Patent Application
20140347868
The present disclosure relates generally to LED luminaires and particularly to recessed or suspended ceiling and wall mounted LED luminaires. More particularly, the present disclosure relates to a system and method for replacing the power supply unit (PSU) and other internal components of a recessed or suspended ceiling or wall mounted LED luminaire.
LED luminaires that are recessed in a drop ceiling include a housing that can be fitted into common ceiling grid systems. The housing is commonly an extruded aluminum outer shell that is able to lay on the edge of the ceiling grids. The housing encloses the PSU and the LED module, which is generally attached to a heat sink. The housing also encloses any reflectors that are used in the luminaire as well as a diffuser which generally forms the floor of the housing.
A prior art LED luminaire 20 is shown in
In order to access and replace the PSU 26 of the prior art luminaire 20, the diffuser 36, reflectors 38, and heat sink 30 must first be removed. The diffuser 36 and reflectors 38 are lightweight and relatively simple elements to remove. However the heat sink 30 is heavy and it is awkward to unfasten screws 32, 34 and lower the heat sink from the luminaire. Moreover, heat sink 30 has mounted thereto the LED module 28 which is quite fragile and must be carefully handled to avoid damage. Furthermore, any wiring between the LED module 28 and the PSU 26 must be disconnected in order to remove and replace the PSU 26.
In other words, to remove the heat sink 30 from the prior art luminaire 20, the two rows of screws 32, 34 are removed to release the heat sink 30. The heat sink 30, along with any wiring connecting the heat sink 30, LED module 28, and the PSU 26, is then carefully removed. The PSU 26 is then exposed and can be removed and replaced.
Issues with the prior art assembly are evident. The LED module can be damaged during the removal and temporary storage of the heat sink. The heat sink is heavy and awkward and its removal from the housing can be dangerous.
The above-described shortcomings significantly limit the usefulness of field-serviceable LED luminaires (i.e. luminaires having a replaceable PSU). Therefore, there remains a need for an LED luminaire assembly which allows for the easy and safe removal and replacement of the PSU and other internal components.
In at least one aspect, the present disclosure provides a field serviceable solid state lighting device luminaire assembly which allows for the easy and safe removal and replacement of the power supply unit and other internal components.
In at least another aspect, the present disclosure provides a solid state lighting device luminaire assembly wherein the heat sink can be folded aside to allow access to and removal of the PSU.
The present disclosure describes a solid state lighting device luminaire assembly having a housing with a first side wall, a second side wall, a first end wall, and a second end wall and a power supply unit located within the housing. The solid state lighting device module is connected to a heat sink which blocks access to the power supply unit. The heat sink folds or pivots to allow access to the power supply unit.
In one aspect the heat sink extends across the housing and is attached to the first side wall of the housing with a fixed attachment and to the second side wall of the housing with a pivot attachment so that when the fixed attachment is disconnected the heat sink stays attached to the housing at the pivot attachment and pivots towards the second side wall. When the heat sink is pivoted the power supply unit is exposed.
In another aspect, the heat sink extends across the housing and is attached to the first end wall with a fixed attachment and to the second end wall with a removable attachment and the heat sink includes at least two segments connected by a hinged connection. The heat sink can be unattached from the second end wall and folded at the hinged connection to expose the power supply unit.
The present disclosure may take form in various components and arrangements of components, and in various process operations and arrangements of process operations. The present disclosure is illustrated in the accompanying drawings, throughout which like reference numerals may indicate corresponding or similar parts in the various figures. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the disclosure. Given the following enabling description of the drawings, the novel aspects of the present disclosure should become evident to a person of ordinary skill in the art.
The following detailed description is merely exemplary in nature and is not intended to limit the applications and uses disclosed herein. Further, there is no intention to be bound by any theory presented in the preceding background or summary or the following detailed description. While embodiments of the present technology are described herein primarily in connection with LED luminaires for use in recessed drop ceilings, the concepts are also applicable to other types of LED luminaires and luminaires having other light sources. In addition, while the invention is described herein as applicable to LED luminaires it should be understood that it is applicable to other solid-state lighting devices as well. For example light-emitting transistors or organic light-emitting diodes/devices (OLEDs) are applicable alternative SSL devices.
