this case, the case comprises a top plate, a side plate which continued from the top plate, and a support port which is opened across the top plate and side plate. The support port comprises a hitching part, and a entering part. The hitching part is provided in the top plate, and is formed to permit insertion of the suspension bolt and not to permit insertion of a nut to be attached to the suspension bolt. The entering part is provided in the side plate continuing to the hitching part, and is formed to permit insertion of the nut attached to the suspension bolt.
The lighting circuit has a power cable extending from a side in which the case and the support frame are jointed. The light-emitting unit has a lead wire extending from the terminal unit arranged on the side having the engaging piece. The power cable is connected to the lead wire. The support frame has two or more spots to assemble the case along the corresponding side.
The luminaire further comprises an engagement unit to hold the main body frame inside the support frame. The engagement unit consists of a stopper piece, and a lock mechanism. The stopper piece is provided in one of an outer peripheral edge of the main body frame opposite to a side having the engaging piece, and an inner peripheral edge of the support frame adjacent to the outer peripheral edge. The stopper piece moves relatively to the main body frame and support frame, and engages them. The lock mechanism holds the stopper piece at a position to engage the main body with the support frame.
The engagement unit may further comprise a shaft having a stopper piece, and a bearing capable to rotationally move the stopper piece about the shaft. In this case, the lock mechanism is provided between the shaft and bearing, and holds the stopper piece to a rotational position where the main body frame engages with the support frame.
When the light-emitting unit has a plurality of the base substrates, each terminal unit of the base substrates is arranged in a cavity surrounded by the reflector and base substrate. The terminal units provided on adjacent base substrates are connected through connecting lead wires arranged in the cavity.
When the light-emitting unit has a plurality of the reflectors, each reflector has a jointing piece extending perpendicularly from the outer periphery to the base substrate. The reflectors are arranged so that the jointing pieces are opposed to each other and the adjacent outer peripheries are fit. The jointing pieces of the adjacent reflectors are united with each other by a fastening means which determines the relative positions and fastens the jointing pieces. The luminaire configured as above is easy to install in an installation place on a ceiling.
In the invention, the luminaire is preferably applied to relatively large luminaire installed on a ceiling, such as luminaire for home, office and other facilities. The luminaire of the invention may be applied to small luminaire. The luminaire of the invention may also be applied to luminaire, which is recessed in an appropriate installation site on a ceiling, or directly assembled to a ceiling.
In the invention, the light-emitting element may use a semiconductor such as a light-emitting diode, an organic electroluminescence (EL), and semiconductor laser, as a light-emitting source. An incandescent lamp such as a small halogen lamp or a small cold cathode fluorescent lamp may be used as a light-emitting source, as long as it can form a flat light-emitting unit. The light-emitting element is not limited to a white light-emitting element. According to the purposes of the luminaire, red, blue or green light-emitting element may be used, or these colors may be combined.
Necessary number of light-emitting elements of the light-emitting unit are selected and arranged on a substrate. The whole figure of the unit is square or rectangular, and forms a flat surface light source. The light-emitting unit comprises sixteen light-emitting element groups, for example. The light-emitting unit may comprise one or more, four for example, light-emitting element groups. The shape of the light-emitting unit may be selected from rectangle shape which include a linear long bar, round shape which is circle or ellipse, or polygonal shape which is hexagon or octagon.
The light-emitting unit may have a reflector to reflect light from a light-emitting element, for example. The light-emitting unit may be provided with a transmissive plate made of opaque or translucent synthetic resin or reinforced glass, on the front side of the light-emitting unit to cover the light-emitting element. A lattice-shaped light control unit may be provided on the front side of the light-emitting unit.
The main body frame supports the light-emitting unit on the inner peripheral side, and forms a square equipment body together with the light-emitting unit. The main body frame is preferably made of heat-resistant weather-resistant insulating synthetic resin, such as polybutylene terephthalate (PBT). The main body frame may be made of a steel plate or metal such as stainless steel or lightweight material, such as aluminum, with high heat conductivity, considering heat radiation performance.
The equipment main body comprises a main body frame and a support frame. The equipment main body may be a housing comprising a single piece. The structure connecting the main body frame to the support frame is configured to be easily removed by engaging a engaging piece of the main body frame with a groove of the support frame. The structure connecting the main body frame to the support frame may be an ordinary hinge or a permanently-set hinge mechanism.
The base substrate is a part to mount light-emitting elements. Therefore, as the light-emitting unit is formed linear, round or polygonal, the base substrate is formed to meet the shapes of the light-emitting units. The base substrate shall be formed to meet the equipment main body, and may not correspond to the shape of the light-emitting unit.
The engaging piece is made in the form of a hook projecting on one side of the rectangular main body frame, and is preferably formed in one piece with the main body frame made of synthetic resin, for example. A separate hook-shaped metallic engaging piece may be provided to one side of the main body frame.
The lighting unit consists of a lighting circuit, which converts ac 100V into dc 24V, and supplies the converted dc voltage to a light-emitting diode, for example. The lighting unit includes a case member to install the lighting circuit. The lighting unit is allowed to be supported by the equipment main body.
Once the lighting unit is assembled to the support frame, the lighting unit is installed together with the support frame when the support frame is installed on a ceiling. This facilitates installation of the luminaire. The length of the lead wire used for wiring and connecting the lighting unit and light-emitting unit can be reduced, when the terminal unit of the lighting unit is provided close to the engaging piece of the main body frame. Since the lead wire does not disturb the installation and maintenance operations for the luminaire, the operations become easily.
