Modular light fixture with adjustable light distribution pattern

A modular light fixture includes an elongate light fixture base having a longitudinal axis and a plurality of light fixture modules. Each light fixture module includes a housing having an open face, and a light emitting device positioned inside the housing. The modular light fixture also includes a light emitting device driver configured for driving the light emitting devices. The light fixture modules are independently mounted to the light fixture base and extend perpendicularly from opposing sides of the light fixture base with the open faces facing a common direction to produce an initial light distribution pattern. Each light fixture module has a housing adjustment feature for independently pivoting the light fixture module about a pivot axis parallel to the longitudinal axis to modify the initial light distribution pattern. The modular light fixture includes a planar configuration in which the light fixture module housings are oriented along a common plane.

TECHNICAL FIELD

The present disclosure relates generally to light fixtures, and more particularly to the production of different light distribution patterns.

BACKGROUND

Light fixtures are provided for a wide variety of applications, including both interior and exterior applications. Even among interior and exterior uses, there are a variety of different lighting requirements, depending on where the light fixture will be installed and the intended use. Thus, light fixtures are designed and manufactured with specific purposes in mind, including providing security, safety, and/or aesthetics. As should be appreciated, there are high costs associated with producing a variety of unique light fixtures, each specifically customized for a specific use and to provide a specific, predetermined lighting effect.

There is a continuing need to reduce manufacturing costs, and improve efficiency and effectiveness of both the manufacturing process and the resulting products. The incorporation, or use, of LEDs in both interior and exterior light fixtures is one example of the growing trend to improve efficiency. In particular, LEDs consume less energy and last longer than traditional fluorescent and incandescent light sources. Additional means for improving efficiency and effectiveness in the lighting industry are also needed. The present disclosure is directed to such an effort.

SUMMARY OF THE DISCLOSURE

In one aspect, a modular light fixture includes an elongate light fixture base having a longitudinal axis and a plurality of light fixture modules. Each of the light fixture modules includes a housing having an open face, and a light emitting device positioned inside the housing. The modular light fixture also includes a light emitting device driver configured for driving the light emitting device of each light fixture module. The light fixture modules are independently mounted to the elongate light fixture base and extend perpendicularly from opposing sides of the elongate light fixture base with the open faces facing a common direction to produce an initial light distribution pattern. Each of the light fixture modules has a housing adjustment feature for independently pivoting the respective light fixture module about a pivot axis parallel to the longitudinal axis to modify the initial light distribution pattern. The modular light fixture includes a planar configuration in which the housings of the light fixture modules are oriented along a common plane.

In another aspect, a modular light fixture system includes an elongate light fixture base selected from a plurality of light fixture bases. Each of the plurality of light fixture bases houses a light emitting device driver and has a different length to support one or more pairs of light fixture modules. The one or more pairs of light fixture modules are selected from a plurality of interchangeable light fixture modules. Each of the interchangeable light fixture modules includes a housing having an open face and a light emitting device positioned inside the housing. In an assembled configuration, each module of the one or more pairs of light fixture modules is independently mounted to the elongate light fixture base using a housing adjustment feature, wherein the housing adjustment feature permits pivotable movement of the module relative to the elongate light fixture base.

DETAILED DESCRIPTION

Referring toFIGS. 1 and 2, a first exemplary embodiment of a modular light fixture according to the present disclosure is shown at10. The modular light fixture10may generally include an elongate light fixture base12having a longitudinal axis A1, and a plurality of light fixture modules14attached to or supported by the light fixture base12. Each of the light fixture modules14may be similar, and may include a housing16having an open face18and at least one light emitting device20positioned inside the housing16. For example, the one or more light emitting devices20may be light emitting diodes (LEDs). However, alternative light sources or light producing devices, including conventional light sources, may also be used with the modular light fixture10.

The light fixture modules14may be independently mounted to the elongate light fixture base12and may extend perpendicularly from opposing sides22and24of the elongate light fixture base12with the open faces18facing a common direction d. According to an exemplary mounting arrangement for the modular light fixture10, the light fixture base12and the light fixture modules14may have horizontal orientations and the common direction d may correspond to a downward direction, such as toward the ground or the floor. The light fixture base12may have a first fixed length l1sized to support a first light fixture module26and a second light fixture module28. Together, the first and second light fixture modules26and28may define a first pair of light fixture modules14. The first and second light fixture modules26and28may be positioned on opposite sides22and24of the light fixture base12at a common axial position along the longitudinal axis A1, as shown. The dimensions of the light fixture base12, as well as the number of light fixture modules14, may vary, as will be described in greater detail below.

