Embodiments described herein relate generally to light fixtures, and more particularly to systems, methods, and devices for modular light fixtures that can be expanded or reduced in size.
In certain applications, the size and shape of a light fixture for a particular application can vary. For example, an industrial high bay (IHB) light fixture is commonly used in warehouses, assembly plants, and similar environments that have very high ceilings and vast open spaces. The preferences of a user can also vary. Thus, a light fixture of a certain shape and size may be effective to use in a certain application, but the user of that light fixture may have more preferable shapes and/or sizes for that application.
In general, in one aspect, the disclosure relates to a modular light fixture. The modular light fixture can include a frame having at least one light module coupling device, where the at least one light module coupling device includes at least one light module coupling feature. The modular light fixture can also include at least one light module coupled to the frame, where the at least one light module includes at least one frame coupling feature that couples to the at least one light module coupling feature of the at least one light module coupling device.
In another aspect, the disclosure can generally relate to a light module for a modular light fixture. The light module can include a body having a length and a width, where the width defines a first end and a second end of the body, and where the length defines a first side and a second side of the body. The light module can also include a first frame coupling feature disposed at the first end of the body, where the first frame coupling feature is configured to couple to a first light module coupling feature of a frame of the modular light fixture.
In yet another aspect, the disclosure can generally relate to a frame for a modular light fixture. The frame can include at least one wall. The frame can also include at least one light module coupling device disposed on the at least one wall, where the at least one light module coupling device includes at least one light module coupling feature and is configured to couple to a frame coupling feature of at least one light module of the modular light fixture.
These and other aspects, objects, features, and embodiments will be apparent from the following description and the appended claims.
The drawings illustrate only example embodiments of modular light fixtures and are therefore not to be considered limiting of its scope, as modular light fixtures 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 example 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 for modular light fixtures. Such modular light fixtures (or components thereof, such as light modules of a modular light fixture) can use any one or more of a number of lighting technologies. For example, a light module can have one or more of a number of types of socket into which one or more light sources are electrically and mechanically coupled. Examples of types of sockets can include, but are not limited to, an Edison screw base of any diameter (e.g., E26, E12, E 14, E39), a bayonet style base, a bi-post base, a bi-pin connector base, a wedge base, a terminal block, and a fluorescent tube base. A light source of an example modular light fixture can electrically and mechanically couple to the socket and can be of a light source type that corresponds to the type of socket.
Examples of light source types of the light source can include, but are not limited to, light-emitting diodes (LEDs), incandescent lamps, halogen lamps, G10/GU10, G9/GU9, AR111/PAR36, T3, MR-11, and MR-16. If the light source of a modular light fixture (including any portion thereof) is a LED, the LED can be of 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.
An example modular light fixture (also more simply called a light fixture herein) can be mounted in any of a number of locations and/or be used in any of a number of applications. For example, modular light fixtures described herein can be used as industrial high bay light fixtures in warehouse, assembly plant, power plant, chemical plant, and/or any such similar applications. A modular light fixture can be electrically coupled to a power source to provide power and/or control to the modular light fixture. The power source can provide the modular light fixture with one or more of a number (and/or a range) of voltages, including but not limited to 120 V alternating current (AC), 110 VAC, 240 VAC, 24 V direct current (DC), and 0-10 VDC.
Due in part to the modular aspect described herein, such modular light fixtures can be of any size and/or shape, and can have any number of light modules. Such modular light fixtures can be located indoor and/or outdoors and can be mounted to a surface (e.g., cabinet, wall, ceiling, pillar), be part of a lamp, or be used with any other suitable mounting instrument. Such modular light fixtures can be used in residential, commercial, and/or industrial applications. Such modular light fixtures can operate from a manual fixture (e.g., on/off switch, dimming switch, pull chain), a sensor (e.g., a photocell, a motion detector), a timer, and/or any other suitable mechanism.
Any components (e.g., frame) of example modular light fixtures, or portions thereof, described herein can be made from a single piece (as from a mold, injection mold, die cast, or extrusion process). In addition, or in the alternative, a component (or portions thereof) can be made from multiple pieces that are mechanically coupled to each other. In such a case, the multiple pieces can be mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to epoxy, welding, fastening devices, compression fittings, mating threads, and slotted fittings. One or more pieces that are mechanically coupled to each other can be coupled to each other in one or more of a number of ways, including but not limited to fixedly, hingedly, removeably, slidably, and threadably.
