Luminaire housing with retrofit panel

A luminaire retrofit panel including a main wall adapted to support a luminaire in a central opening of the main wall, and including an outer perimeter. A side wall extends from the outer perimeter of the main wall. A plurality of secondary walls extend from the side wall and extend over a portion of the main wall toward the central opening of the main wall. The secondary walls are substantially parallel to the main wall. The plurality of secondary walls support at least one hinge and at least one latch. The hinge is engagable with a frame and allows the main wall to pivot with respect the frame. The latch is engagable with the frame to hold the main wall to releasably secure the main wall to the frame.

FIELD OF THE INVENTION

The present invention relates to a luminaire adapted to mount to a canopy or ceiling that can support a lamp in different orientations. Additionally, the present invention relates to a luminaire that facilitates installation and replacement of the lamp. More specifically, the luminaire includes a socket holder capable of supporting the lamp in first and second orientations and that is movable between unlocked and locked positions.

Also, the present invention relates to a luminaire housing having a removable panel that supports the luminaire. More specifically, the removable panel can fit various existing luminaire housings.

BACKGROUND OF THE INVENTION

A luminaire is a light fixture that is typically mounted to a canopy, ceiling or light pole. Conventional luminaires include a ballast electrically connected to a socket and lamp, and an optical refractor or lens that encloses the lamp and allows light rays from the lamp to emanate therethrough.

Conventional luminaires generally provide only one lamp orientation, usually either vertical or horizontal. Additionally, problems arise in installing and maintaining conventional luminaires. For example, installation often requires more than one person. Also, performing maintenance such as replacing the lamp often requires disassembly of the luminaire. Also, some conventional luminaires are bulky and include unnecessary parts. Moreover, some conventional luminaires are not easily adaptable to a variety of optical refractors.

Additionally, some conventional luminaires include removable or retrofit panels. However, conventional retro-fit panels are often difficult to latch and leave unsightly hardware or fasteners exposed. Also, conventional luminaires that use retro-fit panels often do not provide adequate protection to electrical shock, particularly when removing or opening the panel.

SUMMARY OF THE INVENTION

Accordingly, an object of the present invention is to provide a luminaire capable of supporting a light source, such as a lamp, in at least two different orientations.

Another object of the present invention is to provide a luminaire that facilitates installation and maintenance thereof, particularly when replacing the light source or lamp of the luminaire.

Yet another object of the present invention is to provide a luminaire that is compact and includes a minimal number of parts.

Still another object of the present invention is to provide a luminaire that allows a variety of optical assemblies to be used with the luminaire.

Another object of the present invention is to provide a luminaire housing that includes a panel that can be used in a retrofit application and is easily latched and hides hardware and fasteners used with the panel.

A further object to the present invention is to provide a luminaire housing that includes a panel with a safety mechanism for protection against electrical shock particularly when opening the panel.

The foregoing objects are basically attained by a luminaire comprising an optical assembly that has a mounting interface. A socket holder has a mounting member that is adapted to mount the socket holder to the mounting interface of the optical assembly. First and second proximate surfaces are adapted to support a socket and a light source in first and second orientations, respectively. The socket holder defines a central axis. A longitudinal axis is defined by the socket and the light source in the first orientation is substantially parallel to the central axis of the socket holder and a longitudinal axis of the socket and the light source in the second orientation is angled with respect to the central axis of the socket holder.

The foregoing objects are also attained by a luminaire, comprising an optical assembly having a mounting interface including at least one mounting aperture. A socket holder is coupled to the optical assembly and supports a socket and a light source at a first end. The socket holder is movable between locked and unlocked positions with respect to the mounting interface of the optical member. Socket holder includes a mounting member at a second end opposite the first end that is adapted to mount the socket holder to the mounting interface of the optical assembly. The mounting member has a guide portion and a locking portion engaged with the mounting aperture of the mounting interface of the optical assembly in the locked position thereby interlocking the socket holder and optical assembly, and disengaged with the mounting aperture in the unlocked position, wherein the guide portion facilitates engagement and disengagement of the locking portion with the mounting aperture.

The foregoing objects are also attained by a luminaire comprising a support panel and an optical assembly including a reflector coupled to a refractor. The reflector is releasably secured to the support panel thereby substantially restricting movement of the optical assembly with respect to the support panel. The reflector includes a mounting interface. A socket holder is coupled to the reflector of the optical assembly at the mounting interface. The socket holder is movable between locked and unlocked positions with respect to the reflector and the optical assembly. The socket holder supports a socket and a light source with the reflector and the refractor substantially enclosing the light source.

The foregoing objects are also attained by a luminaire retrofit panel including a main wall adapted to support a luminaire in a central opening of the main wall, and including an outer perimeter. A side wall extends from the outer perimeter of the main wall. A plurality of secondary walls extend from the side wall and extend over a portion of the main wall toward the central opening of the main wall. The secondary walls are substantially parallel to the main wall. The plurality of secondary walls support at least one hinge and at least one latch. The hinge is engagable with a frame and allows the main wall to pivot with respect the frame. The latch is engagable with the frame to hold the main wall to releasably secure the main wall to the frame.

The foregoing objects are also attained by a luminaire housing including a frame and a panel releasably coupled to the frame and movable between open and closed positions with respect to the frame. The panel has a main wall for supporting a luminaire and includes an outer perimeter. A side wall extends from the outer perimeter of the main wall. A plurality of secondary walls extend from the side wall and extend over a portion of the main wall. The secondary walls are spaced from the main wall by the side wall. The plurality of secondary walls support at least one hinge and at least one latch. The hinge is pivotally engaged with the frame thereby allowing the panel to move between the open and closed positions. The latch is engaged with the frame to hold the panel in the closed position and disengaged with the frame when the panel is in the open position.