Each of the light fixture modules14may have its own housing adjustment feature30for independently pivoting the respective light fixture module14about a respective pivot axis A2, which may be substantially parallel to the longitudinal axis A1. An attached, or inner, end32of each light fixture module14, or housing16, may be mounted to the light fixture base12at the housing adjustment feature30, with a free, or outer, end34, which is opposite the attached end32, being rotatable, or pivotable, about the respective pivot axis A2. The modular light fixture14may have any number of different configurations, including a planar configuration, shown inFIGS. 1 and 2, in which the housings16of the light fixture modules14are oriented along a common plane P. According to the exemplary embodiment, the common plane P may be substantially horizontal.

Turning now toFIGS. 3 and 4, the modular light fixture10may also have a first adjusted configuration, as shown, in which the free end34of each light fixture module14is pivoted upward, using the housing adjustment feature30, to modify a light distribution of the modular light fixture10, as will be discussed further below. Depending on the particular application, each light fixture module14may be pivotable in one or both directions about the pivot axis A2from the planar configuration ofFIGS. 1 and 2. For example, the free end34of each light fixture module14may be pivoted upward and/or downward from its position shown inFIGS. 1 and 2. Further, the free ends34may be pivoted in a common direction or in different directions.

The components of the first exemplary modular light fixture10are discussed in greater detail with reference toFIG. 5. Including the components already introduced, the modular light fixture10may also include a light emitting device driver40configured for driving the one or more light emitting devices20of each light fixture module14. For example, the light emitting device driver40may be an LED driver configured for driving one or more LEDs in a known manner. The light emitting device driver40may be housed within the light fixture base12, as shown, and may be configured to drive any number, including all, of the light fixture modules14included in the modular light fixture10. In addition, an electrical junction box42, which includes, supports, or joins electrical wires43, may be supported on the light fixture base12. The modular light fixture10may be attached or mounted to a ceiling, or other support structure, using any known attachment or mounting means.

Each of the light fixture modules14may be substantially similar, and may generally include the housing16supporting the one or more light emitting devices20, and additional components or features common in lighting fixtures. For example, and according to the exemplary embodiment, each light fixture module14may also include a door44, such as a hinged door, for protecting and accessing an interior portion46of the housing16. A lens48, or another transparent or translucent component made from any of a variety of materials, such as plastic or glass, may be supported by and movable with the door44. One or more reflectors50may be positioned within the housing16for directing light produced by the one or more light emitting devices20through the lens48. According to some embodiments, the one or more light emitting devices20may be independent emitters arranged in a planar array. However, alternative numbers and arrangements of light emitting devices20are also contemplated.

Referring additionally toFIGS. 1-4, each light fixture module14may also include a plurality of cooling fins52. The cooling fins52may be positioned on, or may be integral with, a back side54of the housing16opposite the open face18, and may function to transfer and dissipate excess heat that may be generated by the light emitting devices20. The cooling fins52may vary in number, size, orientation, and configuration to provide a desired cooling effect. As shown, the cooling fins52may span an entirety of the back side54of the housing16. According to some embodiments, however, the cooling fins52may not be required. Additionally, or alternatively, the modular light fixture10may include one or more cooling channels55positioned between the attached end32of each light fixture module14and the elongate light fixture base12on either side, or both sides, of the housing adjustment feature30. That is, the housing adjustment feature30may span only partially across the attached end32to define cooling channels between the light fixture module14and the elongate light fixture base12.

Each housing adjustment feature30may interconnect a respective light fixture module14with the light fixture base12, and may facilitate the movement, or adjustment, described herein. According to the exemplary embodiment, each housing adjustment feature30may be, or may include, a swivel mount. For example, a first portion56of the housing adjustment feature30may attach to or may be integral with the housing16, while a second portion58of the housing adjustment feature30may attach to or may be integral with the light fixture base12. The first and second portions56and58may be attached or joined by a fastening device60, or other component, which may define a pivot location of the housing16relative to the light fixture base12. Together, the first portion56, the second portion58, and the fastening device60may permit the movement described herein and may include appropriate additional and/or alternative components for permitting, restricting, and/or fixing particular movements. For example, each housing adjustment feature30may incorporate or use stop members to limit the range of motion of the respective light fixture module14.

Materials selected for the components described herein may vary, depending on particular applications. For example, each of the light fixture base12, the housings16, and the housing adjustment features30may be made from any of a number of materials known to those skilled in the art. According to an exemplary embodiment, one or more of the light fixture base12, the housings16, and the housing adjustment features30may be made from a die cast aluminum or an aluminum alloy.

In the planar configuration, which was described with reference toFIGS. 1 and 2, the modular light fixture10may produce an initial light distribution pattern, as shown inFIG. 6. According to the initial light distribution pattern, the modular light fixture10may produce a lateral distribution of light on a lighted surface having a first width w1. As described herein, the free end34of each light fixture module14may be pivoted upward using the housing adjustment feature30and may assume a first adjusted configuration to produce an adjusted light distribution pattern having a second width w2, as shown inFIG. 7. As shown, the second width w2may be wider than the first width w1.