Components and/or features described herein can include elements that are described as coupling, fastening, securing, abutting, or other similar terms. Such terms are merely meant to distinguish various elements and/or features within a component or device and are not meant to limit the capability or function of that particular element and/or feature. For example, a feature described as a “coupling feature” can couple, secure, fasten, abut, and/or perform other functions aside from merely coupling. In addition, each component and/or feature described herein (including each component of an example modular light fixture) can be made of one or more of a number of suitable materials, including but not limited to metal, ceramic, rubber, and plastic.
A coupling feature (including a complementary coupling feature) as described herein can allow one or more components and/or portions of a modular light fixture (e.g., a light module) to become mechanically and/or electrically coupled, directly or indirectly, to another portion (e.g., a frame) of the modular light fixture. A coupling feature can include, but is not limited to, a clamp, a portion of a hinge, an aperture, a recessed area, a protrusion, a slot, a spring clip, a tab, a detent, and mating threads. One portion of an example modular light fixture can be coupled to another portion of the modular light fixture by the direct use of one or more coupling features.
In addition, or in the alternative, a portion of an example modular light fixture can be coupled to another portion of the modular light fixture using one or more independent devices that interact with one or more coupling features disposed on a component of the modular light fixture. Examples of such devices can include, but are not limited to, a pin, a hinge, a fastening device (e.g., a bolt, a screw, a rivet), and a spring. One coupling feature described herein can be the same as, or different than, one or more other coupling features described herein. A complementary coupling feature as described herein can be a coupling feature that mechanically couples, directly or indirectly, with another coupling feature.
In certain example embodiments, the modular light fixtures (or portions thereof) described herein meet one or more of a number of standards, codes, regulations, and/or other requirements established and maintained by one or more entities. Examples of such entities include, but are not limited to, Underwriters' Laboratories (UL), the National Electric Code (NEC), and the Institute of Electrical and Electronics Engineers (IEEE). For example, UL may require that an example modular light fixture used as a high bay light fixture be suitable for operation in damp environments.
As described herein, a user can be any person that interacts with example modular light fixtures. Examples of a user may include, but are not limited to, a consumer, an electrician, an engineer, a mechanic, a home owner, a business owner, a consultant, a contractor, an operator, and a manufacturer's representative. For any figure shown and described herein, one or more of the components may be omitted, added, repeated, and/or substituted. Accordingly, embodiments shown in a particular figure should not be considered limited to the specific arrangements of components shown in such figure.
Further, if a component of a figure is described but not expressly shown or labeled in that figure, the label used for a corresponding component in another figure can be inferred to that component. Conversely, if a component in a figure is labeled but not described, the description for such component can be substantially the same as the description for the corresponding component in another figure. The numbering scheme for the various components in the figures herein is such that each component is a three or four digit number and corresponding components in other figures have the identical last two digits.
Example embodiments of modular light fixtures will be described more fully hereinafter with reference to the accompanying drawings, in which example embodiments of modular light fixtures are shown. Modular light fixtures 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 modular light fixtures to those of ordinary skill in the art. Like, but not necessarily the same, elements (also sometimes called components) in the various figures are denoted by like reference numerals for consistency.
Terms such as “first”, “second”, “third”, “height”, “width”, “length” “distal”, “top”, “bottom”, “side”, “left”, and “right” 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 modular light fixtures. 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.
In certain example embodiments, the frame 120 includes one or more light module coupling devices (e.g., light module coupling device 126, light module coupling device 136) that are used to couple one or more (in this case, two) light modules 110 to the frame 120. Each light module coupling device can be a separate component that couples to the frame 120 (as shown in
The frame 120 can have any characteristics (e.g., shape, size, contours) suitable for the application and environment of the modular light fixture 100. In addition, the frame 120 can have any of a number of components. In this example, the frame 120 includes a housing 130 and a connecting bracket 125 that are not directly coupled to each other. The housing 130 has one light module coupling device 136, and the connecting bracket 125 has another light module coupling device 126. Each of the light module coupling device 136 and the light module coupling device 126 can couple to one or more light modules 110. The housing 130 and/or the connecting bracket 125 can also include one or more of a number of other coupling features (e.g., apertures in this case) that allow the frame 120 to couple, directly or indirectly, to one or more other components (e.g., a light module) of the modular light fixture 100.
In addition, or in the alternative, the housing 130 and/or the connecting bracket 125 can include one or more coupling features (e.g., apertures in this case) that allow the housing 130 and/or the connecting bracket 125 to couple, directly or indirectly, to one or more mounting devices 106. In such a case, each mounting device 106 can be used to mount the modular light fixture 100 within a space (e.g., a warehouse, an assembly plant).
