Reflector and sealing assembly for lighting assembly

A lighting assembly is provided having a housing supporting a lighting source such as a plurality of LEDs, a reflector having a central opening for the light source, a light transmitting cover and a frame attached to the housing to couple the frame and the light transmitting cover to the housing. The reflector has an outer perimeter with a channel formed in the top face and the bottom face for a continuous seal member. The frame is coupled to the housing to capture the frame and the light transmitting cover between the frame and the housing so that the seal members form a weatherproof seal between the light transmitting cover and the frame and between the frame and the face of the housing.

FIELD OF THE INVENTION

The present invention is directed to a lighting assembly having a reflector and a sealing device. In particular, the invention is directed to lighting assembly having reflector capable of forming a seal between the housing and transparent cover or lens of the lighting assembly.

BACKGROUND OF THE INVENTION

Lighting assemblies are constructed to illuminate an area and typically include a housing and a lens, cover or other transparent or translucent member to protect the light source. Exterior lighting assemblies generally require waterproof or weatherproof enclosures to protect the internal components from water and dirt. Gaskets are often used in exterior lighting assemblies between the various components of the housing to protect the internal components.

Many of the current exterior lighting assemblies use LEDs as the light source. The LEDs are commonly mounted on a circuit board that is then mounted in a housing to enclose the circuit board. The housing requires a weatherproof enclosure to protect the circuit board from water and dirt.

Examples housing for use with LEDs are disclosed in U.S. Pat. No. 8,267,544 to Zheng et al. discloses an LED lamp having a circuit board with a transparent cover. A sealing ring as shown inFIG. 3is received between the circuit board and the transparent cover to form a seal around the printed circuit board between the cover and the housing. The housing and the reflector do not appear to have a channel to receive the seal.

U.S. Pat. No. 8,292,449 to Poissonnet et al. discloses a modular lamp for underwater environments. As shown inFIG. 2, the lamp includes a housing supporting a circuit board and a plurality of LEDs. The housing includes a channel surrounding the circuit board for receiving a seal. The cover includes a frame that is attached to the housing to compress the seal to form a weatherproof seal around the circuit board.

U.S. Pat. No. 8,529,085 to Josefowicz et al. discloses an LED lighting fixture having a main body supporting a circuit board with a plurality of LEDs and a light transmitting cover. The housing has a recess in the housing surrounding the circuit board which forms a seal between the housing and the cover.

While the prior lighting assemblies have been generally suitable for the intended purpose, there is a continuing need in the industry for improved lighting devices.

SUMMARY OF THE INVENTION

The present invention is directed to a lighting assembly having a weatherproof enclosure. The invention is particularly directed to a lighting assembly for use with LEDs and a circuit board where the assembly includes a housing to enclose and support the LEDs and the circuit board and provide a weatherproof enclosure.

One object of the invention is to provide an enclosure for a lighting assembly having a reflector to direct light outwardly from the light source and where the reflector forms a weatherproof seal between the housing and the lens or light transmitting cover.

Another feature of the invention is to provide a lighting assembly that is economical to produce and easy to assemble while providing a weatherproof enclosure to protect the internal components during outside use.

The invention is particularly directed to a lighting assembly having a reflector where the reflector has a seal member on an outer surface for forming a seal between the reflector and the lens or light transmitting cover and a seal member on an inner surface for forming a seal between the reflector and the surface of the housing.

The housing of the lighting assembly is able to provide a weatherproof enclosure for the light source and drivers or other electrical components using the reflector to support the gasket member during assembly without the need to modify the housing or the lens to accommodate the seal member and the reflector.

The invention is suitable for a lighting assembly having an extruded or continuous molded metal housing that requires minimal machining after extrusion. The extruded housing has a substantially flat mounting surface for the LED array and circuit boards. The reflector is able to form a waterproof or weatherproof enclosure around the LED array and circuit board with the need to modify the housing. In other embodiments, other forms of housings and construction can be used. In one embodiment, the housing can be made from sheet metal that is cut and folded to the desired form.

In one embodiment of the invention, the reflector has an outer surface with a channel surrounding the perimeter and a continuous gasket or seal member received in the recess to form a seal between the reflector and the inner surface of a lens. The bottom surface of the reflector has a continuous recess around the perimeter receiving a continuous seal member for forming a seal between the reflector and the outer face of the housing.

