FLEXIBLE HOUSING ASSEMBLY FOR SSL LIGHT FIXTURES

The present disclosure provides solid state lighting fixtures and housing assemblies for solid state lighting fixtures. The housing assemblies according to the present disclosure include multiple joints to permit manipulation of the housing assembly relative to its mounting structure so that a single solid state lighting fixture can be used with different mounting structures, and adjusted so that the light emitted by the solid state lighting fixture is in a desired direction.

BACKGROUND

The present disclosure relates to solid state lighting fixtures. More particularly, the present disclosure relates to housing assemblies for solid state lighting fixtures that include multiple joints to permit manipulation of the housing assembly to accommodate different mounting structures and adjust the direction of light emitted by fixture.

2. Description of the Related Art

Luminaires (light fixtures) utilizing light emitting diodes (LEDs) have in recent years become somewhat practical and continue to penetrate the lighting market due to the increased luminous efficacy of commercially available LED components. LED luminaires are desirable as they offer customers energy savings due to good luminous efficacy combined with the ability to precisely control light distribution patterns, which is of particular importance for certain lighting scenarios, such as outdoor environments, and open environments, such as parking garages and canopies. Another benefit of LED luminaires is that with the right control mechanism the LEDs are controllable. Each LED luminaire can start-up (i.e., illuminate) on a near-instantaneous basis, and may be dimmed to any level within the driver's operational range by varying the current through each LED via dimming drivers, e.g. power supplies, that offer dimming leads accepting the standard 0-10V input format.

Further energy savings of LED luminaires can be realized by providing light only where and when needed. For example, LED luminaires can be dimmed or turned off until motion is detected in an area. The LED luminaires can also be dimmed according to a time of day, or set to illuminate at full brightness from dusk through midnight or another time, and then dimmed, saving energy, but still providing an acceptable level of lighting for overnight security purposes. Selective dimming or on/off operation of LED luminaires also retards lumen depreciation and extends the service life of the LED luminaires.

Housings for solid state lighting fixtures are typically designed to rigidly mount to a wall, ceiling, pole or other mounting structure, and remain in a fixed orientation relative to the mounting structure. As a result, such fixtures have a single utility in that they can only be attached to the mounting structure they were designed for.

SUMMARY

The present disclosure provides solid state lighting (SSL) fixtures and housing assemblies for solid state lighting (SSL) fixtures. The housing assemblies according to the present disclosure include multiple joints to permit manipulation of the housing assembly relative to its mounting structure. In an exemplary embodiment, the SSL fixture includes a main body and a mounting assembly. The main body includes a housing and a light assembly within the housing. The mounting assembly has a first mounting joint for securing the mounting assembly to a mounting structure, at least one main body support member having one end secured to the first mounting joint, and at least one second mounting joint for coupling the at least one main body support member to the main body. The first mounting joint provides a first articulating joint for adjusting the position of the main body, and the second mounting joint provides a second articulating joint for adjusting the position of the main body.

DETAILED DESCRIPTION

The present disclosure provides solid state lighting (SSL) fixtures and housing assemblies for solid state lighting (SSL) fixtures. The housing assemblies according to the present disclosure include multiple joints to permit manipulation of the housing assembly relative to its mounting structure so that a single SSL fixture can be used with different mounting structures, and adjusted so that the light (visible and/or non-visible light) emitted by the SSL fixture is in a desired direction. For example, the SSL fixture can be positioned for post top mounting, the SSL fixture can be positioned for arm mount if the yoke is rotated to a horizontal position, or the SSL fixture can be positioned as a flood light if the fixture is rotated around the yoke in the post top position or the arm mount position.

Referring toFIGS. 1-3, various views of an SSL fixture10according to the present disclosure are shown. In this exemplary embodiment, the SSL fixture10is configured for upright mounting (or post top mounting) on, for example, a pole as the mounting structure. InFIGS. 1-3, the SSL fixture10includes a main body20and a mounting assembly50. The main body20includes a housing22and an SSL light assembly100that will be further described below with regard toFIGS. 16-18. In this exemplary embodiment, the housing22includes an outer housing portion24and an inner housing portion26(seen inFIG. 12). The main body housing22can be made of metal, such as aluminum, die cast aluminum, stainless steel, galvanized steel or powder coated steel, or other rigid material to provide sufficient structural integrity and provide direct convective heat exchange between the SSL light assembly100and the ambient air, especially via heat dissipating fins in the housing portions. The outer housing portion is used to couple the main body20to the mounting assembly50, and acts as a protective outer shell to protect the SSL light assembly within the housing22from the elements and damage. The outer housing portion24includes a cover28that provide access to the inner housing portion26of the housing22. The inner housing portion26is used to support the components of the SSL light assembly100.