The engagement unit moves the stopper by the rotational operation, and engages the main body frame with the support frame. This facilitates the operation of assembling the main body frame and support frame. The engagement unit is configured to engage the frames by two or three times of simple rotational operation or sliding operation. The lock mechanism to control the movement of the stopper may be configured to fit a projection into a recess, or to fit a projection into a hole or groove, so as to release the locking. The lock mechanism is configured not only to control movement, but also to release the locking. However, when the installation operation is given priority, the lock mechanism needs not to be releasable. The lock mechanism may not have a release function.
The base substrate comprises a substrate and a circuit board. The substrate is made of synthetic resin, or metal with high heat conductivity, such as steel, aluminum and copper. The circuit board is a part to mount light-emitting elements. The circuit board may be made of metal such as copper and aluminum, or nonmetal such as glass epoxy material, paper phenol material, and glass composite. The circuit board may also be made of ceramics when the cost is reasonable. Further, the base substrate may comprise a circuit board only. A light-emitting diode chip as a light source is mounted on a wiring pattern formed on the circuit board. A specific means is not used for forming and mounting the circuit board.
The support frame supports the main body frame on the inner periphery, and forms the square luminaire together with the light-emitting unit and main body frame. Heat-resistant weather-resistant insulating synthetic resin, such as polybutylene terephthalate (PBT), is suitable for material of the support frame, like the main body frame. The main body frame may be made of a steel plate or metal such as stainless steel or lightweight aluminum with high heat conductivity, considering radiation performance.
The receiving place is formed as a groove on each side, or four inner sides, of the square support frame. The receiving place may be formed only on one side, not on all of the four sides of the support frame. The receiving place may also be formed in one piece with the synthetic resin support frame, or a separate groove-shaped metallic member may be attached to each side of the support frame.
The reflector is optically designed to be able to obtain desired light distribution. The reflector is configured to have a reflection surface covering the area around the light-emitting element to obtain light distribution rotationally symmetric with respect to the center axis of the light-emitting element. The reflection surface is a side of so-called square pyramid, or a concave side of a conical having a rectangular opening shape. On the rear side of the reflection surface, a cavity having a triangular vertical cross-section is formed. The reflection surface may be formed as a concave of a conical having a circular shape of opening. In this case, on the rear side of a curved and inclined bowl-shaped reflection surface, a corresponding cavity is formed. The reflection surface is not limited to a specific shape.
As a material of reflector, heat-resistant weather-resistant insulating synthetic resin, such as polybutylene terephthalate (PBT), acrylic, or acrylonitrile-Butadiene-Styrene (ABS) is used considering radiation performance. A reflector is formed in one piece. The surface of the reflector may be painted white, or mirror finished, or semi-mirror finished by evaporating or plating metal such as aluminum and silver. Further, the reflector may be made of metal such as aluminum and copper, and may be painted white, evaporated, or plated.
The reflector may be provided in the number corresponding to the number of light-emitting elements, or the number of light-emitting element groups. Reflectors formed separately may be combined to obtain the same light distribution. Reflectors with different light distribution may be combined. One common reflector may be provided for one or more light-emitting elements or light-emitting element groups. The reflector is arranged so that it is layered on the base substrate. The reflector is combined with a light-emitting element and base substrate, forming a light-emitting unit as a module.
For example, when four reflectors constitute a reflection unit, the jointing pieces of adjacent reflectors are diagonally placed at the corners of each reflector. Each jointing piece is formed as a ¼-divided part of a cylinder so that four jointing pieces form one cylinder when they are combined. The shape of a jointing piece may be rectangular or polygonal, and the shape of combined jointing pieces may be a square or polygonal column. The shape of a jointing piece may not be a perfect circle in cross section when it is combined with other jointing pieces. Clearance is allowed between jointing pieces. Namely, a jointing piece may have any form as long as no clearance exists between adjacent reflectors when combined with other jointing pieces. A jointing piece may be formed in one piece with the reflector, or may be separately formed and attached to the corners of a reflector.
The terminal unit connected to the light-emitting element is configured to electrically connect the lead wires, which supply electrical power to the light-emitting elements, provided on the base substrate. The light-emitting element and terminal are connected by using a connector on a wiring pattern formed on the base substrate. The lead wires may be directly soldered or screwed to the wiring pattern. Wires may be directly connected to the light-emitting elements without using a wiring pattern.
The lead wires are used to connect the terminal unit to the light-emitting unit As a power supply, or to connect adjacent light-emitting units. The lead wires and terminal unit are connected through the above-mentioned connector. The lead wires may be directly connected to the wiring pattern on the base substrate by soldering and or screwing. The lead wires connected to the terminal unit are housed in the cavity formed between the reflector and base substrate. The lead wires may be completely or partially housed in the cavity, as long as the lead wires do not disturb the installation operation.
When the light-emitting unit having a plurality of the base substrates is used in one luminaire, the terminal unit is located in the cavity formed between the reflector and base substrate. The terminal units are connected with lead wires arranged in the cavity. Therefore, the lead wires are not exposed to the rear side of the luminaire.
A fastening means unites adjacent reflectors by bundling the jointing pieces, and determines the relative positions of the reflectors. A fastening means may use a circular jointing ring made of metal or synthetic resin. The jointing ring gathers the jointing pieces by bundling them. The jointing ring may be a C-shaped incomplete ring spring member. A fastening means may use a wire or string for bundling and uniting the jointing pieces. These fastening means may be attached assuming later removal. When the jointing pieces are bonded by adhesive means, the adhesive means is included in the fastening means. The above-mentioned fastening means may be combined. Clearance between the reflectors is allowed as long as it comes within an allowable range of light leakage, or it does not spoil the appearance of the equipment.