The foregoing objects are also attained by a luminaire housing including a frame and a panel releasably coupled to the frame and movable between open and closed positions with respect to the frame. The panel has a main wall for supporting a luminaire and includes an outer perimeter. A side wall extends from the outer perimeter of the main wall. At least one secondary wall extends from the side wall and over a portion of the main wall, the secondary wall includes a guide slot with first and second opposite ends. A first latch is supported by the secondary wall. The first latch includes a latching plate and a coupling extension extending from the latching plate and through the guide slot of the secondary wall coupling the latching plate to the secondary wall. The coupling extension is slidable between the first and second ends of the guide slot to move the latching plate between latched and unlatched positions, respectively.

The foregoing objects are also attained by a luminaire housing including a frame and a panel releasably coupled to the frame and movable between open and closed positions with respect to the frame. The panel supports a luminaire. A switch assembly is supported by the panel and includes a switch housing having a lever pivotally coupled thereto and at least one electrical switch received within the switch housing. The electrical switch being electrically connected to the luminaire. The lever engages the frame and engages the electrical switch when the panel is in the closed position thereby turning on power to the luminaire. The lever is disengaged from the frame and releases the electrical switch when the panel is in the open position.

Other objects, advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with annexed drawings, discloses preferred embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Embodiment of FIGS.1–10

Referring toFIGS. 1–10, a luminaire10in accordance with a first embodiment the present invention includes a socket holder12releasably coupled to an optical assembly14. Socket holder12supports a socket16and a light source18, which is preferably a high intensity discharge lamp. Optical assembly14encloses light source18and allows light rays to emanate therefrom. Socket holder12can support light source18in more than one orientation, as seen inFIGS. 2 and 3, allowing selection of a desired orientation. Luminaire10is mounted to a support panel20, such as a canopy or a panel retrofitable to a canopy.

Socket holder12generally includes a housing22with a first end24that supports socket16and light source18and a second end26that is adapted to mount socket holder12to optical assembly14. Housing22is preferably conical in shape and hollow thereby defining an inner receiving area28for receiving socket16and the end of light source18engaged with socket16. Housing22is also preferably formed of a substantially heat resistant material, such as metal, and is a unitary one-piece member.

First end24of housing22, which is preferably the top end of housing22, defines a central axis30and first and second surfaces32and34for supporting socket16and light source18in first and second orientations, respectively, as seen inFIGS. 2 and 3. An optional cap35, seeFIG. 4, can be used to cover first end24thereby protecting socket18. First and second surfaces32and34are preferably proximate or close to one another. First and second surfaces32and34are preferably disposed on first and second walls36and38, respectively. First wall36is substantially horizontal with respect to the sidewall40of housing22. Second wall38extends away from first wall36and is angled with respect thereto. A shoulder wall42joins first and second walls36and38. Disposed in both the first and second walls36and38are fastening holes44that receive fasteners46for securing socket16to either first wall36in the first orientation or second wall38in the second orientation.

As seen inFIG. 2, socket16is secured to first wall36by fasteners46so that light source18is in the first orientation. In the first orientation, first wall36, socket16and light source18define a longitudinal axis48that is substantially parallel to central axis30of socket holder12. The first orientation is preferably a substantially vertical orientation when luminaire10is mounted to support panel20that is substantially horizontal such that longitudinal axis48is substantially perpendicular to panel20. However, if luminaire10is mounted to a vertical support panel or sidewall, or is mounted to a slanted support panel or wall, then the first orientation of socket16and light source18would be substantially perpendicular to the panel.

As seen inFIG. 3, second wall38, socket16and light source18define a second longitudinal axis50in the second orientation. Second longitudinal axis50is angled with respect to central axis30of socket holder12. An angle a is defined between longitudinal axis50and central axis30. Angle a is preferably acute, such as 15 degrees, however, angle a can be substantially 0 degrees or substantially 90 degrees.

Although it is preferable that first wall36is substantially horizontal and second wall38is substantially angled therefrom, first wall36can also be angled thereby changing the first orientation of socket16and light source18. For example, the first and second walls36and38can converge and meet to form an inverted V so that each longitudinal axis48and50, respectively, is angled with respect to socket holder central axis30. Similarly, the angle of second wall38can be varied between being generally aligned with first wall36so that longitudinal axes48and50are substantially parallel, and being generally perpendicular to first wall36so that second longitudinal axis50is substantially perpendicular to longitudinal axis48.

The second end26of housing22, which is preferably the bottom end, includes an outwardly extending circumferential flange52extending from a bottom edge of housing22. Flange52includes generally planar upper and lower surfaces54and56and an outer shoulder58. First and second mounting members60are supported by flange52and engage optical assembly14. Although it is preferable to use two mounting members60, any number of mounting members60can be employed and only one mounting member60is required.

Each mounting member60includes a guide portion62for facilitating engagement of the mounting members60with optical assembly14and a locking portion64for interlocking the mounting members60with optical assembly14, as seen inFIG. 4. Locking portion64is preferably a mounting bolt.

As seen inFIG. 6, guide portion62includes a ring body66with depending arcuate ears68extending from opposite radial sides of ring body66. The central opening70of ring body66is threaded. A first dimension d1′ of guide portion62is defined between the outer surfaces72and74of ears68respectively. A second dimension d2′ of guide portion62is defined between the sides76of each ear68. Each guide portion ring body66is attached to flange lower surface56so that ears68extend downwardly from flange lower surface56at substantially ninety degrees, as seen inFIG. 4. Although it is preferably to use ring body66, body66can be eliminated such that ears68are directly attached to and extend from flange lower surface56. Central opening70of each ring body66is aligned with first and second threaded receiving wells78and80, respectively.