In certain example embodiments, the frame 120 can include one or more of a number of other components that are used to operate the light modules 110 coupled to the frame 120. Examples of such other components can include, but are not limited to, a power source, an electrical conductor, a terminal block, a controller, a discrete component (e.g., capacitor, resistor, inductor, diode), a heat sink, and a charge transfer device (e.g., a transformer, an inductor, a converter). Each of these components can be disposed on or in any portion of the frame 120. In addition, or in the alternative, one or more of these other components can be disposed in or on one or more of the light modules 110. For example, as shown in
Among other components, a light fixture 100 can include at least one power source 195. The power source 195 (e.g., a LED driver, a ballast) can be used to provide power and/or control signals to one or more light modules 110. As shown in
When the light modules 110 are coupled to the frame 120, there can be an air gap 109 between two adjacent light modules 110. The distance of the air gap 109 can vary (as by a user) between adjacent light modules 110 in the light fixture 100. Alternatively, the distance of the air gap 109 can be fixed (for example, based on detents in the frame 120 to fix where the light modules 110 are disposed with respect to the frame 120 and each other). The air gap 109 can serve one or more of a number of purposes. For example, the air gap 109 can be used to help air (e.g., ambient air) circulate around thermally-conductive components (e.g., heat sink) that absorb heat generated by heat-generating components (e.g., light source, power source) of the modular light fixture 100. Thus, in such a case, the air gap 109 helps to keep one or more components of the modular light fixture 100 from overheating, which can cause failure or deterioration of the modular light fixture 100.
For example, as shown in
The wall (or portions thereof) of the housing 430 can include one or more of a number of coupling features that allow the housing 430 to couple to one or more other components of the modular light fixture. For example, as discussed above, a light module coupling device 436 can be disposed on the wall (in this case, on the outer surface of the bottom wall 431). The light module coupling device 436 can have one or more of a number of coupling features that allow the light module coupling device 436 to couple, directly or indirectly, to a complementary coupling feature (also called a frame coupling feature 611, discussed below with respect to
For example, in this case, the light module coupling device 436 is shaped as an inverted “T”, with a stem 438 and a bottom portion 437 that is disposed at the end of, and perpendicular to, the stem 438. In this way, the stem 438 and/or the bottom portion 437 can be considered coupling features of the light module coupling device 436. The light module coupling device 436 can run along all or one or more portions of the housing 430. Further, the light module coupling device 436 can be used to expand the light modules of the light fixture in one or two dimensions.
In certain example embodiments, the housing 430 can include one or more of a number of other coupling features (e.g., an aperture) to allow the housing 430 to couple to a light module and keep the light module in a fixed position relative to the housing 430. For example, if the coupling feature is an aperture that traverses the bottom wall 431 proximate to the light module coupling device 436, the aperture can allow a fastening device (e.g., a screw, a rivet) to traverse the therethrough as well as at least a portion of a light module.
As another example of coupling features of the housing 430 that allow the housing 430 to one or more other components of the modular light fixture, coupling feature 445 (e.g., aperture, slot, recess, tab) of the bottom wall 431 can allow one or more mounting devices (e.g., mounting device 106) to couple, directly or indirectly, to the housing 430 of the frame. Further, some or all of the housing 430 can be made of one or more of a number of thermally conductive materials. As a result, the top wall 432 and/or the bottom wall 431 of the housing 430 can have one or more features (e.g., fins or protrusions, as shown in
The wall 529 (or portions thereof) of the connecting bracket 525 can include one or more of a number of coupling features that allow the connecting bracket 525 to couple to one or more other components of the modular light fixture. For example, as discussed above, a light module coupling device 526 can be disposed on the wall 529. The light module coupling device 526 can have one or more of a number of coupling features that allow the light module coupling device 526 to couple, directly or indirectly, to a complementary coupling feature (also called a frame coupling feature 611, discussed below with respect to
For example, in this case, the light module coupling device 526 is shaped as an inverted “T”, substantially similar to the configuration of the light module coupling device 436 described above. Thus, the light module coupling device 526 can include a stem 528 and a bottom portion 527 that is disposed at the end of, and perpendicular to, the stem 528. In this way, the stem 528 and/or the bottom portion 527 can be considered coupling features of the light module coupling device 526. The light module coupling device 526 can run along all or one or more portions of the connecting bracket 525. Further, the light module coupling device 526 can be used to expand the light modules of the light fixture in one or two dimensions.