When the light-emitting unit having a plurality of the reflectors is used in one luminaire, the reflectors can be easily assembled without clearance by bundling the jointing pieces by the jointing ring. Therefore, the reflectors do not leak light.
As cavities formed in the reflectors are combined, a cavity formed between the reflector and base substrate at the junction of adjacent reflectors may be larger than a single cavity. A cavity may be formed only in one reflector. Adjacent reflectors are preferably joined without clearance from the viewpoint of the equipment appearance. Clearance between adjacent reflectors is allowed as long as it does not spoil the appearance of the equipment.
When the case of the lighting unit has a support port which includes a entering part and a hitching part, the luminaire can be securely installed in an installation site on a ceiling, and the installation workability is improved. The position to attach the case of the lighting unit to the support frame can be selected from two or more positions. This provides excellent workability in the luminaire.
The luminaire comprising the stopper piece and lock mechanism as the engagement unit can securely engage the equipment main body with the support frame. The equipment main body can be engaged with the support frame by a simple operation, when the stopper piece is configured to be rotationally movable. The stopper piece is not carelessly moved, and the engagement unit is not released, when the lock mechanism is provided.
In the luminaire, in which the terminal unit and lead wires are arranged in the cavity between the reflector and base substrate, the lead wires can be easily handled, and the lead wires do not disturb the installation operation. Further, by arranging the reflectors flatly along the base substrate, a larger light-emitting unit can be formed. The terminal units provided in the reflector and the lead wires connecting the terminal units are housed in the cavity formed at the junction of adjacent reflectors. As the lead wires are not exposed, the lead wires are easy to handle, and improves the workability of installing the luminaire.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
A luminaire 10 according to a first embodiment of the invention will be explained with reference to
A luminaire 10 is a recessed ceiling type made in the form of a flat square panel. As shown in
The light-emitting element 11 comprises a light-emitting diode (LED), and a fluorescent substance. In this embodiment, the light-emitting element comprises a blue LED chip, and a yellow fluorescent substance excited by the LED chip, and emits white high power light. The light-emitting unit A comprises a base substrate 11a, a reflector 11c, and a terminal unit 40, as shown in
The base substrate 11a is made of heat-resistance weather-resistant insulating synthetic resin, white polybutylene terephthalate (PBT) in this embodiment, and is molded as a square flat plate. The base substrate 11a may comprise a glass epoxy or aluminum substrate. The light-emitting elements 11 are mounted on the front surface of the base substrate 11a. The light-emitting elements 11 are arranged in square, four each in vertical and horizontal directions, total 16 pieces. Four base substrates of the same shape are combined. As shown in
The reflector 11c is provided on the front surface of the base substrate 11a, on which the light-emitting elements 11 are mounted. The reflector 11c is made of heat-resistant insulating synthetic resin, white polybutylene terephthalate (PBT) in this embodiment. As shown in
As shown in
The reflector 11c is molded in one piece with sixteen concave portions 11d corresponding to each light-emitting element 11. As shown in
The reflector 11c is configured to have a reflection surface 11h on the inside surface of the square conical-shaped concave portion 11d, to obtain light distribution rotationally symmetric with respect to the center axis of the light-emitting element 11. The reflection surface 11h covers the part surrounding the light-emitting element 11, and extends to the square exit port 11f. The reflection surface 11h may be mirror finished by evaporating or plating aluminum or silver.
Four square base substrates 11a and reflectors 11c configured as described above form a square light-emitting unit A, that is a light-emitting unit, as shown in
The base substrate 11a is positioned on the radiator plate 11j by the brim 11k. The reflector 11c is applied to the front side of the base substrate 11a. The reflector 11c is fastened to the base substrate 11a from the rear side of the radiator plate 11j with a screw, so that the bottom of the reflector closely contacts the surface of the base substrate 11a. The reflector 11c may be attached to the front surface of the substrate 11a with heat-resistant insulating adhesive made of silicon resin or epoxy resin. The square flat light-emitting unit A, which has the light-emitting elements 11 as a light source, is configured as described above.
The main body frame 14 is made of metal with high heat conductivity, white painted aluminum in this embodiment, and is formed in one piece with a square frame body 14a. The frame body 14a is sized to contain the light-emitting unit A. The equipment main body B of the square luminaire is constructed by inserting the light-emitting unit A into the main body frame 14. The main body frame 14 is formed in one piece with an outer flange 14b that is an ornamental frame projecting outward, on four outer sides the frame body 14a. The outer flange 14b has a hook-shaped projecting engaging piece 14d on one side, as shown in
The main body frame 14 has an engagement unit 14e at substantially the middle of the side opposing the side on which the engaging piece 14d is formed, as shown in
As shown in
The screw head 14e3 has a groove to rotate the stopper 14e1. As long as the stopper 14e1 can be rotated, the shape of the groove may be linear or cross, or may be a hexagonal hole or a particular shape corresponding to a specific jig. By making the screw head in the form not applicable to a common tool, operation by a third person can be prevented.
The projection 14e4 and recess 14e6 form a lock mechanism 141 as shown in
The metallic shaft of the stopper 14e1 is inserted into the bearing 14e2 through a penetrated hole 14m formed in the outer flange 14b of the main body frame 14. When the screw head 14e3 is turned, the stopper piece 14e5 is separated from the side plate 14k of the main body frame 14, and engages with the inner flange 16b of the support frame 16. At the same time, the projection 14e4 of the lock mechanism 141 is rotated. At this time, the resin-made bearing 14e2 is bent by its own elasticity. In the state in which the stopper piece 14e5 engages with the inner flange 16b, the projection 14e4 fits in the recess 14e6 of the bearing 14e2. As a result, the rotation of the stopper 14e1 is controlled, and the stopper is locked.