As seen inFIGS. 7 and 8, first and second receiving wells78and80each extend upwardly from flange upper surface54and includes a hollow threaded interior82, an open end84aligned with ring body66and an opposite closed end86. Each guide portion62and corresponding receiving wells78or80are preferably disposed on opposite sides of socket holder housing22. Threaded central opening70of ring body66of guide portion62and threaded interior82of each receiving well78and80are adapted to engage a part of locking portion64, preferably a threaded stem88of the locking portion or mounting bolt64.

Locking portion64of each mounting member60includes a bolt head90at a distal end of stem88. Mounting bolt head90is adapted to engage a part of optical assembly14, thereby interlocking socket holder12and optical assembly14. The diameter of mounting bolt head90defines a first dimension d1″ of locking portion64, as best seen inFIGS. 7 and 8, that is substantially the same as the first dimension d1′ of guide portion62. A second dimension d2″ of locking portion64is defined by the diameter of mounting bolt stem88, as best seen inFIGS. 9 and 10, that is substantially the same as the second dimension d2′ of guide portion62. As such, when locking portion64is coupled with guide portion62, the ears68of guide portion62will be as wide, i.e. the first dimension d1′, as locking portion bolt head90, i.e. the first dimension d1″, as seen inFIGS. 6,7and8. Ears68will also be as narrow, i.e. the second dimension d2′, as locking portion stem88, i.e. the second dimension d2″, as seen inFIGS. 6,9and10(ears68being shown in dashed lines). This design facilitates engagement of locking portion64with optical assembly14.

A gasket receiving recess94is formed between shoulder58and the lower surface56of flange52. A ring shaped gasket96is received in recess94. Gasket96abuts flange lower surface56and is disposed outside of mounting members60and adjacent outer shoulder58of flange52. Gasket96is preferably made of compressible foam but can be any known compressible material such as rubber, felt and silicone. Secondary receiving wells98can be optionally included on socket housing22that are similar to but smaller than receiving wells78and80. Secondary receiving wells98allow socket holder12to attached directly to support panel20as will be described below with respect to the second embodiment.

As seen in FIGS.4and6–8, the distance D that guide portion ears68extend from the lower surface56of socket housing flange52controls the depth at which locking portion bolt stem88of each mounting member60extends or is threaded into receiving wells78and80. This dictates the appropriate location of locking portion64, particularly bolt head90, for proper securement of locking portion64with optical assembly14. This prevents locking portion64of each mounting members60from being threaded into receiving wells78and80too far which would create difficulty in engaging locking portion64with optical assembly14, or not far enough which would create a loose or less secure engagement of locking portion64with optical assembly14.

As seen inFIGS. 1–3, optical assembly14generally includes a reflector100coupled to a refractor102with light source18being enclosed therebetween. Reflector100is preferably bowl shaped with a circular outer perimeter104and inner and outer curved surfaces106and108. Reflector100includes first and second end portions110and112with first end portion110being substantially smaller than second end portion112. A reflector wall114extends between first and second end portions110and112and slopes or tapers outwardly from first end portion11to second end portion112. Although it is preferable that reflector100is bowl shaped, reflector100can be other shapes such as a box or plate shaped as long as reflector100can engage support panel20.

First end portion110of reflector100includes a central planar surface116having a mounting interface118for engaging mounting members60of socket holder12and a central opening120for receiving light source18. Mounting interface118preferably includes mounting apertures122that engage locking portions64of mounting members60. Mounting apertures122are preferably key hole shaped and disposed concentrically around central opening120. Each key hole mounting aperture122includes first and second sections124and126with first section124being substantially larger than second section126. A pair of locking detents128are also disposed of either side of each mounting aperture122.

Second end portion112of reflector100includes an outer shoulder130extending from outer perimeter104and is formed by a first wall132that extends outwardly and a second wall134extending generally perpendicularly from first wall132. Attached to the outer surface108of reflector100at shoulder first wall132is a conventional starter146and conventional capacitor148supported on a bracket149, as seen inFIG. 1. Although it is preferable that reflector100supports starter146and capacitor148, starter146and capacitor148can be located remotely therefrom such as on support panel20.

Refractor102is preferably a glass lens but can be formed of a plastic material as well. Refractor102has bowl shape with smooth inner and outer surfaces138and140and an outer edge142. A ring shaped gasket144is disposed between reflector100and refractor102and is preferably disposed on outer edge142of refractor102. Gasket144is preferably made of a rubber material but can be made of any known material such as felt.

Support panel20is preferably a panel that can be retrofit into an existing canopy or ceiling150(seeFIGS. 2 and 3) in the same manner disclosed in commonly owned U.S. Pat. No. 6,276,818 to Wang and entitled Latch Assembly For Luminaire Housing Door, and U.S. Pat. No. 6,182,848 to Wang and entitled Luminaire Housing With Universal Dual Surface cantilever Hinge, the subject matter of each of which is herein incorporated by reference. In such a retrofit application, support panel20includes at least one hinge152and at least one latch154for mounting the panel20to an existing canopy or ceiling in the same manner described in U.S. Pat. No. 6,394,628. However, support20can also be just the canopy or ceiling in new installation applications.

Support panel20, whether in a retrofit or new installation application, includes an opening156for supporting optical assembly14. Securing fasteners158are used to secure reflector100and refractor102with respect to panel20thereby securing optical assembly14and restricting the movement thereof with respect to panel20. Support panel also includes generally planar upper and lower surfaces160and162. Opening156is defined by a perimeter edge of164.

