Field replaceable power supply cartridge

A field replaceable power supply cartridge is provided for coupling with a socket. The cartridge has a latch mechanism that can be actuated by the user to couple the cartridge to the socket, such that latches of the cartridge releasably engage recessed portions in the socket. The cartridge has a key feature that corresponds to a key feature on the socket, allowing the cartridge to be coupled to the socket in only one orientation, thereby preventing the incorrect electrical connection between the cartridge and the socket. The cartridge can have a multi-pin electrical connector for coupling to a corresponding connector on the socket. The socket can be a relatively short socket, where the electrical wires are bottom fed, or can be a relatively tall socket, where the electrical wires are side fed via one or more openings in the body of the socket.

BACKGROUND

Field

The invention is directed to a field replaceable power supply cartridge and more particularly to a field replaceable power supply cartridge for use within lighting fixture assemblies.

Description of the Related Art

There are many different electric lighting technologies, which all require a power supply, a transformer or a ballast (e.g., LED, HID, Compact Fluorescent, linear fluorescent, low-voltage halogen, etc.). All of the above mentioned lighting technologies can be used in many different form factors, such as recessed down lights, pendants, sconces, chandeliers, exterior lighting, high-bay warehouse fixtures, landscape lighting, cove lighting, linear lighting, under-cabinet lighting, ceiling mounted fixtures, track lighting, etc. One of the most common types of light fixtures which use an integrated power supply is recessed down lights.

Recessed down lights are a popular and elegant way to provide lighting to a space, with the recessed down lights mounted in a ceiling so that only a trim ring and the light bulb is open to view, while the rest of the components, including the power supply (e.g. LED driver, fluorescent ballast, HID ballast or step down transformer), are disposed on the other side of the ceiling and hidden from view. The power supply is typically housed in a sheet metal or plastic box. Power supplies fail over time, for example, due to the exposure of the electronics to heat generated by the lighting system.

One drawback with conventional power supplies is that they can be difficult and time consuming to replace because of the limited access space through the ceiling opening where the recessed down light is mounted. In a typical recessed down light, replacing the power supply includes reaching through the aperture in the ceiling and around the lighting assembly, removing wing nuts or thumb nuts (or other types of threaded fasteners) that attach the power supply to the lighting assembly, removing the power supply through the ceiling aperture along with the lead wires that wire the power supply to the lighting assembly, cutting and stripping the wires and attaching them to the new power supply, inserting the new power supply through the ceiling aperture, and coupling the new power supply to the lighting assembly with the thumb screws or thumb nuts. Because all of this is done through the limited space provided by the ceiling aperture for the recessed down light, a user has to perform all of these steps with a single hand, which makes the process take longer, particularly because of all the different parts and steps that are involved in replacing the power supply. And in most cases the user cannot see the power supply within the recessed down light, and therefore has to remove and replace the fasteners without a line of sight to the power supply assembly while performing these steps.

Accordingly, there is a need for an improved and simpler system and method for replacing a power supply within a light fixture assembly.

SUMMARY

In one embodiment, a field replaceable power supply cartridge is provided for coupling with a socket. The cartridge can have a latch mechanism that can be actuated by the user to couple the cartridge to the socket, such that the one or more latches of the cartridge releasably engage one or more recessed portions in the socket. The cartridge can have a key feature that corresponds to a key feature on the socket, allowing the cartridge to be coupled to the socket in only one orientation, thereby preventing the incorrect electrical connection between the cartridge and the socket. The cartridge can have a multi-pin electrical connector for coupling to a corresponding connector on the socket. The socket can be a relatively short socket, where the electrical wires are bottom fed (e.g., from an electrical box), or can be a relatively tall socket, where the electrical wires are side fed via one or more openings in the body of the socket. The socket can be made of a thermally conductive material (e.g., aluminum) for transferring heat from the cartridge to the socket when the two are coupled to each other, such that the socket can provide for a thermal connection as well as an electrical connection between the cartridge and the socket.

In one embodiment, the field replaceable power supply cartridge can be an LED driver, such as a replaceable LED driver cartridge for use with down lighting (e.g., recessed lighting) systems. In another embodiment, the field replaceable power supply cartridge can be a ballast, such as a ballast for a fluorescent lighting system, a ballast for a compact fluorescent lighting system, a ballast for an HID (high intensity discharge) lighting system, or used in connection with any other light source or lighting system that uses a power supply or ballast. In another embodiment, the field replaceable power supply cartridge can be an LED driver cartridge for use within an LED light fixture assembly. In still another embodiment, the field replaceable power supply cartridge can be a transformer.