The inner flange 14n is formed in one piece with the main body frame 14 in the inner periphery of the frame body 14a as shown in
The luminaire 10 of this embodiment comprises a transmissive plate 18 and a light control unit 19 as shown in
The support frame 16 is provided in an installation site on a ceiling as shown in
The support frame 16 has an inner flange 16b in the frame body 16a, which is formed in one piece of the support frame and extended inward. The distal end portion of the inner flange 16b is formed in one piece with a step 16c, as shown in
The groove-shaped receiving place 16d engages with the engaging piece 14d of the main body frame 14 as shown in
The support frame 16 and main body frame 14 are shaped square. The receiving place 16d is formed on four sides of the support frame 16. Therefore, the engaging piece 14d of the main body frame 14 can engage with any receiving place 16 on any side. The support frame 16 has a steel-plate mount piece 16g on a pair of opposing side plates 16f as shown in
The lighting unit 17 comprises a lighting circuit 171 and a case 17a. The lighting circuit 17a converts ac 100V into dc 24V, and supplies it to a light-emitting diode chip. The ac voltage and converted dc voltage supplied to the lighting circuit are not limited to the above valves. The voltage values are different in countries and localities where the luminaire 10 is installed, or the conditions of using the luminaire 10.
As shown in
The case 17a formed as above is supported by suspension bolts 20 and nuts 21 as shown in
The side plate 17c has a connecting hole 17g in the lower part of the entering part 17e. The case 17a holding the lighting circuit 171 is located across the side plates 16f provided on the opposite sides of the support frame 16, as shown in
Further, as shown in
As described above, the luminaire 10 comprising a light-emitting unit A, a main body frame 14, a support frame 16, and a lighting unit 17 is installed on a ceiling X that is an installation place in the procedures shown in
First, as shown in
After the suspension bolt 20 is inserted into the support port 172, the support frame 16 is adjusted to the hole h. At this time, the installation position is adjusted by sliding the support frame 16 to the suspension bolt 20 in the range of the hung-up part 17f of the case 17a, so that the jagged inner inside edge of the hole h is hidden by the outer flange 16e, which becomes an ornamental frame of the support frame 16. As a result, the installation position of the support frame 16 to the ceiling X is determined. After the installation position of the support frame 16 is determined, two nuts 21 of each suspension bolt 20 are tightened so as to hold the case 17a from the upper and lower sides. As a result, the case 17a is secured to two suspension bolts 20. In the above procedure, the support frame 16 is supported by the support member 30 on the backside of the ceiling through the case 17a of the lighting unit 17, as shown in
The lighting unit 17 is attached across two sides of the support frame 16, crossing over the frame body a. Therefore, as shown in
Next, the main body frame 14 is raised, and the engaging piece 14d is engaged with the receiving place 16d of the support frame 16. As the receiving place 16d is formed on four sides of the square support frame 16, the engaging piece 14d of the main body frame 14 can engage with any lock mount 16d. Therefore, it is possible to engage appropriate engaging piece 14d with suitable receiving place 16d, according to conditions such as obstacles around the ceiling X. As described above, the main body frame 14 is suspended from one side of the support frame 16. The light control unit 19, transmissive plate 18, and light-emitting unit A are inserted in this order into the frame body 14a of the suspended main body frame 14, and held by a holding member. As a result, the light-emitting unit A is assembled in one piece with the main body frame 14 as shown in
The terminal unit 17j led out from one side of the case 17a of the lighting unit 17 is connected to the connector 12c attached to the distal end of the lead wire 41 of the light-emitting unit A. When the wiring of the lighting unit 17 and light-emitting unit A is done close to the hinge C, the lead wire 41 of the light-emitting unit A can be educed. The wire connecting operation can be done while the main body frame 14 is being suspended from the support frame 16, and improving the workability.
The hinge C is constructed by engaging the engaging piece 14d with the receiving place 16d. The main body frame 14 is rotationally moved about the hinge C, the center of axis, in the direction of pushing up the hinge C as indicated by the arrow in
The main body frame 14 makes the engagement unit 14e provided on the side opposite to the hinge C contact with the flange 16b of the support frame 16. As shown in
The projection 19e4 of the lock mechanism 141 fits in the recess 14e6 of the bearing 14e2 and the rotational movement of the stopper 14e1 is limited as shown in
The edge of the opening on the ceiling X is covered by the outer flange 162 of the support frame 16 as shown in
The heat generated from the light-emitting elements 11 during lighting of the luminaire 10 is radiated from the base substrate 11a to the outside through the steel-plate radiator 11j. The heat from the lighting unit 17 is radiated through the steel-plate case 17a and aluminum support frame 16. This prevents lowering of the light-emitting efficiency of the light-emitting diodes constituting the light-emitting elements 11. In other words, the luminaire 10 can prevent lowering of light flux accompanying with a temperature increase. The service life of the light-emitting diodes is increased, and the reliability of the circuit components of the light-emitting unit 17 is improved.