Assembly of Embodiment of FIGS.1–10

Assembly of luminaire10initially requires mounting socket holder12to optical assembly14at the mounting interface118of reflector100. Specifically, locking portions64of each mounting member60are coupled to corresponding guide portions62and receiving wells78and80, respectively, of socket housing22. Since mounting members60are substantially identical, the assembly of only one mounting member60is described. Mounting bolt stem88of mounting member60is threaded through central opening70of a respective guide portion ring body66and into a threaded receiving well78and80, respectively, (seeFIG. 7, showing receiving well78) until mounting bolt head90abut ears68of the guide portion62. This places mounting bolt head90at the appropriate distance from socket housing flange52for proper engagement with reflector100of optical assembly14.

Socket holder12can then be mounted to mounting interface118of reflector100by inserting mounting bolt heads90of each mounting member60into first sections124of respective mounting aperture key holes122of the mounting interface118, as seen inFIG. 7. Since mounting members60of socket holder12are substantially identical and key holes122are substantially identical, the engagement of only one mounting member and one key hole122is described. In this initial position, socket holder12is unlocked with respect to reflector100, the bottom of ears68of mounting member guide portion62abut a distal edge136of key hole first section124. Also, mounting bolt head90is located just below reflector wall114with mounting bolt stem88extending through key hole first section124. The first dimension d1′ of guide portion ears68and the first dimension d1″ of mounting bolt head90are slightly less than the width of key hole first section124allowing easy insertion of mounting bolt head90and ears68into key hole first section124, as seen inFIG. 9. Gasket96is received in receiving recess94of socket holder12and rests on outer surface108of reflector wall114surrounding mounting aperture key holes122. Gasket96is sandwiched between socket housing flange52and reflector100.

Socket holder12can then be rotated about its central axis30, preferably clockwise, to a locked position with reflector100remaining stationary. Specifically, while rotating socket holder12, gasket96is compressed, thereby lowering mounting bolt head90with respect to reflector wall114to clear locking detents128located on reflector wall inner surface106as guide portion62and mounting bolt stem88pass from key hole first section124to key hole second section126. Once locking detents128are cleared, socket holder12is released allowing gasket96to expand to its near normal thickness, thereby lifting mounting bolt head90until it abuts reflector wall inner surface106to provide a tight engagement between mounting bolt head90and reflector wall114. Gasket96also provides a seal against water and insects. In this locked position, ears68of mounting member60abut a distal edge137, opposite distal edge136, of second section126of mounting aperture key hole122. Since the second dimension d2′ of ears68is less than the mounting bolt head first dimension d1″ and is generally equal to mounting bolt stem dimension d2″, ears68fit into key hole second section126, as seen inFIG. 10. Mounting bolt head90is trapped underneath reflector wall114with locking detents128preventing lateral movement of mounting member60, as seen inFIGS. 8 and 10.

To move socket holder12back to the unlocked position, gasket96is again compressed while socket holder12is rotated about central axis in a direction opposite that direction to lock socket holder12, preferably a counter clockwise direction. By compressing gasket96, mounting bolt head90is lowered and clears locking detents128as ears68and mounting bolt stem88pass from key hole second section126back to key hole first section124. Socket holder12can then be disengaged from reflector100by lifting mounting member60, specifically mounting bolt head90and ears68from key hole first section124. Since ears68have the same width or first dimension d1as mounting bolt head first dimension d1″, disengagement and removal of mounting bolt head90from key hole122is facilitated. In particular, ears68will abut distal edge of key hole first section124thereby so that mounting bolt head90can be pulled straight through key hole first section124without interference from reflector wall114. Without ears68, a portion of mounting bolt head90would likely slide underneath reflector wall114so that when attempting to pull mounting bolt head90through key hole first section124, that portion of mounting bolt head90would abut inner surface106of reflector wall114, thereby preventing easy removal of mounting bolt head90.

The mounting member60and key hole122arrangement is preferably used to releasably secure socket holder12to reflector100of optical assembly14since this allows easy installation of socket holder212and light source18and facilitates replacement of light source18by simply rotating and unlocking socket holder12. However, other known mounting mechanisms can be used such as using brackets or clips. Also, a fixed attachment can be used to secure socket holder12and reflector100such as by welding or using a sealant or adhesive. Additionally, although it is preferable that each mounting member60be formed of a separate guide portion62and locking portion64coupled together, each mounting member60can be formed as a one-piece member incorporating guide portion62and locking portion64.

Socket16and light source18can then be mounted to socket holder12in a desired position, i.e. in the first or second orientation. In the first orientation, socket16is secured to first surface32on first wall36by fasteners46so that socket16abuts first wall36and the longitudinal axis48of light source18is generally parallel to central axis30of socket holder12, as seen inFIG. 2. Similarly, in the second orientation, socket16is secured to second surface34on second wall38by fasteners48so that the longitudinal axis50of light source18is angled with respect to socket holder central axis30, as seen inFIG. 3. In either orientation, light source18extends through central opening120of first end portion110of reflector100.

Optical assembly14is mounted to support panel20by securing reflector100to the upper surface160of panel20with outer edge142of refractor102being disposed between reflector100and panel20, as best seen inFIGS. 2 and 3. Socket holder12can be mounted to reflector100as described above either before or after optical assembly14is mounted to support panel20. Refractor102is placed in panel opening156allowing refractor102to drop below panel20due to its bowl shape with the outer edge142remaining above panel20. The outer surface140of refractor102rests on the perimeter edge164of panel opening156. Reflector100is placed over panel opening156above panel20, thereby covering refractor102, with second wall134of outer shoulder130resting on panel upper surface160. Light source18extends through panel opening156and below panel20. Refractor102encloses light source18from below and allows light to emanate therefrom. Second wall134of reflector outer shoulder130is spaced from refractor outer edge142. Gasket144is disposed between reflector shoulder first wall132and refractor outer edge142to provide a seal therebetween.