The reflector of the invention is a one-piece member having a continuous side wall that surrounds the light source. An inner face mates with the housing and an outer face mates with a light transmitting cover member to form a weatherproof seal around the light source. Typically the reflector is made of a molded plastic material.

These and other aspects and advantages of the invention are basically attained by providing a lighting assembly having a heat conducting housing with a top face for dissipating heat and a bottom face, a circuit board coupled to the housing, a light transmitting cover, and frame for coupling the light transmitting cover and the reflector to the housing. The circuit board having a plurality of LEDs mounted thereon is coupled to the bottom face of the housing to transfer heat to the base. The reflector has a central opening surrounding the circuit board and the LEDs for reflecting light away from the LEDs. The reflector has a bottom face with a continuous channel circumscribing a perimeter of the bottom face of the reflector and a top face with a continuous second channel circumscribing said perimeter of said reflector. A first continuous seal member is mounted in the first channel and surrounds the perimeter and the central opening to form a seal between the reflector and the housing. A second continuous seal member is mounted in the second channel and surrounds the perimeter and the central opening. A transparent cover is mounted to the housing to overlie the front face of the reflector so that the second seal member forms a seal between the reflector and the transparent cover. A reflector frame is coupled to the housing to attach the reflector and transparent cover to the housing.

The features of the invention are further attained by providing a lighting assembly having a housing, a reflector, a first seal member, a transparent cover, a second seal and the reflector frame. The housing has a mounting face with a circuit board coupled to the front face. The circuit board has a plurality of LEDs mounted thereon. The reflector is mounted to the mounting face of the housing and has an inner face contacting the mounting face of the housing and an outer face opposite the inner face, and a central opening extending between the outer face and the inner face to surround the LEDs. The first seal member surrounds the central opening and is positioned between the inner face of the reflector and the mounting face of the housing to form a weatherproof seal. The transparent cover overlies the outer face of the reflector and the central opening. The second seal is positioned between the transparent cover and the outer face of the reflector. The frame overlies the transparent cover and has a central opening aligned with the LEDs where the frame is coupled directly to the housing for coupling the reflector and cover to the housing and forming a weatherproof seal between the transparent cover and the frame.

The various features of the invention are further attained by providing a lighting assembly comprising a housing, a circuit board attached to the housing, a reflector, a light transmitting cover, and a frame. The housing is made from a heat conducting material and has a mounting face. The circuit board has a plurality of LEDs mounted thereon where the circuit board is coupled to the mounting face for transferring heat to the housing. The reflector is coupled to the mounting face of the housing and has a central opening for receiving the LEDs and an outer rim surrounding the central opening. An inner top face of the reflector contacts the mounting face of the housing to form a seal between the mounting face of the housing and the reflector. An outer bottom face of the reflector forms a seal between the outer bottom face of the reflector and the light transmitting cover. The light transmitting cover overlies the reflector and the LEDs. The frame has an inwardly extending flange with an inner edge forming a central opening and overlying an outer surface of the cover. An outwardly extending flange is coupled to the housing to couple the frame and cover to the housing.

These and other aspects, objects and features of the invention will become apparent from the annexed drawings and the following detailed description of the invention, which disclose various embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a lighting assembly having a weatherproof enclosure. The invention is particularly directed to a lighting assembly for use with LEDs and a circuit board where the assembly includes a housing to enclose and support the LEDs and the circuit board and provide a weatherproof enclosure.

The lighting assembly in the embodiment shown is adapted for exterior use such as a floodlight to illuminate an area. The lighting assembly can be mounted to various supports and oriented to direct the light to a selected target area.

Referring to the drawings, the lighting assembly10includes a housing12, a reflector14, a transparent cover16, and a reflector frame18. The housing12is constructed for supporting a lighting source and for mounting to a support structure such as a pole for directing light to a selected area.

In the embodiment shown, the housing12has a top wall20, a bottom wall22, and opposite side walls24. The side walls24are provided with a plurality of longitudinally extending cooling fins26for dissipating heat and protecting the electrical components. In one embodiment of the invention, the fins26extend the length of the housing and project outwardly a distance to provide sufficient cooling and heat dissipation to prevent overheating of the electrical components.

As shown inFIG. 2, the housing12has a hollow interior28for receiving various electrical components and drivers for the lighting assembly. End caps30are coupled to the opposite ends of the housing12to enclose the interior cavity28and the electrical components. As shown inFIGS. 1 and 2, the end caps30are coupled to the longitudinal ends of the housing12by screws threaded into screw holes formed in the ends of the housing. An adjustable mounting bracket or yoke can be coupled to the end caps30to position the assembly with respect to a support and direct the light to a selected area. The top wall20has an opening32for accessing the interior cavity of the housing which is closed by a suitable cover (not shown).

