Abstract:
A field configurable industrial light fixture is disclosed that includes a power module unit to which an arbitrary number of petals containing LEDs can be coupled. The fixture enables configuration of the amount and orientation of the light emitted from the solid-state lighting devices to be adapted in the field to suit the particular application of the fixture.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates to solid-state lighting, and in particular to an industrial LED light fixture that may be configured in the field to meet desired lighting needs for particular locations and applications. 
         [0002]    Numerous types of fixtures are now a well known for use with light emitting diodes (LEDs). Such fixtures, however, generally have been of the type that does not permit adjustment of the orientation or amount of light provided by the fixture. In many applications, however, it is desirable to be able to provide light in varying amounts at varying locations within the facility. For example, more light may be required portions of the facility where fine manufacturing operations are carried out, as opposed to in offices, where users of the offices may have lamps on their desks. 
         [0003]    In general, and in previous approaches to this need, different types and sizes of fixtures were installed at different locations in the factory, office building, or other location. This has the disadvantage of requiring removing and replacing the lighting fixtures when different tasks are moved to different locations. Of course each different fixture may require its own different type of installation, its own special attachment to the building, and other customization. In addition, the varying fixture types require inventorying each type of fixture in appropriate numbers, training installers to install each type, and various other fixture specific aspects. With these varying types of fixtures comes increased costs, increased maintenance, and additional time required for installation, modification, or repair. These disadvantages can become even more problematical when existing incandescent or florescent fixtures are to be replaced by fixtures that use light emitting diodes (LEDs). 
         [0004]    What is needed is a lighting fixture for solid-state lighting, such as LEDs, which may be adapted in the field to the needs of each particular facility and location within that facility, but which is otherwise “universal.” 
       SUMMARY OF THE INVENTION 
       [0005]    The field configurable industrial light fixture described here includes a base unit (or puck) to which multiple LED lighting units (or petals) can be coupled. The fixture enables configuration of the amount and orientation of the light emitted from the solid-state lighting devices on each petal to be arbitrarily modified in the field to suit the particular application of the fixture. 
         [0006]    In a preferred embodiment a lighting fixture for solid-state light emitting devices includes a base unit to which electrical power can be supplied. The base unit includes a lower portion having an outer perimeter; and a series of fittings arranged around the outer perimeter, each fitting being adapted to mechanically support a petal coupled to that fitting. Each of the individual petals includes a mechanical connector configured to be physically supported by one of the series of fittings arranged around the outer perimeter of the base, a heat sink, and an array of solid state light emitting devices affixed to the heat sink. A desired number of petals may be affixed to the base in arbitrary orientations around the base. 
         [0007]    Preferably the solid-state light emitting devices comprise light emitting diodes (LEDs) with a lens over them to diffuse the emitted light. Each of the fittings includes a slot having an open end and a closed end, and each of the petals includes a protruding portion that slides into the slot and is retained in position by the closed end of the slot. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  illustrates a field configurable industrial led light fixture; 
           [0009]      FIG. 2  illustrates a field configurable industrial LED light fixture with an extension unit; and 
           [0010]      FIG. 3  is a more detailed view of the mechanical and electrical connections between the base unit and the lighting units. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0011]      FIG. 1  is a perspective view of a field configurable solid-state lighting fixture  10  illustrating its principal components and assembly. The assembled field configurable solid-state lighting fixture  10  is shown at the bottom of  FIG. 1 . The manner in which the components are combined to make the fixture is illustrated in the remaining portion of  FIG. 1 . 
         [0012]    The particular implementation in  FIG. 1  includes a power module  20 , a top cover  25 , a bottom cover  30 , and four petals  40 . A post  15  is used to connect the unit  10  to an appropriate fitting in the facility to which it is to be installed. The post  15  will usually be connected to an electrical box in the ceiling of the facility where the fixture  10  is to be mounted. Typically, conventional AC electric power will be provided in the ceiling of the facility, and the appropriate electrical cabling extends down through the post  15  into the power module  20 . The power module will usually include an Ac to DC converter unit, and one or more controller boards upon which LED control electronics has been mounted. 
         [0013]    The power module  20  includes connections to distribute that necessary electrical power to the individual light petals  40  of the fixture  10 . We refer to the architecture illustrated in  FIG. 1  as “petal-puck” architecture because the base unit  10  resembles a “puck,” and as many “petals” as desired may be affixed to it. In the illustration of  FIG. 1  four petals  40  are shown, however, as many as desired may be affixed to the “puck” depending upon its size. As will be described in more detail below, each petal  40  includes an array of light emitting diodes mounted to the lower surface of the petal, over which a lens is usually placed. 