Securing fasteners158are used to secure optical assembly14with respect to panel20. In particular, each fastener158is inserted through panel20and through reflector shoulder first wall132, as seen inFIGS. 2 and 3. This secures reflector100to panel20and in turn secures refractor102which is sandwiched between reflector100and panel20. Thus, once optical assembly14is mounted to panel20, optical assembly14is substantially restricted from moving with respect to panel20. Also, reflector100acts as a support for socket holder12including socket16and light source18. This eliminates the need for an additional part to support socket16and light source18. A conventional ballast (not shown) is preferably remotely located such as on the panel upper surface160. However, the ballast does not have to be remotely located. For example, the ballast can be placed closed to socket holder12by any type of known support member. Wires166(seeFIG. 4) electrically connect socket16and the ballast.

In retrofit applications, panel20with luminaire10mounted thereon as described above, is itself mounted to a canopy or ceiling160in the same manner as described in U.S. Pat. Nos. 6,276,818 and 6,182,848 and therefore is not described in detail. In general, panel20with luminaire10mounted thereto is inserted into a canopy or ceiling opening168(seeFIGS. 2 and 3), typically after an existing luminaire has been removed. Hinges152engage the canopy and allow panel20to pivot with respect to the canopy. Latches154secure panel20and luminaire10in the canopy when the panel20is pivoted up into the canopy or ceiling opening168. Either the ballast from the pre-existing luminaire or a new ballast can be connected to socket16of luminaire10by wires166. In new installation applications, luminaire10is simply mounted to support panel20as described above.

Embodiment of FIGS.11–14

Referring toFIGS. 11–14, a luminaire210in accordance with a second embodiment of the invention generally includes a socket holder212secured to a support panel220and an optical assembly214releasably coupled to socket holder212. Support panel220can be either a retrofit panel for attachment to a canopy or ceiling or can be the canopy or ceiling itself. Socket holder212supports a socket216and a light source218. Socket holder212can support light source218in more than one orientation, as seen inFIGS. 12 and 13, allowing selection of a desired orientation. Optical assembly214encloses light source218and allows light rays to emanate therefrom.

Socket holder212is substantially identical to socket holder12of the first embodiment and therefore the reference numerals used to describe socket holder212are the same as the reference numerals for socket holder12with the numeral 2 added to the front. Gasket296differs from gasket96of the first embodiment in that it is wider and includes openings304, seeFIG. 11, that allow mounting members or bolts260to extend through gasket296. Socket holder212includes mounting members260that are mounting bolts264each with a bolt head290. Two mounting members260do not include a guide portion like guide portion62of the first embodiment. Each mounting bolt264is threaded into a portion of respective receiving wells278and280leaving a substantially part of each mounting bolt264exposed under socket holder212for easy engagement with optical assembly214.

Optical assembly214is substantially similar to the optical assembly disclosed in U.S. Pat. No. 6,394,628 to Wang and entitled Ballast Housing For Luminaire, the subject matter of which is herein incorporated by reference, and is therefore described only in sufficient to understand the present invention. In general, optical assembly214includes a mounting casting300coupled to a refractor302. Inner surface306of mounting member306includes a reflective coating so that mounting member300acts a reflector. Mounting casting300includes a central mounting interface318including a mounting cone316and mounting apertures or key holes322, as best seen inFIG. 14. Key holes322are substantially identical to key holes122of the first embodiment.

A second gasket334is generally square shaped with a central hole and rests on the upper surface308of mounting casting300surrounding key holes322, as seen inFIG. 14. Mounting casting300includes an outer perimeter shoulder330adapted to engage refractor302by hinges332and latch336(seeFIG. 14.), as described in U.S. Pat. No. 6,394,628. Extending from the inner or lower surface306of mounting casting300are optional fasteners312for supporting a reflector314.

Refractor302is preferably a bowl shaped glass lens with a flat bottom338and includes a frame340that is attached to and disposed around an upper outer edge342of refractor302. As with refractor102of the first embodiment, refractor302can be a variety of shapes as desired. Frame340is adapted for engaging reflector outer shoulder330via hinges332and latch336. A third ring gasket344is disposed around refractor outer edge342between frame340and refractor302thereby creating a seal between refractor102and frame340.

Support panel220includes upper and lower surfaces360and362and an opening368for mounting luminaire210. Disposed concentrically around panel opening368are preferably four mounting holes370(seeFIG. 11showing two mounting holes370).

Assembly of Embodiment of FIGS.11–14

Assembly of luminaire210initially requires assembly of mounting members260with receiving wells278and280of socket holder212by threading each mounting bolt264into a respective receiving well278and280and leaving a substantial part of each bolt254exposed, as best seen inFIG. 11. Additionally, mounting bolts264of each mounting member260are also inserted through openings304of gasket296with gasket296being located between socket holder flange252and the mounting bolt heads290of bolts264. Socket216and light source218are secured to socket holder212first end224in either the first or second orientation as described above with respect to the first embodiment.

Socket holder212is then secured to the upper surface360of panel220by fasteners350, as seen inFIG. 13. In particular, socket holder212is placed over panel opening368so that gasket296of socket holder212is disposed on panel upper surface360around panel opening368and socket holder flange252also extends around panel368. Preferably two fasteners350are inserted through two of the panel mounting holes370, respectively, and threaded into secondary receiving wells298of socket holder212thereby securing socket holder212to panel220, as seen inFIG. 13. At the same time, mounting bolts264of mounting members260are inserted through the remaining two panel openings270, as seen inFIG. 12, as extend below panel220. Light source218, whether in the first or second orientation extends through panel opening268. A conventional ballast, starter and capacitor (not shown) are preferably located on panel upper surface360and electrically connected to socket216by wiring.