In the embodiment shown, the housing12is preferably made of aluminum or other heat conducting material by extrusion molding process or other molding process as known in the art. The extrusion molded housing provides a cost effective means for producing the housing with various lengths and to form continuous longitudinal surfaces that extend the length of the housing. In other embodiments, the housing can be constructed from sheet metal or other materials as known in the art that are suitable for making a housing for an electrical lighting assembly.

The bottom wall22of the housing12in the embodiment shown has a substantially flat mounting surface34. The mounting surface34preferably extends the full-length and width of the bottom wall22and has a substantially planar surface area for supporting a lighting source. In the embodiment shown, the mounting surface34is substantially flat and planar corresponding to the dimensions of the bottom wall22. Openings36are provided at the opposite longitudinal ends of the mounting surface34for supplying electrical wires and connectors to the lighting source. As shown inFIGS. 1 and 2, the longitudinal side edges of the bottom wall22include an outwardly extending cooling fin38that extends substantially perpendicular to the plane of the mounting surface34.

The lighting source40in the embodiment shown is a circuit board42having a plurality of LEDs44mounted thereon to form an array. A connector46is provided at the end of each of the circuit boards42for connecting the LEDs to a driver or power source mounted within the interior cavity28of the housing12. The LED drivers mounted within the housing can be a conventional driver an electrical components as known in the art for actuating the LEDs. The LED array44is mounted on the circuit board42to project the light away from the plane of the circuit board42and the mounting surface34.

In the embodiment shown, the circuit board42for each the lighting source40is substantially planar and has a dimension to mount directly to the mounting surface34of the housing12. The circuit boards42can be attached to the mounting surface34by a suitable adhesive, fastener or other fastening means as known in the art. The number of LEDs mounted to the circuit board can vary depending on the properties and characteristics of the circuit board, the power source and the amount of light intended to be produced by the lighting assembly. In the embodiment shown, three circuit boards are mounted on the mounting surface although the number can vary as needed. The circuit boards are mounted by a suitable means to transfer heat to the housing to prevent overheating of the LEDs and circuit board.

The reflector14has a length and width to complement the dimensions of the mounting surface34of the housing12. The reflector in one embodiment of the invention is a molded plastic material such as polycarbonate. The reflector14is preferably a one piece integrally formed unit.

The reflector14has a central opening48with a dimension complementing the dimensions of the circuit board42and the corresponding LEDs so that the central opening48surrounds the circuit boards42of the light source40. In the embodiment shown, the reflector14has a substantially rectangular shape and the central opening48has a substantially rectangular shape complementing the rectangular dimensions of the housing12, the mounting surface34, and the LED array.

The reflector14is formed by a continuous outer radial wall50having an outer radial surface52and an inner radial surface54. The outer wall50forms a perimeter of the reflector14and encircles the central opening48and defines the outer dimensions of the reflector. The outer wall50has an inner surface56configured for contacting the mounting surface34as shown inFIG. 5. An outer face58is provided opposite to the inner face56. The outer surface52and the inner surface54of the outer wall50extend between the inner face56and the outer face58. In the embodiment shown, the inner face56and the outer face58are substantially parallel to each other and substantially perpendicular to the outer surface52of the outer wall50.

The outer wall50in the embodiment shown is defined by a first end wall portion60, a second end wall portion62, and side wall portions64extending between the end wall portion60and62. A light reflecting flange66extends inwardly from the outer wall50and has an inner edge68defining the central opening48. The light reflecting flange66as shown inFIG. 6has an inwardly extending planar portion70along the first end wall portion60that extends inwardly from the outer face58toward the central opening48in a direction substantially parallel to the outer face58. An inclined portion72extends from the planar portion70and is inclined toward central opening48and annular face56and extends a distance to contact the mounting surface34when mounted on the mounting surface.

The reflecting flange66includes an inwardly extending portion74extending from the end wall portion62as shown inFIG. 7. An inclined portion76extends from the planar portion74and is inclined towards the central opening48and the inner face56. As shown inFIG. 7, the inclined portion76has a length to define a gap78between the edge of the inclined portion76to allow the wires80to pass between the opening in the mounting surface34and the connector of the circuit board42. The light reflecting flange66has side portions82extending substantially parallel to the plane of the outer wall50and spaced inwardly from the outer wall50by a connecting portion84. The side portions extend between the inclined portions72and76.

