Complex environment troffer

A light fixture includes a housing configured to be secured to a support surface. The housing includes a first end, a second end, and a first and a second side extending between the first end and the second end. A control component is positioned in the housing. A reflector assembly is positioned in the housing. A light emitter is connected to the reflector assembly. A door assembly is releasably connected to the housing. The door assembly has a frame bordering a central opening, a lens, positioned over the central opening, and a gasket positioned between the lens and the frame.

FIELD

The present disclosure relates to light fixtures, and particularly to a recessed light fixture.

BACKGROUND

Numerous lighting fixtures for directly illuminating areas are generally known. A common lighting assembly used in ceilings of commercial buildings includes a troffer with one or more downwardly-facing light emitters. A modular dropped ceiling grid is generally formed of interconnected inverted T-bars that are permanently attached to rigid ceiling supports, via wires or other structural means, to form a rectangular or square grid structure. Troffer lighting fixtures and ceiling tiles rest within the rectangular or square grid structure to complete the drop ceiling. Troffer lighting fixtures include a housing having four sidewalls forming a square or rectangular shape to fit within the rectangular or square grid structure. When installed, the housing is recessed within the drop ceiling.

SUMMARY

According to certain aspects, a light fixture includes a housing configured to be secured to a support surface. The housing includes a first end, a second end, and a first and a second side extending between the first end and the second end. A control component is positioned in the housing. A reflector assembly is positioned in the housing. A light emitter is connected to the reflector assembly. A door assembly is releasably connected to the housing. The door assembly has a frame bordering a central opening, a lens, positioned over the central opening, and a gasket positioned between the lens and the frame.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

FIG.1shows an example of a troffer light fixture100is supported in a recessed position relative to a ceiling102such that the bottom of the troffer is substantially flush with the ceiling102. The light fixture100includes a central opening through which light is emitted to an area, for example a room. In certain aspects, the light fixture100has a rectangular or square shape and is sized to fit in a specific ceiling opening. For example, the light fixture100may be sized to fit within a 2 ft. by 2 ft., 1 ft. by 2 ft., 1 ft. by 4 ft., 2 ft. by 4 ft., or other similar recesses. Other rectilinear or curvilinear shapes can also be used.

As best shown inFIGS.2and3, the light fixture100includes a housing110and a door assembly112. The housing110includes first and second sides114, first and second ends116, and a top118. The first and second sides114can each include a lower vertical section120and an upper vertical section122connected by a horizontal section124. This forms a stepped configuration where a lower portion of the housing110is wider than the upper portion. A lower edge126can extend from the sides114and ends116. The sides114, ends116, top118, and lower edge126can be formed from one or more discrete extruded metallic members. In certain aspects, the housing110can be formed as a unitary structure. For example, the housing110can be formed from a single piece of stamped material and folded into an appropriate shape.

In certain aspects, one or more flanges128are connected to the housing110, as best shown inFIG.3. For example, a flange128can be connected to each of the sides114and ends116. The flanges128can be attached with one or more fasteners. In an exemplary embodiment, rivets are used to connect the flanges128to the housing110. In certain aspects, a housing gasket130can be connected to the lower edge126. The housing gasket130can extend along the full length of the sides114and ends116.

One or more adjustable wing hangers132can also be connected to the housing110. For example, a pair of wing hangers132can be connected to each of the sides114. As best shown inFIG.4, the winger hangers132include a bracket134connected to the side114and an adjustment arm136movably connected to the bracket134. The adjustment arm136can be connected to the bracket134by a threaded fastener138. Rotation of the fastener138can move the arm136relative to the bracket134. When placed in a ceiling or other support structure, the position of the wing hangers132can be adjusted to provide level mounting of the housing110. For example, the arms136can engage a T-bar support structure and the position of the arms136can be adjusted for level mounting of the housing110on the T-bars.

As best shown inFIG.5, the housing110contains one or more associated electrical control components, such as drivers, controllers, sensors, etc. for operating one or more light emitters. The control components can be connected to the top118of the housing110. In the illustrated example, the control components include drivers140that are individually mounted to a support142that is attached to a lower surface of the top118. The drivers140can then be removed individually or as a group from the housing110as needed. Knockouts can be formed in the top of the housing110so that one or more main power supply lines can be run inside of the housing110and connected to one or more of the control components.

The housing110contains a light emitter assembly configured to provide a specific light distribution from the housing110.FIG.5shows an exemplary embodiment of an asymmetric light emitter assembly144that includes a plurality of LED boards146. The LED boards146include a plurality of LEDs mounted on a circuit board. The control components can be connected to the LED boards146to provide power and control the activation of the LEDs. The control components can also be configured to provide dimming, color tuning, or other output control.