The light-emitting unit A is removed in the following procedures, when the light-emitting unit A is removed for maintenance of the light-emitting elements 11 as a light source or other parts. First, as shown in
When the engagements are completely released, the main body frame 14 is rotationally moved about the center of axis of the hinge C, in the direction reverse to the arrow shown in
First the holding member is removed, and the light-emitting unit A is removed from the main body frame 14, when the light-emitting unit A is removed from the main body frame 14 in the state in which the main body frame 14 is being suspended from the support frame 16. When the light-emitting unit A is removed together with the main body frame 14, the main body frame 14 is turned farther from the state shown in
Further, when the luminaire 10 is replaced, first the equipment main body B is removed from the ceiling X as described above, and then the support frame 16 and lighting unit 17 are removed from the ceiling X in the procedures reverse to the installation. In particular, the nuts 21 of the suspension bolts 20 are loosen, one of the suspension bolts 20 is curved, and slid from the hitching part 17f to entering part 17e of the case 17a. One of the suspension bolts 20 is removed from the case 17a by passing the nut 21 through the entering part 17e. The case 17a is slid for the other suspension bolt 20, after the one of the suspension bolts 20 is removed. The nut 21 is through the entering part 17e, and the other suspension bolt 20 is removed from the hitching part 17f. The lighting unit 17 can be removed together with the support frame 16 in being attached to the support frame. The operation of removing the support frame 16 and lighting unit 17 can be performed while monitoring the states of the suspension bolts 20 and nuts 21 through the opening a of the support frame 16.
As described above, according to this embodiment, the luminaire 10 comprises the main body frame 14 to house the light-emitting unit A, and the support frame 16 to hold the main body frame on a ceiling, which are formed as separate disassembling parts. The main body frame 14 has a hook-shaped engaging piece 14d on one side of the square frame body 14a shaped. The support frame 16 has a groove-shaped receiving place 16d to engage with the engaging piece 14d on each side of the square frame body 16a. First, only the support frame 16 is installed on the ceiling X, and then the main body frame 14 combined with the light-emitting unit A is installed, when the luminaire 10 is installed. The installation operation can be performed while monitoring the situation of the backside of the ceiling and the states of the suspension bolts 20 and nuts 21 through the opening a of the support frame 16. The main body frame 14 and support frame 16 can be separately installed. Hence the installation operation is light and easy.
The main body frame 14 is jointed to the support frame 16 by engaging the engaging piece 14d with the receiving place 16d of the previously installed support frame 16. The light-emitting unit A can be installed in the main body frame 14 being suspended from the support frame 16. As described above, when the luminaire 10 is installed on a ceiling, first the support frame 16 made of light material such as synthetic resin or light metal such as aluminum is installed, and then equipment main body B combined with the light-emitting unit A and main body frame 14 is installed. In a conventional luminaire formed in one piece, a relatively light part such as a lighting unit must be supported until a luminaire is completely installed and suspended from a ceiling.
The luminaire 10 of this embodiment facilitates installation on an installation site such as a ceiling. In particular, the luminaire 10 adopting a light-emitting diode as a light source is light in weight and excellent in workability in installation.
Further, the support frame 16 has a receiving place 16d on four sides of the square frame body 16a, as shown in
The engaging piece 14d and receiving place 16d are shaped long along one side of the frame body 14a and 16a of the main body frame 14 and support frame 16 as shown in
The case 17a of the lighting unit 17 is attached to the support frame 16 as shown in
In the luminaire 10 of this embodiment as shown in
The case 17a is supported across the support frame 16. An opening a is formed on both sides of the lighting unit 17. The states of the suspension bolt 20 and nut 21 can be checked and adjusted through the opening a by inserting a hand.
Further, the luminaire 10 is provided with the engagement unit 14e in the main body frame 14 opposite to the hinge C as shown in
The engagement unit 14e has a lock mechanism 141 which shown in
The engagement unit 14e shown in
In the luminaire 10 of this embodiment, the receiving place 16d of the support frame 16 is provided on all of four sides of the frame body 16a as shown in
The plurality of the screw hole 16h of the mount piece 16g attached to the side plate 16f located on the opposing side of the support frame 16 are provided, three screw holes 16h are provided in this embodiment, as shown in
For example, the screw hole 16h is chosen to assemble the lighting unit 17 at the position indicated by a broken line in
Further, as shown in
In this case, the hinge C supporting the main body frame 14 rotationally movable with respect to the support frame 16 is provided on the higher side or lower side of the inclination of the ceiling X as shown in
The engagement unit 14e is not limited to the rotationally movable mechanism shown in
The stopper piece 14e5 may slide, and engage the main body frame 14 with the support frame 16 as shown in
Further, the engagement unit 14e may be provided in the support frame 16 as shown in
The lock mechanism 141 may have a projection 14e4 and a recess 14e6 as shown in
In the lock mechanism 141 of this embodiment, the projection 14e4 is formed in the metallic stopper 14e1, and the recess 14e6 is formed in the bearing 14e2 by opening a small hole. The small hole or groove-shaped recess 14e6 may be formed in the metallic stopper 14e1 or a slidable piece 14e5′, and the projection 14e4 may be formed inside the bearing 14e2 or guide hole 14e7. The lock mechanism 141 is configured to engage/disengage the projection 14e4 with/from the recess 14e6 by the elasticity of the member itself.
When the bearing 14e2 and stopper 14e1 are made of metal, the projection 14e4 formed in the stopper 14e1 consists of a metallic ball. The ball is always energized in a projecting direction by a coil spring, and is configured to engage/disengage with/from the recess 14e6 of the bearing 14e2. The lock mechanism 141 secures engagement/disengagement, and clicks when engaging. Therefore, a slidable and highly operable engagement unit can be constructed.