In at least one aspect, the present disclosure provides an LED luminaire assembly. As shown in
Diffuser 60 is held by inner pointing retaining lips 62, 64 that run the length of the lower edge of the housing 52. Similar retaining lips 17, 18 are shown for the prior art luminaire shown in
LED module 66 is mounted on the underside of heat sink 68 by screws, adhesives, or other means (not shown). Heat sink 68 is held in place on one side by fixed attachment to an inwardly directed lip 70 with screws or bolts 72 or temporary or quick release mechanisms such as magnets, tethers, chains, levers, pins, or clevis fasteners. The other edge of heat sink 68 is held in place by a pivoting or hinged attachment 74.
Heat sink 68 is typically aluminum but can be another thermally conductive metal, thermally conductive plastic, or other plastic. Its thickness generally ranges between about 0.5 to 20 mm.
To remove the PSU 54, the diffuser 60 and reflector 61 are removed from the luminaire assembly and placed aside. The screws 72 or other fastening devices are removed, allowing the heat sink 68 to hinge or pivot within the housing 52.
Pivot attachment 74 is shown in more detail in
Pivot attachment 74 can be segmental along the inside of housing 52 (one or more mechanisms 74) or can be a continuous element.
Pivoting attachments can be used other than the embodiment shown by
Heat sink 68 can be attached to housing 52 on its non-pivoting side in a number of ways. One embodiment is shown in
A number of other fastening devices can be used including screws, bolts, slide bolt latches, magnets, rivets, cotter pins, leaf springs, or wedges.
A second embodiment of a field serviceable luminaire assembly 148 is illustrated in
As shown in
It should also be noted that the luminaire 148 could have multiple power supplies or there may be other components, such as controllers, sensors, terminal blocks, etc. that the service-operator may need to access. Also, the pivoting segment need not be attached at an end of the housing 150. There may be three (or more) segments with the pivoting segment in the middle, for example.
Heat sink 164 is shown with segment 170 folded downwards. In use, heat sink 164 is mounted within housing 150 generally from one end wall 158 to the other end wall 160 and from side wall 154 to the opposite side wall (not shown). The permanent segment is mounted with screws, adhesive, or other attachment means to the housing. The removable segment 170 is attached to the permanent segment 168 with a hinged connection 172 and is attached to the inside of the end wall 160 with a tab 174 which mates in a slot (not shown) on the end wall 160. Other methods of removably attaching the removable segment 170 can be employed.
It should be noted that the hinged connection 172 should accommodate any electrical connections between segments 168 and 170. One embodiment of an appropriate hinged connection 172 is shown in
The electrical connection between heat sink sections could be a pin connector, ribbon cable, flexible wire, or flexible printed-circuit board. Alternatively, the entire heat sink could be a flexible circuit board that has enough slack at the hinged joint that it can pivot without damaging the board. In that embodiment, a slotted hinge would not be necessary and a standard hinge or other pivoting mechanism would suffice.
This embodiment will desirably include reflectors and these must be removed to access the removable segment 170 of the heat sink 164. The removable segment 170 is then folded down and the power supply unit 162 can be serviced or removed.
Alternative embodiments, examples, and modifications which would still be encompassed by the disclosure may be made by those skilled in the art, particularly in light of the foregoing teachings. Further, it should be understood that the terminology used to describe the disclosure is intended to be in the nature of words of description rather than of limitation.
Those skilled in the art will also appreciate that various adaptations and modifications of the preferred and alternative embodiments described above can be configured without departing from the scope and spirit of the disclosure. Therefore, it is to be understood that, within the scope of the appended claims, the disclosure may be practiced other than as specifically described herein.