In accordance with one aspect of the present invention, a field replaceable LED driver system is provided. The system comprises an LED driver cartridge having a cartridge body, the cartridge body having a key feature defined on a bottom side of the cartridge body. The system also comprises one or more gripping members spring loaded relative to a portion of the cartridge body, the one or more gripping members configured to actuate one or more latches and configured to be pushed by a user to move the one or more latches inward relative to the cartridge body. The system also comprises a printed circuit board coupled to the cartridge body and an electrical connector on the bottom side of the cartridge body electrically connected to the printed circuit board. The key feature facilitates installment of the LED driver in a single predetermined orientation.

In accordance with another aspect of the present invention, a field replaceable LED driver system is provided. The system comprises an LED driver cartridge body, the cartridge body having a key feature defined on a bottom side of the cartridge body. The system also comprises one or more gripping members spring loaded relative to a portion of the cartridge body, the one or more gripping members configured to actuate one or more latches and configured to be pushed by a user to move the one or more latches inward relative to the cartridge body. The system also comprises an electrical connector on the bottom side of the cartridge body. The system also comprises a socket having a socket body coupleable to an electrical box and configured to releasably couple to the cartridge body, the socket body comprising one or more recess portions configured to releasably engage the one or more latches, the socket body having a key portion defined on a top side thereof, the key portion having a shape corresponding to a shape of the key feature such that the LED driver cartridge body couples to the socket in the single predetermined orientation. The key feature of the cartridge body and the key portion of the socket facilitate coupling of the LED driver cartridge body to the socket body in a single predetermined orientation.

DETAILED DESCRIPTION

The embodiments disclosed below describe an improved system and method for a field replaceable power supply cartridge. In one embodiment, the field replaceable power supply cartridge can be an LED driver cartridge, such as a replaceable LED driver cartridge for use with down lighting (e.g., recessed lighting) systems. In another embodiment, the field replaceable power supply cartridge can be a ballast, such as a ballast for a fluorescent lighting system, a ballast for a compact fluorescent lighting system, a ballast for an HID (high intensity discharge) lighting system, or used in connection with any other light source or lighting system that uses a power supply or ballast. In another embodiment, the field replaceable power supply cartridge can be an LED driver cartridge for use within an LED light fixture assembly. In still another embodiment, the field replaceable power supply cartridge can be a transformer (e.g., step down transformer).

One of skill in the art will recognize that the embodiments disclosed herein for a field replaceable power supply cartridge can be used as part of many lighting technologies, such as those discussed above. Additionally, the field replaceable power supply cartridge can be used in many different form factors, such as recessed down lights, pendants, sconces, chandeliers, exterior lighting, high-bay warehouse fixtures, landscape lighting, cove lighting, linear lighting, under-cabinet lighting, ceiling mounted fixtures, track lighting, etc.

FIGS. 1-2show one embodiment of a field replaceable power supply cartridge100(hereinafter “cartridge”) coupled to one embodiment of a socket200. In the illustrated embodiment, the cartridge100can be generally rectangular in shape. However, in other embodiments, the cartridge100can have other suitable shapes, such as square, round, etc. The cartridge100can have one or more gripping members10allowing a user to grip the cartridge100(e.g., grip with the user's fingers). In the illustrated embodiment, the cartridge100has two gripping members10on opposite sides of the cartridge100. However, in other embodiments, the cartridge100can have more or fewer gripping members10.

As shown inFIGS. 1-2, the socket200can have generally the same shaped perimeter as the cartridge100. In another embodiment, the socket200can have a larger or smaller perimeter than the cartridge100. In the illustrated embodiment, the socket200is a relatively short socket with a height H1. The socket200can be attached to an electrical box400, as shown inFIG. 5, which can house one or more wires that couple to a multi-pin connector210of the socket200for coupling with a multi-pin connector110of the cartridge100. The multi-pin connectors110,210allow the cartridge100to provide multiple functions to the lighting system. For example, some of the pins of the connectors110,210can take in house power, some of the pins of the connectors110,210can provide driving control for the lighting system, some of the pins of the connectors110,210could be used for dimming of the lighting system, some of the pins can be used to supply power and control to an active cooling system (e.g., fan) to cool the driver100, and some of the pins of the connectors110,210can communicate control signals to and from the driver100.

In one embodiment, the socket200can be made of a thermally conductive material, such as Aluminum. However, the socket200can be made of other suitable materials (e.g., other metals or plastics). Additionally, in some embodiments, a thermal interface member (e.g., thermal pad) can be disposed between the cartridge100and the socket200to facilitate heat transfer between the cartridge100and the socket200. That is, in some embodiments, the connection between the cartridge100and the socket200can be a thermal connection as well as an electrical connection.

With continued references toFIG. 2, the socket200can have one or more apertures220that can receive a fastener (e.g., screw)410therethrough to couple the socket200to, for example, the electrical box400(seeFIG. 5). Additionally, the socket200can have a key feature230, further described below, that allows the cartridge100to couple to the socket200in only one orientation, thereby preventing the erroneous coupling of the cartridge100to the socket200, which may result in an incorrect alignment between the male and female multi-pin connectors and improper electrical connection between the cartridge100and the socket200.