In certain example embodiments, the connecting bracket 525 can include one or more of a number of other coupling features (e.g., an aperture, a protrusion) to allow the connecting bracket 525 to couple to a light module and keep the light module in a fixed position relative to the connecting bracket 525. For example, if the coupling feature is an aperture that traverses the wall 529 proximate to the light module coupling feature 526, the aperture can allow a fastening device (e.g., a screw, a rivet) to traverse the therethrough as well as at least a portion of a light module. As another example, coupling feature 547 can be a protrusion that extends from a portion of the wall 529 so that, when the connecting bracket 525 is properly placed relative to one or more light modules, the coupling feature 547 abuts against a portion of a light module.
As another example of coupling features of the connecting bracket 525 that allow the connecting bracket 525 to one or more other components of the modular light fixture, coupling feature 546 (e.g., aperture, slot, recess, tab) of the wall 529 can allow one or more mounting devices (e.g., mounting device 106) to couple, directly or indirectly, to the connecting bracket 525 of the frame. Further, some or all of the connecting bracket 525 can be made of one or more of a number of thermally conductive materials. As a result, the wall 529 of the connecting bracket 525 can have one or more features (e.g., fins or protrusions, as shown in
The light module 610 can have any of a number of shapes and/or sizes. In this case, the light module 610 is rectangular (when viewed from above) and has a length and a width, where the length is longer than the width. The light module 610 of
Each frame coupling feature 611 has a configuration (e.g., shape, size) that complements the corresponding coupling feature of the frame to which the frame coupling feature 611 couples. In this case, since light module coupling device 436 of the housing 430 and light module coupling feature 526 of the connecting bracket 525 have substantially the same shape and size as each other, the two frame coupling features 611 that couple to the light module coupling device 436 and light module coupling feature 526 have substantially the same shape and size as each other. While a frame coupling feature 611 of a light module 610 is shown as coupling to the frame of a light fixture, a frame coupling feature 611 can, in the alternative, couple to another light module 610.
In this example, each frame coupling feature 611 is a channel disposed in the heat sink 614. As such, one frame coupling feature 611 slidably receives and couples to the light module coupling device 436 (or portion thereof) of the housing 430, and the other frame coupling feature 611 slidably receives and couples to the light module coupling feature 526 (or portion thereof) of the connecting bracket 525. The channel of each coupling feature 611 of
In certain example embodiments, the light module 610 can include one or more other coupling features that allow the light module 610 to couple to the frame. For example, the heat sink 614 can have one or more apertures that traverse at least partially therethrough, so that a fastening device can traverse an aperture in a portion of the frame as well as in the aperture of the heat sink 614. As another example, the heat sink 614 can have a protrusion that mates with a coupling feature (e.g., coupling feature 547) of the frame.
The light module 710 of
In this case, coupling feature 907 (e.g., a bolt, a nut) is used to fixedly couple the light module coupling device 936 to one or more light modules 910. Further, as shown in
In certain example embodiments, the cover 1250 is used to provide protection to one or more components of the light fixture 1200 from elements (e.g., dust) outside the light fixture 1200. The cover 1250 can have any of a number of shapes, sizes, and other configurations. For example, as shown in
In some cases, the cover 1250 allow access to one of more portions of the light fixture 1250 while still remaining coupled to the rest of the light fixture 1250. For example, as shown in
In some cases, such as when the frame 1220 includes a housing (e.g., housing 430), the housing can be opened, allowing the user to access the cavity (e.g., cavity 439) of the housing and any of a number of components (e.g., a power source) disposed therein while the light fixture 1200 remains affixed in its normal position. When any such work is completed, the user can recouple the latch 1255 and the catch 1222 to put the light fixture back into a closed position.
The frame portion 1360A of the hinge 1360 can have spirally-shaped components. For example, as shown in
As another example, as shown in
By contrast, when the light fixture 1300 is in the open position, the curving piece 1366 abuts against the end piece 1364. As a result, the end piece 1364 acts as a stop to prevent the cover 1350 and the frame 1320 from separating any further with respect to each other. Those of ordinary skill in the art will appreciate that the hinge configuration described herein can be used for any of a number of other applications that use hinges and hinge assemblies.
In the light fixture assembly 1403A of
In this case, the extension 1552 of the cover 1550 is not used as an attachment means for the light fixture 1500. Instead, the gap 1553 traverses the body 1551 of the cover 1550, creating a vent. As a result, the extension 1552 serves to provide protection from dust, water, and other elements from entering the interior of the light fixture 1500 through the gap 1553. There can be any of a number of gaps 1553 that traverse the body 1551 of the cover 1550. The cover 1550 can also include a side portion 1554 on one or both ends of the light fixture 1500, enclosing the space between the cover 1550 and the tops of the frame 1520 and the light modules 1510. In certain example embodiments, the pitch of the body 1551 and/or the extension 1552 can be large enough so that most dust and dirt that settles on the cover 1550 falls off the cover 1550.