The mounting assembly (or yoke)50includes a mounting joint, such as slip fitter52, and a pair of main body support members54and56. The slip fitter52is provided to connect the SSL fixture10to a mounting structure51, such as the pole identified above. Preferably, the slip fitter52has a hollow center for electrical power connections and/or to allow wires to pass, and a cover58to permit access to the hollow center. The slip fitter52includes body support retaining members60and62that are configured to receive and support the main body support members54and56relative to the slip fitter52, as shown. The slip fitter52can be made of metal, such as aluminum, die cast aluminum, stainless steel, galvanized steel or powder coated steel, or rigid plastic or composite materials to provide sufficient structural integrity. The slip fitter52may be releasably secured to a mounting structure, e.g., pole51or a tenon, such that the slip fitter can be rotated relative to Axis “A”, and thus relative to the mounting structure supporting the SSL fixture10. In an alternative embodiment, the slip fitter52can be a two-piece member where a first member is used to secure the slip fitter52to the mounting structure, and the second member is coupled to the first member via a swivel joint that can be locked in place using a set screw.

The main body supports54and56secure the main body20to the slip fitter52. Preferably, the main body supports54and56are rigid, hollow members that permit power wires to pass from the slip fitter52to the main body20. Each of the main body supports54and56may be a single member with a hollow center, or a two piece member that is secured together via a fastener such as a rivet, bolt, screw or adhesive. The main body supports54and56can be made of metal, such as aluminum, die cast aluminum, stainless steel, galvanized steel or powder coated steel, plastics, composite materials, or other rigid material to provide sufficient structural integrity. The embodiment ofFIGS. 1-3depict two main body supports, however, the SSL fixture10according to the present disclosure may use a single main body support or a plurality of main body supports.

The main body20is secured to the main body supports54and56via mounting joints70and72. The mounting joints permit manipulation of the main body20relative to the slip fitter52, and thus relative to a mounting structure supporting the SSL fixture10. The mounting joints70and72are preferably locking type mounting joints, such as locking knuckle joints, locking swivel joints, locking ball joints and adjustable locking hinges. In the embodiment ofFIGS. 1-3, the mounting joints70and72are knuckle joints between the main body20and each main body support member54and56. The knuckle joints allow rotation of the main body20about the knuckle joint. In this exemplary embodiment, the knuckle joint70or72uses locking teeth or serrations on opposing faces of the knuckle joint halves, such that one set of locking teeth are on the main body and the other set of locking teeth are on the main body support member. A screw74through the axis of the knuckle joint, which is along Axis B, holds the opposing locking teeth together once the main body20of the SSL fixture10has been positioned and the screw74has been tightened.

As noted above, in the embodiment ofFIGS. 1-3the SSL fixture10is configured for upright mounting (e.g., post top mounting) to, for example, a pole as the mounting structure. In the embodiment ofFIGS. 4-6, the SSL fixture10is configured for arm mounting to, for example an exterior wall, via a mounting bracket80as the mounting structure. Examples of arm mounting configurations are provided inFIGS. 7-10. Referring toFIGS. 7-9, the mounting bracket80includes a flat wall mounting plate82and a tenon84. The wall mounting plate82is secured to a wall, and the tenon84fits within the slip fitter52and can be secured to the slip fitter52with set screws, after the main body is positioned. Referring toFIG. 10, the wall bracket80is U-shaped bracket secured to the slip fitter52via, for example, a nut and bolt. The wall bracket80can be secured to a ceiling, wall or other structure to support the SSL fixture10.

Referring toFIGS. 11-16, an SSL light assembly100according to one embodiment of the present disclosure is shown. In this exemplary embodiment, the SSL light assembly100includes an SSL light engine102, a wireless module104, a voltage regulator106, a real-time clock (RTC)108, status sensors110, dimming output control112, battery back-up114and driver (or dc power supply)116. The SSL light engine102has one or more SSL elements103used to illuminate a desired area. The SSL elements103may include any solid state lighting element, such as an LED lighting element. Preferably, the SSL light engine102includes a plurality of SSL elements103mounted to a printed circuit board referred to herein as primary board105in an array or other configuration capable of lighting a desired area. The SSL light engine102and primary board105are enclosed in the main body housing22for installation in a commercial, industrial, or residential environment either indoors or outdoors.