With socket holder212secured in place on panel220, optical assembly214is mounted to socket holder212by engaging mounting members260with mounting interface318of mounting casting300. Specifically, optical assembly214is lifted so that mounting bolt heads290of mounting members260extend through key holes322of mounting casting300. Also, mounting cone316of mounting casting300extends into inner receiving are228of socket holder212to facilitate proper positioning of optical assembly214with respect to socket holder212. Optical assembly214is rotated, such as clockwise, to lock mounting bolt heads290with respect to key holes322, in the same manner as described above except no guide portions are used with mounting members260. Also the engagement of mounting members260and key holes322is the same as described regarding similar mounting mechanisms in U.S. Pat. No. 6,394,628. To remove optical assembly214, the assembly214is rotated in the opposite direction, such as clockwise.

Although using a mounting bolt264and key hole322engagement is preferable to secure optical assembly to socket holder212. This allows for a variety of optical assemblies to be mounted to socket holder212as long as they include key holes for engagement with mounting members260of socket holder212. However, any known securing or mounting mechanism can be used. For example, fasteners that extend through mounting casting300, panel220and socket holder flange252can be used to fixed optical assembly214with respect to panel220and socket holder212. Alternatively, brackets or clips can be used to connect optical assembly to either socket holder212or panel220or both.

Although it is preferably two employ two mounting members260and two fasteners350with socket holder212, any number of mounting members260or fasteners350can be used and only one mounting member260and one fastener350is required. Similarly, any number of key holes322can be used and only one key hole322is required.

If panel220is a retrofit panel to be used in retrofitting or replacing an existing luminaire, panel220and luminaire210mounted thereon would be mounted to an existing canopy or ceiling in the same manner as described above with respect to the first embodiment.

Embodiment of FIGS.15–28

Referring toFIGS. 15–28, a luminaire410in accordance with a third embodiment of the present invention includes a socket holder412coupled to an optical assembly414that are supported in a host housing418. Housing418is preferably mounted to a ceiling or canopy but can be mounted to any support, such as a pole. Socket holder412and optical assembly414are the same as socket holder12and optical assembly14, respectively, of the first embodiment and therefore will not be described in further detail. Socket holder412and optical assembly414are supported by a support panel420that is engagable with host housing418, as seen inFIG. 15. Panel420can also be mounted in a ceiling or canopy by engaging a grid or frame of the ceiling/canopy. Panel420includes latches422that allow panel420to be releasably latched to housing418and hinges424which allow panel420to pivotally move between open and closed positions with respect to housing418. Latches422and hinges424are supported on secondary walls426of panel420which hide the latches422and hinges424from view. A switch assembly428is disposed on panel420and provides a safety mechanism against electrical shock when changing or operating the lamp of luminaire410.

As seen inFIG. 15, housing418is substantially identical to the housing disclosed in commonly assigned U.S. Pat. Nos. 6,276,818 and 6,182,848 and therefore will not be described in detail. In general, housing418is preferably box shaped with one open side430for accommodating panel420. Housing418includes a base wall432and four depending side walls434which each terminate at a free edge436. The open side430of housing418is located at the free edges436of side walls434. Extending from the inner surfaces438of each side wall434is a frame or flange440for engaging latches422and hinges424of panel420. Disposed within housing420is a conventional ballast442for powering and operating luminaire410, as seen inFIG. 15. Ballast442can be located on any wall of housing418or remote from housing418such as on a ceiling or canopy on which housing418is mounted. Also, ballast442is not required if incandescent lamp is used with luminaire410.

As seen inFIGS. 15 and 16, support panel420generally includes a main wall444that has an outer perimeter446and a central opening448for receiving optical assembly414in the same manner that central opening156of panel20receives optical assembly14of the first embodiment. Fasteners460secure the reflector462, lens464and gasket466of optical assembly414to panel420in the same manner as fasteners158secure reflector100, lens102and gasket144to panel20of the first embodiment.

Main wall444includes opposite first and second surfaces450and452. A plurality of side walls454extend from first surface450at the outer perimeter446of main wall444, as seen inFIG. 16. Although, it is preferable that four side walls454be employed, any number of side walls can be used or only a single side wall can be used. Each side wall454includes a free edge456opposite main wall444. Corners458are formed at the junction of side walls454.

Secondary walls426extend from side walls454at free edges456toward central opening448of main wall444and optical assembly414so that each secondary wall426extends over a portion of first surface450of main wall444, as seen inFIGS. 15 and 16. Secondary walls426support latches422and hinges424. Although it is preferable to employ four secondary walls426, only one secondary walls426that supports a single latch422or a single hinge424, is necessary. In that case, a second latch422or hinge424could be added to main wall444. Alternatively, two secondary walls426can be employed with each supporting a single latch422or hinge424, respectively.

Each secondary wall426is preferably substantially square in shape with one secondary wall426being disposed in each corner458between side walls454, as seen inFIG. 16. However, each secondary wall426can be any desired shape including any polygonal shape such as a rectangle or triangle or any curved shape such as a segment or semi-circle shape. Each secondary wall426is substantially planar with a first surface470facing first surface450of main wall444and a second surface472that is opposite first surface470. A space S is defined between the first surface470of secondary wall426and the first surface450of main wall444, as best seen inFIGS. 18 and 23, for hiding latches422and hinges424and any hardware used therewith. Each secondary wall426includes four sides474with two of the sides474being attached to side walls454at a corner458and the other two sides476being free from attachment. Although it is preferable that sides474of secondary walls are attached to side walls454at corners458, secondary walls426can be attached to any portion of side walls454and/or only one side474of each secondary wall can be attached to a side wall454.

As seen inFIGS. 16–20, two of secondary walls426support first and second latches422, respectively. Preferably the two secondary walls426that support latches422are attached to a common side wall454of panel420, as best seen inFIG. 16. Each of the two secondary walls426include an elongated guide slot478for receiving a portion of each latch422. Elongated slot478extends between one of the attached sides474of secondary wall426and one of the free sides476and includes first and second ends479and481. Elongated slot478is generally aligned with a corresponding slot468in main wall444, as best seen inFIGS. 17,19and20. Since each latch422is identical, only one latch422will be described with respect to one secondary wall426. Although it is preferable to employ more than one latch422, only a single latch422is necessary.