The inner face56of the reflector14includes a continuous open channel86that surrounds the perimeter of the outer wall50. The channel86is defined by a cavity with an open end, a bottom surface88and opposing side surfaces90. At least one rib92extends into the cavity of the channel86toward the open end as shown inFIG. 5. In the embodiment shown, two continuous ribs92extend from the bottom surface88so that the ends are spaced inwardly from the inner face56and the open end of the channel86.

The outer face58includes an open continuous channel94that encircles the perimeter of the outer face and the reflector. The channel94has an open end facing opposite the open end of the channel86in the inner face56. The channel94is defined by a cavity with has an open end, a bottom surface96and side surfaces98. A rib100extends from the bottom surface96toward the open end so that the end of the rib is spaced from the open end and the outer face58. In the embodiment shown, two parallel ribs100extend from the bottom surface96.

A seal member102is received in each of the channels86and94. The seal member102forms a gasket to form a weatherproof seal between the reflector14and the housing12and between the reflector14and the cover16. The seal member102is a continuous one piece seal that is received in the respective channel and surrounding the perimeter of the reflector along the inner face and the outer face. In the embodiment shown, the seal member has an annular or circular cross section with a hollow center104to allow the seal member102to compress, deform and form a seal between the opposing surfaces. The seal member102has a dimension to fit within the respective channels86and94and is sufficiently compressible to form a seal with the ribs92and100and the mounting surface34and the surface of the cover16, respectfully. In the embodiment shown, the inner face56and the outer face58are substantially parallel and face in opposite directions. The respective channels86and94also face outwardly from the plane of the reflector14in opposite directions. The cover16is supported by the reflector14so that cover does not directly contact the housing12.

The cover16is a light transmitting member in the form of a transparent or translucent plate-like member having a dimension corresponding to the outer dimension of the reflector14so that the cover16contacts the outer face58of the reflector14. As shown inFIGS. 5-7, the cover is spaced from the LED array by the reflector. In the embodiment shown, the cover16has a substantially planar configuration with a flat inner surface and a flat outer surface for transmitting light from the light source outwardly from the lighting assembly. In other embodiments, the cover16can be a lens and provided with a textured surface to defuse light or project light in a desired pattern as known in the art. The cover16has a dimension to overlie the LED array to protect the LEDs and circuit boards while transmitting the light to the target area.

The frame18is constructed for coupling directly to the housing12as shown inFIG. 5. The frame18has a continuous side wall106with an inner dimension corresponding to the outer dimension of the reflector so that the frame encircles the perimeter of the reflector. In a preferred embodiment, the side wall106of the frame18has a height corresponding to the combined height of the reflector and the cover. An inwardly extending flange108extends radially inward from the outer end of the side wall106a distance to overlie an outer edge along a perimeter of the cover16and has an inner edge defining a central opening110of the frame18. An inner end of the side wall16has an outwardly extending flange112for mating with the housing and coupling the frame to the housing. In the flange112includes a plurality of screw apertures114for receiving a screw116for coupling to a threaded aperture118in the housing for coupling the frame18to the housing. The central opening110has a dimension complementing the dimension of the LED array and the frame18.

The lighting assembly10is constructed by positioning the seal members102in the respective channels of the reflector14and positioning the reflector on the mounting surface34of the housing so that the reflector and seal member surround the circuit board42and the respective LED array44so that the LED array44is positioned within the central opening of the reflector14. The cover16is positioned on the outer face58of the reflector14and the frame18is positioned over the cover16and secured to the housing. The frame18is coupled to the housing by the screws116so that the outwardly extending flange112apply sufficient pressure to the cover16to compress the seal members102and form a weatherproof seal between the inner face56of the reflector and the mounting surface34of the housing12and a weatherproof seal between the outer face58of the reflector14and the inner surface of the cover16. In one embodiment, the cover16can be coupled to the frame18, such as by a double face adhesive tape, for use in assembly the cover and the frame to the housing.

In the lighting assembly of the invention, the seal members10to form a continuous seal around the perimeter of the inner face56and outer face58of the reflector16so that additional seals and gaskets are not necessary to provide a waterproof or weatherproof enclosure for the electrical components of the LEDs and circuit boards.

While various embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made without departing from the scope of the invention as defined in the appended claims.