In the above description, the equipment main body B is square, and comprises the light-emitting unit A and main body frame 14, and the support frame 16 supporting the equipment main body. The front side shape of the luminaire 10 may be circular as shown in
A luminaire 10 according to a second embodiment of the invention will be explained with reference to
As shown in
As shown in
The radiator plate 11j is made of metal with high heat conductivity, such as a steel plate and aluminum. In this embodiment, the radiator plate 11j is made of a steel plate. The radiator plate 11j is formed in size equivalent to two or more circuit boards 11a1 arranged along the same plane. In this embodiment, the radiator plate 11j is formed in square of the size equivalent to four circuit boards 11a1 arranged in square. The radiator 11j has a brim 11k formed by raising the parts opposing to the sides of the circuit board 11a1 in one piece.
The electrical insulating plate 11a2 is inserted between the circuit board 11a1 and radiator plate 11j. The electrical insulating plate 11a2 is a film-like insulating sheet made of heat-resistant insulating silicon resin or epoxy resin. The electrical insulating plate 11a2 is shaped square to be fit inside the brim 11k of the radiator plate 11j.
The reflector 11c is arranged on the front surface of four circuit boards 11a1 provided with the light-emitting elements 11. Four reflectors 11c have the same optical design to have desired light distribution. The reflector 11c is made of heat-resistant weather-resistant insulating synthetic resin in the form of a square part having the same dimensions as the circuit board 11a1. In this embodiment, the reflector 11c is made of white polybutylene terephthalate (PBT).
The reflector 11c has a square pyramid concave portion 11d corresponding to the number of light-emitting elements 11, and is formed like a so-called waffle. In other words, conical-shaped or funnel-shaped concave portions 11d are arranged corresponding to the light-emitting elements 11, as shown in the cross section of
A part corresponding to the upper contour of the concave portion 11d forms a square exit port 11f to emit the light from the light-emitting element 11 to the outside. The reflector 11c comprises sixteen concave portions 11d made of polybutylene terephthalate (PBT) and formed in one piece correspond to each light-emitting element 11 of one circuit board 11a1. Each concave portion 11d is formed surrounding the light-emitting element 11. The inside surface of the concave portion 11d forms a reflection surface 11h as shown in
The wall forming the reflection surface 11h is made to have substantially the same thickness in any portion as shown in
As shown in
Four pieces of electrical insulating plate 11a2 and circuit board 11a1 are positioned by the brim 11k and mounted on the radiator plate 11j. Four reflectors 11c1 are arranged on the exit side of the circuit board 11a1, and fixed to the circuit board 11a1 with a screw from the rear side of the radiator plate 11j. The circuit board 11a1 and reflector 11c may be bonded by heat-resistant insulating adhesive, such as silicon resin and epoxy resin.
Sixteen light-emitting elements 11 are connected in series according to a wiring pattern one the rear side of the circuit board 11a1. Four circuit boards 11a1 are connected in series by the lead wire 41 as shown in
The connector 40 is an example of terminal unit, and is connected to the input terminal of the wiring pattern. The connector 40 is a small connector 40 in this embodiment. The connector 40 is removably fixed to the front side of the circuit board 11a1. The connector 40 is placed in the cavity 11g to be placed between adjacent light-emitting elements 11 as shown in
The lead wire 41 connecting the connectors 40 of each circuit board 11a1 in series is wired as follows. First, as shown in
Four reflectors 11c are layered on each circuit board 11a1 so that they are mounted along one plane. As a result, as shown in
As shown in
The luminaire 10 of the second embodiment comprises an equipment main body B, a support frame 16, an engagement unit 14c, and a lighting unit 17, as shown in
The main body frame 14 is made of metal with high heat conductivity, white painted aluminum in the second embodiment, and is formed in one piece with a square frame body 14a. The frame body 14a is sized to house the light-emitting unit A inside as shown in
The luminaire 10 of the second embodiment comprises a transmissive plate 18 and a light control unit 19, as in the luminaire 10 of the first embodiment, as shown in
The light-emitting unit A, transmissive plate 18, and control unit 19 are held in the frame body 14a by the support member 30 that is a holding member, as shown in
The proximal end of the support member 30 is fixed to the side plate 14k of the main body frame 14 as shown in
When the wire 30a is rotationally moved, the distal end of the wire 30a extending radially from the center of rotation is moved along the inclined circular orbit. As a result, by sliding the proximal end 30b of the support member 30 and rotationally moving the wire 30a, the distal end of the wire 30b is moved outward from the center of the radiator plate 11j, and displaced in the direction of pushing the radiator plate 11j down to the circuit board 11a1. The three small holes 32a, 32b an 32c shown in
The luminaire 10 is provided with a mechanism which changes the position of the distal end of the support member 30 in the thickness direction of the main body frame 14, that is, in the light emission direction. This permits use of the reflector 11c, transmissive plate 18 and light control unit 19 with different dimensions in the light emission direction. As shown in
The main body frame 14 has an engagement unit 14e to engage the main body frame 14 with the support frame 16, on the side plate 14k of the frame body 14a that is the side opposite to the side forming the engaging piece 14d as shown in
The luminaire 10 configured as above is installed on a ceiling as shown in
The luminaire of this embodiment comprises a support member 30. As shown in
The connector 12c provided in the end portion 31b of the lead wire 41 led out from the light-emitting unit A is connected to the terminal unit 17j of the lighting unit 17. As the lighting unit 17 and light-emitting unit A can be wired and connected in the hinge C, the lead wire 41 of the lighting unit may be short and does not disturb the installation operation. Further, operation of assembling the light control unit 19, transmissive plate 18 and light-emitting unit A to the main body frame 14, and the operation of wiring and connecting the terminal unit 17j to the connector 12c can be performed in the state in which the main body frame 14 is pulled out and suspended from the support frame 16. This makes the operation visible, and improves the workability.