Latch422includes a latching plate480and a coupling extension482for coupling latching plate480to the secondary wall426supporting latch422. Latching plate480is substantially square but can be any polygonal or circular shape. Coupling extension482extends from a first surface484of latching plate480at a first end486thereof and preferably includes a flange portion488with a extension portion490extending between flange488and first end486. Flange portion488and extension portion490are substantially coplanar, substantially perpendicular to latching plate480and form a substantially T-shaped member. Extension portion490has a width that is slightly less than the width of elongated slot478, as best seen inFIG. 17. Flange portion488preferably has a length slightly less than the length of elongated slot478. However, the length of flange portion488can range between slightly less than the length of slot478to slightly greater than the width of slot478. Coupling extension482is slidable between first and second ends479and481of elongated guide slot478to move latching plate480between latched and unlatched positions. Coupling extension482is allowed to extend into the space S between the respective secondary wall426and main wall444, thereby hiding coupling extension482from view when panel420is closed with respect to host housing418and frame440, as seen inFIG. 19.

Extending from a second surface492opposite first surface484at a second opposite end494is a second extension or flange496, as seen inFIGS. 17–20. Second flange496is preferably substantially perpendicular to latching plate480. Although it is preferable to include second flange496with latching plate480, flange494can be eliminated so that no structure extends from the second end494of latching plate480.

An actuating member498extends through slot468of panel main wall444and through elongated guide slot478of the secondary wall426supporting latch422and engages a threaded aperture500of latching plate480, as best seen inFIGS. 17,19and20. Actuating member498is preferably a fastener, such as a screw and provides a handle for operatively moving latch422. Since extension portion490of latching plate480has a width that is only slightly less than the width of elongated guide slot478and has substantially the same shape in cross-section, e.g. rectangular, as guide slot478, latching plate480will not rotate with actuating member498when member498is threaded into aperture500of latching plate480because the edges of extension portion490will abut the edges of slot478.

As seen in FIGS.16and21–23, the other two secondary walls426support first and second hinges424. Preferably the two secondary walls426that support hinges424are attached to a common side wall454of panel420. Each hinge426is the same as hinges152of the first embodiment which are the same as the hinges disclosed in U.S. Pat. Nos. 6,276,818 and 6,182,848 and therefore will not be described in detail. In general, each hinge426includes a first section504that pivotally engages frame440of host housing418and a second section506that attaches to the second surface472of respective secondary walls426. Fasteners508extend through second section506and the secondary wall426, thereby securing hinge424to the secondary wall426. The ends510of fasteners508are allowed to extend into the space S between secondary wall426and main wall444and are thus hidden from view when panel420is closed, as seen inFIG. 23. Although it is preferable to use two hinges424, only a single hinge422is necessary.

As seen in FIGS.16and24–28, switch assembly428is disposed on one of secondary walls426. In particular, switch assembly428is preferably disposed on one of the hinges424so that the hinge424is located between switch assembly428and secondary wall426. Switch assembly428provides a safety mechanism for interrupting power to socket holder412and optical assembly414of luminaire410upon opening panel420with respect to host housing418. In general, switch assembly428includes a switch housing514that receives an electrical switch516and a lever518for actuating electrical switch516.

Electrical switch516is any conventional electrical switch, such as the V7-3E11E9 made by Honeywell, and includes a spring loaded actuator button520and electrically connected input and output leads522and524. Connected to input lead522are electrical wires526which are connected to a power source528(FIGS. 27 and 28). Connected to output lead524are electrical wires530which are connected to ballast442. Actuator button520is biased in an open position where the electrical connection between input and output leads522and524is interrupted thus ceasing power to ballast442and luminaire410, as seen inFIGS. 25 and 27.

Electrical switch516is received within switch housing514and is secured thereto by pins532such that switch516is suspended within housing514. Switch housing514includes a cover wall534with two depending walls536extending from opposing side edges538of cover wall534. Electrical wires526and530can extend into and out of housing514through first and second open ends540and542between cover wall534and depending walls536. A securing flange544extends from one of the depending walls536remote from cover wall534and is attachable to hinge second section506. Preferably, fasteners508extend through both switch housing flange544and hinge second section506and through the respective secondary wall426, thereby securing switch assembly428and hinge422to the secondary wall426, as seen inFIG. 24.

Lever518includes first, second and third portions546,548,550and first and second opposing ends552and554. Second portion548is located between first and third portions546and550and is substantially perpendicular to first and third portions546and550, as seen inFIGS. 25 and 26. First end552is engagable with frame440and second portion is pivotally engagable switch housing514. First portion546extends through first open end540of switch housing514so that first end552extends outside of switch housing514. Extension portions556extend laterally outwardly from third portion550near second end554and pivotally engage corresponding apertures558in switch housing depending walls536, as seen inFIGS. 24–26. The pivotal engagement of lever third portion550and switch housing514is spaced from electrical switch516so that lever third portion550rests on actuating button520, as seen inFIGS. 25 and 26. Additionally, one of the depending walls536includes a vertical slot557connected to pivot aperture558of that depending wall536, as seen inFIG. 25. Vertical slot557facilitates assembly of lever518and switch housing514.