With continued reference toFIGS. 2 and 5, the short socket200can be coupled to the electrical box400, and the electrical wires housed in the electrical box400. The wires can be bottom fed to the connector210of the socket200from the electrical box400. The electrical box400can be made of metal. In an embodiment where the cartridge100is a power supply cartridge (e.g., LED driver cartridge for a down lighting system), the electrical box400can be mounted above the ceiling and out of view to the user. In another embodiment, the electrical box may take the form of a cavity created within the light fixture housing (e.g. an internal wall of the light fixture that the socket can be mounted to, with a hollow cavity behind the wall). In yet another embodiment, the socket can be mounted to a wall of the light fixture housing or any surface of the light fixture housing.

FIGS. 3-4show the cartridge100coupled to another embodiment of a socket200′. The socket200′ has a height H2 that is greater than the height H1 of the socket200, so that the socket200′ is a relatively tall socket. Like the socket200, the socket200′ can include a multi-pin connector210′ and one or more apertures220′ that can receive a fastener (e.g., screw) therethrough to couple the socket200′ to another component (e.g., to mount the socket200′ to a structural beam above the ceiling). The socket200′ can also include one or more openings202′ sized to receive one or more wires therethrough and into an inner space240′ of the socket200′ so the wires can be connected to the connector210′. Unlike the socket200, the one or more openings202′ allow side feeding of the wires into the socket200′. The socket200′ can be made of a thermally conductive material, such as Aluminum. However, other suitable materials can be used (e.g., other metals, other thermally conductive plastic materials or other types of plastics).

FIG. 5shows the key feature230of the socket200. The socket200can have a recessed portion240defined at least in part by a first side wall242, a second side wall244, a third side wall246and a fourth side wall248. In the illustrated embodiment, the first and second side walls242,244can have the same length, but the third and fourth sidewalls246,248can have different lengths, so that a corresponding key feature130(described further below in with respect toFIG. 10) of the cartridge100can only be coupled to the key feature230of the socket200in one orientation, such that the multi-pin electrical connector210of the socket200can only couple to the multi-pin electrical connector110of the cartridge100in one orientation, thereby preventing an incorrect electrical connection between the cartridge100and socket200. However, the key feature230can have other suitable configurations and still result in allowing the cartridge100to couple to the socket200in only one orientation. For example, in one embodiment, three of the four side surfaces of the recessed portion240can have the same length and the fourth side surface can have a different length. Advantageously, the key feature230allows a user to easily determine whether the cartridge100is in the correct orientation relative to the socket200, and to position the cartridge100in the correct orientation relative to the socket200during the installation process.

The socket200also has one or more recesses250in one or more of the walls242,244,246,248, the one or more recesses250sized to releasably receive a corresponding latch150(seeFIG. 10) of the cartridge100. In the illustrated embodiment, the socket200can have two recesses250on the third and fourth sidewalls246,248for releasably receiving corresponding latches150of the cartridge100. However, in other embodiments, the socket200can have more or fewer recesses250. Additionally, the recessed portion240of the socket200can define a protruding portion260of the electrical connector210, which extends from a bottom surface262of the recessed portion240. In one embodiment, a thermal interface member (e.g., thermal pad) can be inserted into the recessed portion240so that is contacts the bottom surface262, such that the thermal interface member is disposed between the bottom surface262of the socket200and a base surface162of the cartridge100(seeFIG. 10) when the cartridge100is coupled to the socket200, to thereby facilitate heat transfer between the cartridge100and the socket200. In another embodiment, the thermal interface member can be excluded and the base surface162of the cartridge100can contact the bottom surface262of the recessed portion240directly to transfer heat from the cartridge100to the socket200. Heat transfer between the cartridge100and the socket200is not a necessary function of the invention. It can be used to help keep the power supply cool, or in other embodiments the cartridge and the socket can be made of plastic and there would be no thermal connection between the cartridge100and the socket200.

FIG. 7shows the key feature230′ of the socket200′ (the tall socket). The socket200′ can have a recessed portion240′ defined at least in part by a first side wall242′, a second side wall244′, a third side wall246′ and a fourth side wall248′. In the illustrated embodiment, the first and second side walls242′,244′ can have the same length, but the third and fourth sidewalls246′,248′ can have different lengths, so that a corresponding key feature130(described further below in with respect toFIG. 10) of the cartridge100can only be coupled to the key feature230′ of the socket200′ in one orientation, such that the multi-pin electrical connector210′ of the socket200′ can only couple to the multi-pin electrical connector110of the cartridge100in one orientation, thereby preventing an incorrect electrical connection between the cartridge100and socket200′. However, the key feature230′ can have other suitable configurations and still result in allowing the cartridge100to couple to the socket200′ in only one orientation. For example, in one embodiment, three of the four side surfaces of the recessed portion240′ can have the same length and the fourth side surface can have a different length. Advantageously, the key feature230′ allows a user to easily determine whether the cartridge100is in the correct orientation relative to the socket200′, and to position the cartridge100in the correct orientation relative to the socket200′ during the installation process.