Further, according to some embodiments, the modular light fixture10may be used as an “aisle lighter,” positioned and configured to not only light a horizontal surface, such as a floor, but also to light vertical surfaces, such as aisles in a warehouse, for example. As such, the light fixture modules14may be pivoted to provide the appropriate distribution of light along vertical surfaces, such as, for example, vertical planes V1and V2ofFIG. 7.

Each housing adjustment feature30may be configured to permit the movement described herein and also fix, or maintain, a selected adjustment of the light fixture module14. Although not necessary, each of the housing adjustment features30may limit the angular range of motion of the free end34to less than about 20 degrees, as shown at angle a. Further, the free end34may be infinitely adjustable through the designated angular range of motion. That is, any desired adjustment of the light fixture modules14that is permitted by the housing adjustment features30may be selected, resulting in a desired light distribution pattern. In addition, because the light fixture modules14may be adjusted independently, the selected adjustment of one of the light fixture modules14may vary from that of another of the light fixture modules14.

A second exemplary embodiment of a modular light fixture according to the present disclosure is shown at70inFIGS. 8 and 9. The modular light fixture70may be similar to the modular light fixture10discussed above; however, a light fixture base72of the modular light fixture70may have a second fixed length l2greater than length l1and sized to support four light fixture modules74. That is, the modular light fixture70may include a first light fixture module76and a second light fixture module78, defining a first pair of light fixture modules74, and also may include a third light fixture module80and a fourth light fixture module82, defining a second pair of light fixture modules74. The light fixture modules74in each of the first and second pairs may be positioned on opposite sides of the light fixture base72at a common axial position along a longitudinal axis A3of the light fixture base72, as shown.

The modular light fixture70may also have a planar configuration, shown inFIG. 8, and at least one adjusted configuration, shown inFIG. 9. The light fixture modules74may be adjusted relative to the light fixture base72using housing adjustment features84, which may function similarly to the housing adjustment features30described above. That is, each modular light fixture70may pivot about an axis A4defined by the housing adjustment feature84. The adjusted configuration may be capable of producing a light distribution pattern having a width that is greater than a width of a light distribution pattern produced by the planar configuration, as described above. In addition, however, the light distribution pattern may have a length that is greater than a length of the light distribution pattern provided by the modular light fixture10discussed above.

Turning now toFIGS. 10 and 11, a third exemplary embodiment of a modular light fixture according to the present disclosure is shown at90. The modular light fixture90may be similar to both the first exemplary modular light fixture10ofFIGS. 1-7and the second exemplary modular light fixture70ofFIGS. 8and9; however, a light fixture base92of the modular light fixture90may have a third fixed length l3greater than lengths l1and l2of respective light fixture bases12and72, and sized to support six light fixture modules94. That is, the modular light fixture90may include a first light fixture module96and a second light fixture module98defining a first pair of light fixture modules94, a third light fixture module100and a fourth light fixture module102defining a second pair of light fixture modules94, and also a fifth light fixture module104and a sixth light fixture module106defining a third pair of light fixture modules94. The light fixture modules94in each of the first, second, and third pairs may be positioned on opposite sides of the light fixture base92at a common axial position along a longitudinal axis A5of the light fixture base92, as shown.

The modular light fixture90may also have a planar configuration, shown inFIG. 10, and at least one adjusted configuration, shown inFIG. 11. The light fixture modules94may be adjusted relative to the light fixture base92using housing adjustment features108, which may function similarly to the housing adjustment features30and84described above. That is, each modular light fixture90may pivot about an axis A6defined by the housing adjustment feature108. The adjusted configuration may be capable of producing a light distribution pattern having a width that is greater than a width of a light distribution pattern produced by the planar configuration, as described above. In addition, however, the light distribution pattern may have a length that is greater than the light distribution pattern lengths provided by the light fixture modules10and70.

With particular reference toFIGS. 12 and 13, it is shown that the light distribution length may vary depending on a particular application and/or configuration. That is, the modular light fixture70ofFIGS. 8 and 9, having two pairs of light fixture modules74, may produce a light distribution pattern having a shorter length l4than a length l5of a light distribution pattern of the modular light fixture90ofFIGS. 10 and 11, having three pair of light fixture modules94. As should be appreciated, these light distribution pattern lengths l4and l5may both be longer, or greater, than a light distribution pattern length produced by the modular light fixture10ofFIGS. 1-7, which has one pair of light fixture modules14.

The modular light fixture, or modular light fixture system, of the present disclosure may be configured to include any number, such as an even number, of light fixture modules. The light fixture modules may be similar, such that they may be interchangeable. Manufacturing of modular light fixtures having varying light distribution pattern lengths may, thus, be improved. In addition, the light fixture modules of the modular light fixture are adjustable relative to the light fixture base to modify the width of the light distribution pattern. Further, each of the light fixture modules is independently adjustable to provide a highly customized light distribution pattern.