When the light-emitting unit A as a light source is removed for replacement or maintenance, the procedures reverse to installation of the luminaire are used as same as the first embodiment. In this case, the support member 30 has been combined with the luminaire 10 of the second embodiment. Therefore, first the wire 30a of the support member 30 holding the light-emitting unit A as shown in
When the light-emitting unit A is removed together with the main body frame 14, first the connector 12c is separated from the terminal unit 17j, and as shown in
In the luminaire 10 of this embodiment, a cavity 11g is formed between the circuit board 11a1 provided with the light-emitting element 11 and the reflector 11c covering the area around the light-emitting element 11. By arranging two or more reflectors 11c, a tunnel 11G of the size of combined cavities 11g is formed at the junction Q of adjacent reflectors 11c.
The connector 40 is located between adjacent light-emitting elements 11 in the tunnel 11G. Therefore, the connector 40 does not contact the light-emitting elements 11 and energized parts. The lead wire 41 connected to the connector 40 is housed in the tunnel 11G. The lead wire 41 does not interfere with the light-emitting elements 11 and energized parts. As the connector 40 and lead wire 41 do not interfere with the light-emitting elements and energized parts on the circuit board 11a1, the reflector 11 can tightly contact the circuit board 11a1. As the light emitted from the light-emitting element 11 does not leak to the rear side of the reflector 11c, lighting loss of the luminaire 10 is eliminated.
Further, the lead wire 41 is led from one side of the frame body 14a opposing the light-emitting unit A, and does not interfere with the reflector 11c and light-emitting elements 11. Space for housing the lead wire 41 is unnecessary, and the light-emitting unit A can be made compact. The connector 40 is adjoined to the junction P of circuit boards 11a1, and arranged opposing to the connection terminal 40a. This increases the efficiency of wiring the lead wire 41. The lead wire 41 connecting adjacent circuit boards 11a1 is housed in the tunnel 11G that is normally a dead space. As a result, the lead wire 41 is neatly wired for the light-emitting unit A, and the workability of installation and maintenance is improved.
In the luminaire 10 of this embodiment, cavities 11g are combined at the junction Q of reflectors 11c, forming a tunnel 11G having an isosceles triangular cross section. As shown in
Next, a luminaire according to a third embodiment of the invention will be explained with reference to
As shown in
The radiator plate 11j is made of metal with high heat conductivity, such as a steel plate and aluminum. In this embodiment, the radiator plate 11j is made of a steel plate. The radiator plate 11j is formed in square of the size equivalent to four circuit boards 11a1 arranged in square. The radiator 11j has a brim 11k raised in one piece toward the circuit board 11a1 as shown in
One electrical insulating plate 11a2 is inserted between four circuit boards 11a1 and a radiator plate 11j. The electrical insulating plate 11a2 is a film-like insulating sheet made of heat-resistant insulating silicon resin or epoxy resin. The electrical insulating plate 11a2 is shaped square to be fit inside the brim 11k of the radiator plate 11j.
A reflection unit R comprises four reflectors 11c as shown in
Each reflector 11c has a jointing piece 11g3 extending perpendicularly from the outer periphery to the base substrate 11a. In this embodiment, as shown in
Four reflectors 11c are arranged flatly in 2-row and 2-column square along the base substrate 11a. The corners 11g1 provided with a jointing piece 11g3 are butted against at the center of the base substrate 11a. The jointing pieces 11g3 of the reflectors 11c are joined in the outer peripheral side 11g2, and bound to form one cylinder. The bound jointing pieces 11g3 are united in one piece by a fastening ring 11g4 that is a fastening means, as shown in
In the luminaire 10, the light-emitting unit A is assembled in the following procedure. First, the electrical insulating plate 11a2 is attached inside the brim 11k of the radiator plate 11j. Next, four circuit boards 11a1 are positioned for the radiator plate 11j with reference to the brim 11k. At this time, the circuit boards 11a1 are closely arranged without a clearance at the junction P. Four reflectors 11c are arranged corresponding to the circuit boards 11a1. At this time, the corners 11g1 are opposed so that the jointing pieces 11g3 of adjacent reflectors 11c are made contact each other. As a result, the jointing pieces 11g3 of four ¼-divided parts of a cylinder are joined forming one cylinder as shown in
Four reflectors 11c are tightly connected at the central part of the base substrate 11a by the fastening ring 11g4. As a result, four reflectors 11c tightly contact to one another at the junction Q, and assembled as one reflector unit R. The reflector unit R assembled as one piece is positioned on the top surface of four circuit boards 11a1 by the brim 11k of the radiator plate 11j. The reflector unit R is assembled together with the circuit boards 11a1 by a screw inserted from the rear side of the radiator plate 11j. The reflector unit may be bonded by a heat-resistant insulating adhesive such as silicon resin and epoxy resin.
As the jointing pieces 11g3 are connected by the fastening ring 11g4 at the central part of the light-emitting unit A, four reflectors 11c of the light-emitting unit A assembled as above tightly contact at the junction Q. Therefore, the light emitted from the light-emitting element 11 does not leak from the junction Q.
The light-emitting unit A configured as described above is inserted into the main body frame 14 as in the first and second embodiments. The main body frame 14 assembled with the light-emitting unit A is combined with the support frame 16, forming the luminaire 10. In the luminaire 10, the main body frame 14 may be removed from the support frame 16 for cleaning and maintenance or replacement of light-emitting elements. The light-emitting unit A may be removed from the main body frame 14.