The SSL light engine102illuminates when energized by driver116, and can be dimmed or brightened depending upon the voltage applied to the driver dimming input via the SSL light engine102under the control of the dimming output control112. An example of a suitable driver is the PLED150W-042-C3500-D3 Driver manufactured by Thomas Research Products. Another example of a suitable driver is shown in FIGS. 35 and 36 of Appendix A of Patent Application No. 62/155,264, filed on Apr. 30, 2015, titled “Flexible Housing Assembly for SSL Light Fixtures,” incorporated herein by reference. Dimming control is in the pulse width modulated (PWM) format. The driver116is capable of driving the SSL light engine102down to zero current, i.e. extinguished, where the auxiliary power supply takes over to supply power to the wireless module, since no electrical current would be available from the SSL element103strings to support the wireless module controls. The wireless module104is configured to transmit signals to the controller210(seen inFIG. 19), and receive signals from the controller210via wireless network220. Voltage regulator106maintains a constant voltage supply, e.g., 3.3 volts, for the wireless module104. The status sensors110are used to measure certain operating characteristics of the SSL light assembly100, and may include temperature sensors, and sensors to measure current and voltage (including dim voltage). Measurements from the status sensors110are transmitted to the controller210via wireless module104. The battery back-up114supplies power to the RTC108when power is otherwise unavailable to the RTC108, e.g., when there is a power outage or power to the SSL fixture is turned off. The battery back-up114enables the RTC to maintain accurate time so that the wireless module can perform scheduled operations without the need to reprogram the RTC. Embodiments of detailed circuit diagrams to implement the components disclosed inFIG. 16are provided in Appendix A of Patent Application No. 62/155,264, filed on Apr. 30, 2015, titled “Flexible Housing Assembly for SSL Light Fixtures,” incorporated herein by reference.

Referring toFIG. 17, an SSL light assembly100according to another embodiment of the present disclosure includes an SSL light engine102, a wireless module104, a voltage regulator106, a real-time clock (RTC)108, status sensors110, dimming output control112, battery back-up114, driver (or dc power supply)116and one or more sensors118, such as motion, and light or photo sensors. The SSL light engine102illuminates when energized by driver116, and can be dimmed or brightened depending upon the voltage applied to the driver dimming input via the SSL light engine102under the control of the dimming output control112. An example of a suitable driver is the PLED150W-042-C3500-D3 driver manufactured by Thomas Research Products. Another example of a suitable driver is described above with reference to FIGS. 35 and 36 in Appendix A of Patent Application No. 62/155,264, filed on Apr. 30, 2015, titled “Flexible Housing Assembly for SSL Light Fixtures,” incorporated herein by reference. The wireless module104is configured to transmit signals to the controller210(seen inFIG. 19), and receive signals from the controller210. Voltage regulator106maintains a constant voltage supply, e.g., 3.3 volts, for the wireless module104. The status sensors110are used to measure certain operating characteristics of the SSL light assembly100, and may include temperature sensors, and sensors to measure current and voltage (including dim voltage). Measurements from the status sensors110are transmitted to the controller210via wireless module104. The battery back-up114supplies power to the RTC108when power is otherwise unavailable to the RTC, e.g., when there is a power outage or power to the SSL fixture is turned off. The battery back-up114enables the RTC to maintain accurate time so that the wireless module can perform scheduled operations without the need to reprogram the RTC. The motion and/or photo sensors118can be used to control activation, deactivation or adjustment (e.g., dimming) of one or more SSL fixtures10within the SSL system200described below. An embodiment of a detailed circuit diagram to implement the components disclosed inFIG. 17is provided in Appendix A of Patent Application No. 62/155,264, filed on Apr. 30, 2015, titled “Flexible Housing Assembly for SSL Light Fixtures,” incorporated herein by reference.