         [0014]      FIG. 2  is a perspective view of one petal  40  of a field configurable solid-state lighting fixture  10  illustrating the principal components and assembly of petal  40 . The components illustrated there include the metal substructure  42  which also functions as a heat sink, a sheet of thermally conductive material  44  which couples circuit board  45  to the heat sink  42  enabling heat from the LEDs  46  to be dissipated by the heat sink  42 . Over the LEDs  46 , a lens array  47  is positioned. The lens array can be any lens array of appropriate form factor. Its particular configuration will depend upon the particular application for the fixture  10 . For example, in some installations it will be desired to diffuse the light from the LEDs more than in others, and a suitable lens array can be designed to implement that. A sheet  44  of thermally conductive material  44  helps assure that heat generated by the LEDs  46  on printed circuit board  45 , is dissipated by heat sink  42 . The lens array  47  is secured to the circuit board by a gasket  48  and a lens clamp frame  49 . 
         [0015]    The power module  20  includes cooling fins to help dissipate heat generated by the electrical components within the unit. In addition, each petal  40  includes similar cooling fins to help dissipate the heat from the array of LEDs on each petal. In a preferred embodiment each of the petals is identical to the others, although for unique requirements, different styles of petal may be used. 
         [0016]      FIG. 3  illustrates the power module  20  in more detail. LED controller printed circuit boards  60  and associated circuitry  65  mounted thereon are secured to the power module, and protected from ambient conditions by the top cover  25  (see  FIG. 1 ). The cover can be fastened to the power module using fasteners such as bolts and sealed with an O-ring. The petals  40  connect to the exterior of the power module  20  via a protruding engagement portion  50  (see  FIG. 2 ) on the end of each petal  40 . These portions  50  engage with corresponding slots  68  (see  FIG. 3 ) on the lower portion of the outer perimeter of the exterior of the power module  20 . As shown by the illustration, the petals  40  fit into the slots  68  in the upper portion of the perimeter, and then are locked in place when moved to the lower portion of each slot. The closed end at the lower end of the slot  68  prevents the petals from slipping out of the power module  20 . Electrical connections between the power module circuit boards  60  and the LEDs on each petal  40  is made through openings (not shown) between the base of the petal  40  and the power module  20 . 
         [0017]    As shown by  FIGS. 1 and 3 , the power module  20  can be of arbitrary size, and adapted to provide an arbitrary number of slots  68  for the petals. In the particular unit illustrated in  FIG. 1 , four petals  40  are shown. As shown in more detail by  FIG. 3 , between each two adjacent petals, additional empty slots are provided for additional petals  40  if more light is desired. The power module unit  20  of  FIG. 1  thus can accommodate any number of petals from 1 to 12. Of course, should more pedals be desired, a larger power unit can be provided, or multiple power units can be stacked one atop the other between the top and bottom covers. 
         [0018]    An advantage of the structure described here is that the petals  40  do not need to be arranged symmetrically on the power module  20 . For example, if the power module  20  is near a wall, all of the petals can be inserted into the base unit on the opposite side of the base unit from the wall, or fewer petals can be used. One benefit of the structure illustrated is that by installing an array of connecting posts  15  and power modules  20  throughout a facility, appropriate numbers of petals arranged in any desired orientation can be used on different fixtures in different locations throughout a facility. In this manner more light can be provided in some locations than others without need for use of customized fixtures in different locations. 
         [0019]    All of these capabilities are made possible by the “universal” nature of the power module  20  and petals  40 . For example, if more light is desired on one side of unit  10  than another side, the petals can be arranged to meet that need. If more light is desired in one location than was originally provided, it is a relatively simple matter to add additional petals  40  to the fixture  10  at a later date. Once a technician is appropriately trained in installation, the same installation techniques can be used throughout a facility without the necessity of training the technician in the installation of different types of fixtures. 
         [0020]    In the preferred embodiment the power module  20  is coupled to conventional AC power, and the LED controller circuit boards  60  provide appropriate voltages and current to the LEDs on the individual petals. The electrical connections between each petal and the base unit is preferably made by wiring extending through an opening in the exterior surface of the power module to enable wires to connect between the interior of the base unit and the petals. Alternatively, each slot  68  can include a socket to which the petal “automatically” when it is inserted into the slot.