The LED boards146are mounted to a respective reflector148. Each of the reflectors148has a base150for receiving the LED boards, a first side152extending from the base at an angle, and a second side154extending from the base at an angle. In the illustrated embodiment, the first and second sides152,154extend from the base in an arcing configuration. The first and second sides152,154can have one or more radii of curvature as it extends from the base150. Other configuration can utilize rectilinear portions, other curved portions, or any combination thereof. One of the sides152,154of the reflector148is longer than the other, and the base150is oriented at an oblique angle to each of the sides152,154.

Each of the reflectors148is connected to a tray156. As best shown inFIG.6, the tray156includes a series of base portions158and a series of angled walls160extending from the base portion158. In an exemplary embodiment, the angled walls160extend at approximately 20 degrees relative to the base portion158. Each of the angled walls160receives a reflector148. The tray156is connected to the lower surface of the top118of the housing110. The orientation and configuration of the light emitter assembly144can therefore provide an asymmetric light output directed to one side of the housing110. The LED boards146and reflectors148are oriented to direct light non-perpendicular to the top118of the housing110and the ceiling panel102. The position of the light emitter assembly144can be switched so that light is oriented to either side as desired.

FIG.7shows another exemplary embodiment of a symmetric light emitter assembly162that includes a plurality of LED boards146connected to a tray164. The tray164includes a flat base for receiving the LED boards146. The tray164is connected to the lower surface of the top118of the housing110. The orientation and configuration of the light emitter assembly162can provide a symmetric light output, with the LED boards146oriented to emit light substantially perpendicular to the top118of the housing110and the ceiling panel102.

In certain aspects, one or more secondary reflectors can be positioned inside of the housing110.FIG.8shows a secondary reflector assembly that includes a pair of side reflectors166and a pair of end cap reflectors168. The side reflectors166and end cap168reflectors are positioned around the light assembly reflectors148and connected to the lower edge126of the housing110. In the illustrated embodiment, the side reflectors166have an asymmetric configuration to correspond to the asymmetric output of the light emitter assembly144. The configuration of the secondary reflectors can be altered based on the desired light output.

FIGS.9and10show an exemplary embodiment of a door assembly112that can be connected to the housing110to enclose the light emitter assembly144,162. The door assembly112includes a frame170, a gasket172, a lens174, and one or more lens brackets176. The frame170includes a lower wall178defining a central opening, a side wall180extending from the lower wall178, and an upper edge182that extends from the side wall180towards the central opening. One or more openings extend through the lower wall180to receive a respective fastener184. The gasket172is positioned against the lower wall180around the central opening. In certain embodiments, the gasket172can have a set of ribs positioned against the lower wall178.

The lens174is positioned against the gasket172. The lens brackets176are positioned against the lens174to connect the lens174to the frame170. The lens brackets176have a substantially Z-shaped configuration, with a lower flange186being secured against the frame170and an upper flange188secured against the lens174. Flange nuts can be used to secure the lens brackets176, compressing the lens brackets176against the lens174, and compressing the gasket172between the lens174in the frame170. In this way, a water-tight seal can be formed around the lens174, helping to prevent the ingress of fluid through the central opening in the frame170.

As best shown inFIG.11, the door assembly112can be connected to the housing110utilizing a set of fasteners190. Gaskets192can be positioned around the fasteners190to help seal the door assembly112and the interior of the housing110. The sealed door assembly112can be utilized in sterile environments, such as health care locations, and also harsh environments, such as hazardous and wet locations, where frequent cleaning of the unit is required.

The foregoing detailed description of the certain exemplary embodiments has been provided for the purpose of explaining the general principles and practical application, thereby enabling others skilled in the art to understand the disclosure for various embodiments and with various modifications as are suited to the particular use contemplated. This description is not necessarily intended to be exhaustive or to limit the disclosure to the exemplary embodiments disclosed. Any of the embodiments and/or elements disclosed herein may be combined with one another to form various additional embodiments not specifically disclosed. Accordingly, additional embodiments are possible and are intended to be encompassed within this specification and the scope of the appended claims. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way.

As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” and other orientational descriptors are intended to facilitate the description of the exemplary embodiments of the present disclosure, and are not intended to limit the structure of the exemplary embodiments of the present disclosure to any particular position or orientation. Terms of degree, such as “substantially” or “approximately” are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, and use of the described embodiments. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.