In addition, the cover 1550 can be fixedly coupled to the rest of the light fixture 1500. As a result, since the light fixture is suspended using the mounting devices 1506 disposed on the sides of the frame 1520, a user can remove the cover 1550 from the rest of the light fixture 1500 (in this case, from the frame 1520) to access one or more components disposed on the top side of the frame 1520 and/or the light modules 1510 without first removing the entire light fixture 1500 from its mounting position. In this case, the light fixture 1500 is suspended in place by a number of chains 1505 that are coupled to the mounting devices 1506.
In addition, a bracket 1605 is attached to the mounting devices 1606 disposed on the sides of the frame 1620. The bracket 1605 is bridged over the housing 1650 and has a coupling feature disposed in its center, allowing for the bracket 1605 to couple to a pendant or some similar mounting feature. The location of the mounting devices 1606 along the sides of the frame 1620 is adjustable, as can be seen in
The clamp 1770 can include one or more coupling features. For example, as shown in
The shape, size, and contours of the clamp 1770 (e.g., top surface 1775, side surface 1774, top surface 1772) can be designed to complement features of one or more components (e.g., heat sink 1714, lens 1716) of the light fixture 1700 so that all components abut against the clamp 1770 when the clamp 1770 is coupled to the light fixture 1700. In this way, the clamp 1770 can provide a substantially tight seal, protecting one or more components (e.g., light sources, reflectors) of the light fixture 1700.
In certain example embodiments, the various sensor mounting arrangements of
For the light fixture 2000 of
In this case, there are three power sources 2395 disposed within the cavity 2339. Each power source 2395 can supply power and/or control signals to one or more of the light modules 2310. Alternatively, a power source 2395 can be idle, not providing power or control signals to any of the light modules 2310. In certain example embodiments, a power source 2395 can change the one or more light modules 2310 that it provides power and/or control signals based on one or more of a number of conditions, including but not limited to a passage of time, a change in power received by the power source 2395, the number of light modules 2310, and a user selection.
The power sources 2395 can be wired in series and/or in parallel. The characteristics (e.g., capacity, size, number of input terminals, number of output terminals, type of voltage output, level of voltage output) of each power source 2395 can be substantially the same as, or different than, the corresponding characteristics of the remaining power sources 2395 of the light fixture 2300. The light fixture 2400 of
The power sources 2595 are supplied with power from an external power source 2581. In some cases, the power supplied by the external power source 2581 to the power sources 2595 is alternating current (AC) power. There can be multiple external power sources 2581, where each external power source 2581 supplies power to one or more power sources 2595. Each power source 2595 can receive the power from the external power source 2581 and generate output power and/or control signals that are sent to one or more circuit boards 2585. In this case, power source 2595A has at least one characteristic (e.g., size, capacity) that is different than a corresponding characteristic of power source 2595B.
The terminal blocks 2582 can have varying characteristics, including but not limited to number of terminals, shape of terminals, rating of terminals, and location of terminals. Similarly, the size and other characteristics of an electrical conductor 2583 can be based on one or more of a number of factors, including but not limited to level of voltage/current flowing through the electrical conductor 2582 and the temperature that the electrical conductor 2582 is exposed to. A circuit for a light fixture can also have an earth ground 2589.
The wiring shown in the wiring diagram 2588 of
Other components can be included in the wiring diagram 2588 of
The wiring diagram 2688 of
Example embodiments can be installed without complicated electrical and/or mechanical manipulation or expertise. In other words, many issues common to installing a lighting fixture (e.g., having sufficient light coverage, having the desired number of light modules) can be avoided or minimized using example modular light fixtures. Using example embodiments described herein, the light fixture can be more energy efficient, provide more effective lighting for a particular application, provide particular types of lighting, have optical features that can be easily changed at some point in the future by a user, and provide a number of other benefits expressed or implied herein.
Although embodiments described herein are made with reference to example embodiments, it should be appreciated by those skilled in the art that various modifications are well within the scope and spirit of this disclosure. Those skilled in the art will appreciate that the example embodiments described herein 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 using the present disclosure will suggest themselves to practitioners of the art. Therefore, the scope of the example embodiments is not limited herein.
This application claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application Ser. No. 61/982,803, titled “Industrial High Bay Light Fixture” and filed on Apr. 22, 2014, the entire contents of which are hereby incorporated herein by reference.
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