The reflector 11c of the light-emitting unit A removed from the main body frame 14 can be removed from the circuit board 11a1 in the following procedures. First, the screw assembling the reflector 11c, circuit board 11a1 and radiator plate 11j is removed. The reflector 11c comes off the base substrate 11a as one piece. Then, the fastening ring 11g4 binding the jointing pieces 11g3 is removed. The reflector 11c is disassembled to four pieces.
According to the luminaire 10 of the third embodiment, the reflector 11c is formed in one piece with a jointing piece 11g3 extending from one corner 11g1 to the base substrate 11a. The jointing piece 11ge3 is formed as a ¼-divided part of a cylinder. When four reflectors 11c1 are flatly arranged along the square base substrate 11a, they are placed so that the jointing pieces 11g3 oppose each other. The jointing piece 11g3 does not project outward from the outer peripheral side 11g2, so that the outer peripheral side 11g2 that is the periphery extending from the corner 11g1 provided with the jointing piece 11g3 tightly contact each other. As a result, the reflectors 11c are arranged along the base substrate 11a, and the reflector unit R is formed.
Adjacent reflectors 11c arranged so that the jointing pieces 11g3 contacts at the corner 11g1. Adjacent four jointing pieces 11g3 form one cylinder. Four reflectors 11c of the light-emitting unit A are tightly connected by the fastening ring 11g4 at the central part of the light-emitting unit A. As four reflectors 11c tightly contact without clearance at the junction Q, the light emitted from the light-emitting element 11 does not lead from the junction Q. Further, as no clearance is found at the junction Q when viewed from the front side of the reflector 11c while the luminaire is not lit, the light-emitting unit A and luminaire 10 provide excellent appearance. The jointing piece 11g3 is provided extending perpendicularly to the base substrate 11a in the state not projecting outward from the outer peripheral side 11g2 of the corner 11g1 of the reflector 11c. There is no projection at the junction Q of adjacent reflectors 11c, and the outer peripheral sides 11g2 of adjacent reflectors 11c tightly contact without clearance.
The reflector 11c may be provided with a jointing piece 11g3 at least one corner 11g1. This simplifies the structure of the reflector. When four reflectors 11c are assembled, the reflectors 11c are positioned so that the jointing pieces 11g3 of adjacent reflectors 11c contact each other. Four reflectors may be made in the same shape. The number of parts is decreased, and the cost is reduced.
In the third embodiment, the junction Q of the outer peripheral side 11g2 located on the outer periphery of the light-emitting unit A, connecting the corners 11g1 of the reflectors 11c at the central part of the light-emitting unit A, is positioned by the brim 11k formed on four sides of the radiator plate 11j so that no clearance is generated. A junction may be provided on the outer peripheral side of the light-emitting unit A as shown in
By using the D-shaped semicircular fastening ring, two reflectors 11c can be combined into a light-emitting unit A. As shown in
In the third embodiment, four jointing pieces 11g3 are combined into a cylindrical column. As shown in
In the embodiments described hereinbefore; the main body frame 14 and support frame 16 are made of metal with high heat conductivity. They may be made of heat-resistant weather-resistant insulating synthetic, such as polybutylene terephthalate (PBT).
The engaging piece 14d is formed in one piece of the synthetic main body frame 14. The engaging piece 14d may be made of metal, formed like a hook separately from the main body frame 14, and attached to one side of the main body frame 14. The receiving place 16d is formed on every side, or four sides of the rectangular support frame 16. When the receiving place 16d is provided on only one side of the support frame, not on four sides, the invention may be embodied. The lock mount piece 16d may be formed in one piece with the synthetic resin support frame 16 as described above, or a separate metallic lock mount piece formed like a groove is provided on four sides of the support frame 16.
The lighting unit 17 may be provided in the main body frame 14 or light-emitting unit A. The lighting unit 17 may be installed on the back side of a ceiling, separately from the main body frame and light-emitting unit A.
A luminaire of the type recessed in an installation site on a ceiling is explained hereinbefore as an example of the invention. The invention may be applied to a luminaire to be directly installed on a ceiling. The embodiments described hereinbefore are preferable examples for explaining the invention. Therefore, the invention is not limited to the described embodiments. The design of the invention may be modified various forms without departing from the spirit and essential characteristics of the invention.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
Number | Date | Country | Kind |
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2008-311217 | Dec 2008 | JP | national |
2008-311418 | Dec 2008 | JP | national |
2008-332886 | Dec 2008 | JP | national |
2008-334065 | Dec 2008 | JP | national |
2008-334444 | Dec 2008 | JP | national |
Number | Name | Date | Kind |
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20020118544 | Wang | Aug 2002 | A1 |
20060109665 | Rupert et al. | May 2006 | A1 |
20080068831 | Wilson et al. | Mar 2008 | A1 |
20090034247 | Boyer | Feb 2009 | A1 |
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2511859 | Sep 2002 | CN |
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08-007636 | Jan 1996 | JP |
08-017229 | Jan 1996 | JP |
2001-005409 | Jan 2001 | JP |
2001-014935 | Jan 2001 | JP |
2002-117705 | Apr 2002 | JP |
2008-257903 | Oct 2008 | JP |
Entry |
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Machine English language translation of JP-2002-117705. |
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Machine English language translation of JP-2001-005409. |
English-language Search Report issued in counterpart European Application No. 09 01 5084 on May 7, 2010. |
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English Language Translation of Japanese Office Action issued in JP 2008-332886 on Nov. 20, 2012. |
Japanese Office Action issued in JP 2008-311217 on Dec. 4, 2012. |
English Language Translation of Japanese Office Action issued in JP 2008-311217 on Dec. 4, 2012. |
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Number | Date | Country | |
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20100142202 A1 | Jun 2010 | US |