Assembly and Operation of Embodiment of FIGS.15–28

Referring toFIGS. 15–28, socket holder412and optical assembly414of luminaire410are assembled in the same manner as socket holder12and optical assembly14of luminaire10of the first embodiment. Similarly, socket holder412and optical assembly414of luminaire410are mounted to panel420in the same manner as luminaire10is mounted to panel20of the first embodiment. Each latch422is assembled with a respective secondary wall426of panel420. The assembly of only one latch422with one respective secondary wall426will be described since the assembly is the same for both latches422. Initially latch422is rotated so that coupling extension482is aligned with elongated guide slot478of the secondary wall426. Since the length of flange488of coupling extension482is less than the length of guide slot478, coupling extension can then be inserted through guide slot478until latching plate480rests on secondary wall second surface472. Latch422is then rotated a second time ninety degrees so that flange488of coupling extension482is substantially perpendicular to the length of guide slot478, as best seen inFIGS. 17 and 18. In this position, latch422will not disassemble or disengage from secondary wall426because the length of flange488of coupling extension482is greater than the width of guide slot478. Actuating member498is then inserted through slot468of panel main wall444and through guide slot478and threaded into latching plate480via threaded aperture500. Extension490of latch422will prevent latching plate480from rotating when threaded actuating member498into latching plate aperture500. If removal of latch422is desired, actuating member498is disengaged from latching plate498, latch422is rotated until coupling extension482is aligned with guide slot478allowing flange488of coupling extension482to be pulled back through guide slot478.

Hinges424are attached to respective secondary walls426by extending fasteners508through the second sections506of each hinge424and through each secondary wall426, as seen inFIGS. 22 and 23. Hinges422are positioned on respective secondary walls426such that hinge first portions504extend beyond panel side walls454to facilitate the pivotal engagement of hinges422and frame440of host housing418.

Switch assembly428is preferably secured on top of one of hinges424, as seen inFIGS. 16 and 24. Switch assembly428is first assembled by coupling lever518housing514by inserting extension portions556into pivot apertures558of housing514. Since extension portions556are wider than switch housing514, vertical slot557is provided to facilitate the engagement of portions556and housing514. In particular, at least one extension portion556of lever518is aligned with and inserted into vertical slot557of housing514and is slid along vertical slot557until the extension portion558reaches pivot aperture558. This allows the second extension portion558to be inserted into the second pivot aperture558. The lever518can then rotated into an operative position, as seen inFIGS. 25 and 26. Vertical slot557also prevents lever518from being removed from housing514until lever member518is rotated back and one of the extension portions556is again aligned with vertical slot557. Switch516is then secured to housing514by pins532.

Switch housing514with electrical switch516secured therein is then placed over hinge second portion506so that switch516is located between cover wall534and hinge second portion506, and lever first end552extends outside of switch housing516toward frame440. Electrical wires526and530of switch516extend through switch housing second open end542.

Panel420with socket holder412and optical assembly414of luminaire410, latches422, hinges424and switch assembly428secured thereto is mounted to host housing418in substantially the same manner as the panel and housing described in U.S. Pat. Nos. 6,276,818 and 6,182,848. Panel420is preferably retrofitted to an existing host housing418. This allows the use of the existing ballast442with socket holder412and optical assembly414of luminaire410rather than requiring a new ballast. However, panel420and luminaire410can also be employed in a new installation application with a new ballast.

Initially, hinges424of panel420are pivotally engaged with frame440of host housing418, as best seen in FIGS.15and21–24. In particular, each hinge first section504is engaged with frame upper surface562. This allows hinges424and panel420to pivot with respect to frame440between open and closed positions, as seen inFIGS. 22 and 23, respectively. In the closed position, hinges424and fasteners508will be hidden from view by panel main wall444. Socket holder412and optical assembly414of luminaire410are electrically connected to ballast442.

Latches422allow panel420to be latched to host housing418in the closed position as seen inFIGS. 18 and 19. Since latches422are identical, the latching and unlatching of panel420with frame440will be described with respect to only one latch422. To latch panel420, actuating member498is moved toward first end479of secondary wall guide slot478and simultaneously moved within main wall slot468, thereby sliding latch422toward frame440. The lower surface484of latching plate480slidably engages the upper surface562of frame440and actuating member498and latch422are moved toward frame440, thereby latching panel420to frame440, as seen inFIG. 19. In this position, latch422will be hidden from view expect for actuating member498. To unlatch or release panel420, actuating member498is moved in the opposite direction toward the second end481of secondary wall guide slot478until latching plate480of latch422is disengaged or spaced from frame440, as seen inFIG. 20. In this position, coupling extension482will be adjacent to or abutting the second end481of secondary wall guide slot478.

As seen inFIGS. 25–28, when unlatching panel420from frame440and host housing418, switch assembly428interrupts power to socket holder412and optical assembly414of luminaire410to protect an operator of the luminaire against electrical shock. In particular, electrical switch516is in a normally open position with spring loaded actuating button520being biased such that the electrical connection is interrupted between input lead522, that is connected to wires526of power source528(FIG. 27), and output lead524, that is connected to wires530of ballast442(FIG. 27). This interrupts power coming from power source526to ballast442via electrical wires526and530which in turn powers luminaire410, as seen inFIG. 27. Thus, when panel420is unlatched from frame440, as seen inFIG. 25, power is cut off to luminaire410. In this position lever518of switch assembly514rests on actuating button520and switch516.

When latching panel420to frame440and host housing418, power is returned to luminaire410. Specifically, actuating button520is depressed by lever518thereby restoring the electrical connection between input and output leads522and524and restoring power to luminaire410via wires526and530, as seen inFIG. 28. As panel420is moved to a closed position with respect to frame440, first end552of lever518, which extends outside of switch housing514, is captured between the lower surface564of frame440and the upper surface472of secondary wall426, as seen inFIG. 26. Substantially simultaneously, lever third portion550pivots about extension portions556and switch housing apertures558and lever second portion548abuts and depresses actuating button520, thereby restoring the electrical connection between input and output leads522and524. Open end540of switch housing514allows lever518to freely pivot.