Referring toFIG. 18, an SSL light assembly100according to another embodiment of the present disclosure includes an SSL light engine102, a wireless module104, a voltage regulator106, a real-time clock (RTC)108, status sensors110, dimming output control112, battery back-up114, driver (or dc power supply)116, and a motion sensor interface120in communication with an off the shelf motion sensor122enclosed within the SSL light assembly100. The SSL light engine102illuminates when energized, and can be dimmed or brightened depending upon the voltage applied to the driver dimming input via the SSL light engine104under the control of the dimming output control112. An example of a suitable driver is the PLED150W-042-C3500-D3 driver manufactured by Thomas Research Products. Another example of a suitable driver is described above with reference to FIGS. 35 and 36 of Appendix A of Patent Application No. 62/155,264, filed on Apr. 30, 2015, titled “Flexible Housing Assembly for SSL Light Fixtures,” incorporated herein by reference. The wireless module104is configured to transmit signals to the controller210(seen inFIG. 19) and receive signals from the controller210, via the wireless network220. Voltage regulator106maintains a constant voltage supply, e.g., 3.3 volts, for the wireless module104. The status sensors110are used to measure certain operating characteristics of the SSL light assembly100, and may include temperature sensors, and sensors to measure current and voltage (including dim voltage). Measurements from the status sensors110are transmitted to the controller210via wireless module104. The battery back-up114supplies power to the RTC108when power is otherwise unavailable to the RTC, e.g., when there is a power outage or power to the SSL fixture is turned off. The battery back-up114enables the RTC108to maintain accurate time so that the wireless module can perform scheduled operations without the need to reprogram the RTC. In this embodiment, the motion sensor interface120is configured to interface with off the shelf motion sensors and provides signals to the wireless module104and can be used to control activation, deactivation or adjustment of one or more SSL fixtures10within the SSL system200described below. An embodiment of a detailed circuit diagram to implement the components disclosed inFIG. 18is provided in Appendix A of Patent Application No. 62/155,264, filed on Apr. 30, 2015, titled “Flexible Housing Assembly for SSL Light Fixtures,” incorporated herein by reference.

Referring toFIGS. 19 and 20, the SSL garage or canopy lighting system200(also referred to herein as SSL system) according to an exemplary embodiment of the present disclosure includes at least one SSL fixture10, a controller210that can be used to program or otherwise provide commands, instructions, or program code to each SSL fixture10and a wireless network220interconnecting each device within the SSL system200. Preferably, the SSL system200includes a plurality of SSL fixtures10, as seen inFIG. 19. Examples of suitable controllers210include personal computers, mobile computing devices, such as a smartphone or tablets, or dedicated fixed or portable computing devices capable of providing real-time control of one or more SSL fixtures used to illuminate a desired area. The controller210may communicate to the wireless network220through, for example, a bridge node. The bridge node may be a USB wireless adapter, such as the Snap Stick 200 USB dongle manufactured by Synapse. The wireless network220is preferably a mesh network, which is also capable of communicating with individual SSL fixtures10that are outside the mesh network. When communicating with individual SSL fixtures outside the mesh network, SSL fixtures can be controlled by the controller210when it is in close proximity to the SSL fixture and using, for example, the USB wireless adapter (e.g., the SNAP Stick 200 USB dongle).FIG. 20is an embodiment of the SSL system200similar to the embodiment ofFIG. 19, except the SSL system also includes one or more sensors230, such as a light sensor, or motion sensor, or a combination of sensors. The sensors230are external to the SSL fixtures10, and are used to control one or more SSL fixtures via the wireless network220. A more detailed description of the controller210and wireless network220is provided in Appendix A of Patent Application No. 62/155,264, filed on Apr. 30, 2015, titled “Flexible Housing Assembly for SSL Light Fixtures,” incorporated herein by reference.

The signals sent to the wireless module104by the controller210, via the wireless network220, may include generally, user commands, such as set schedule command, manual control of fixture, turn fixture off, turn fixture on, dim fixture, set schedule to automatically dim fixture, or to activate fixture upon one or more sensor responses. Such commands can be sent to one SSL fixture10or to more than one SSL fixture. Signals sent to the controller210by the wireless module104may include diagnostic information from, for example, the status sensors110, such as printed circuit board temperature, the number of kilowatt hours the SSL fixture has been operating, the RTC time, and other information reflecting that one or more SSL fixture components are not functioning properly and are in need of repair, such as RTC status, battery status, etc. Signals sent to the controller210by the wireless module104may also include acknowledgements that commands from the controller have been received. The real-time clock (RTC)108provides a suitably accurate clock to the SSL fixture10components to ensure timing operations are performed at a desired time of day. More details of these components are described in Appendix A of Patent Application No. 62/155,264, filed on Apr. 30, 2015, titled “Flexible Housing Assembly for SSL Light Fixtures,” incorporated herein by reference.

It will be understood that various modifications can be made to the embodiments of the present disclosure herein without departing from the spirit and scope thereof. Therefore, the above description should not be construed as limiting the disclosure, but merely as embodiments thereof. Those skilled in the art will envision other modifications within the scope and spirit of the invention as defined by the claims appended hereto.