The socket200′ also has one or more recesses250′ in one or more of the walls242′,244′,246′,248′, the one or more recesses250′ sized to releasably receive the corresponding latch150(seeFIG. 10) of the cartridge100. In the illustrated embodiment, the socket200′ can have two recesses250′ on the third and fourth sidewalls246′,248′ for releasably receiving corresponding latches150of the cartridge100. However, in other embodiments, the socket200′ can have more or fewer recesses250′ defined on one or more side surfaces of the recessed portion240′. Additionally, the recessed portion240′ of the socket200′ can define a protruding portion260′ of the electrical connector210′, which extends from a bottom surface262′ of the recessed portion240′. In one embodiment, a thermal interface member (e.g., thermal pad) can be disposed in the recessed portion240′ in contact with the bottom surface262′, such that the thermal interface member is disposed between the bottom surface262′ of the socket200′ and the base surface162of the cartridge100(seeFIG. 10) when the cartridge100is coupled to the socket200′, to thereby facilitate heat transfer between the cartridge100and the socket200′. In another embodiment, the thermal interface member can be excluded and the base surface162of the cartridge100can contact the bottom surface262′ of the recessed portion directly to transfer heat from the cartridge100to the socket200′. Heat transfer between the cartridge100and the socket200′ is not a necessary function of the invention. It can be used to help keep the power supply cool, or in other embodiments the cartridge and the socket can be made of plastic and there would be no thermal connection between the cartridge100and the socket200′.

FIGS. 9-11show one embodiment of the cartridge100. The cartridge100can have one or more gripping members10and one or more latches150that can be actuated by a user via the gripping members10. The cartridge can have a top portion20attached to a bottom portion30with one or more fasteners40(e.g., screws). In another embodiment, the top20and bottom30portions can be attached using an adhesive or other suitable mechanisms (e.g., ultrasonic welding, etc.). The bottom portion30can define a key feature130and base surface162. The key feature130can include a protruding portion140that protrudes from a surface32of the bottom portion30and defines a first side surface142, a second side surface144opposite the first side surface142, a third side surface146and a fourth side surface148opposite the third side surface146. In the illustrated embodiment, the first and second side surfaces142,144can have the same length and the third and fourth146148side surfaces can have different lengths. The key feature130can have the same profile as the key feature230,230′ of the socket200,200′ so that the cartridge100can be coupled to the socket200,200′ in only one orientation.

The protruding portion140can define a socket portion160sized to receive the protruding portion260,260′ of the socket200,200′, so that the connector110can electrically connect with the connector210,210′ on the socket200,200′. As shown inFIG. 11, the connector110can connect to a PCB120, which can be mounted with one or more fasteners122to a socket wall164of the socket160. The top portion20of the cartridge100can define a cavity22therein. As discussed above, the cartridge100can provide a plurality of functions, for example, to a lighting assembly with which it is used (e.g., provide a dimming function, power an active cooling system, etc.).

With continued reference toFIG. 11, the one or more gripping members10can be integrated with the latch150so that each gripping member10has a latch150and forms a single piece with the latch150. The gripping member10can be spring loaded relative to the top portion20of the cartridge100by one or more resilient members50(e.g., leaf springs) that bias the gripping member10outward relative to the housing of the cartridge100.

In operation, a user would grip the one or more gripping members10and pinch them together or squeeze them together or depress to bias the one or more latches150inward relative to the cartridge100housing (see arrow I inFIG. 11), allowing the one or more latches150to clear the one or more recesses250,250′ of the socket200,200′ when the cartridge100is coupled to the socket200,200′. Once the user had properly aligned the key features130,230,230′ of the cartridge100and socket200,200′, and advanced the cartridge100relative to the socket200,200′ to provide the electrical connection between the connector110of the cartridge100and the connector210,210′ of the socket200,200′, the user could release the one or more gripping members10, allowing the latches150to be biased outward relative to the cartridge100housing by the one or more resilient members50(see arrow O inFIG. 11). This outward movement of the one or more latches150causes the one or more latches150to engage the one or more recesses250,250′ of the socket200,200′ to substantially fixedly maintain the cartridge100coupled to the socket200,200′. To decouple the cartridge100from the socket200,200′, the user can again grip the one or more gripping members10on the cartridge100and pinch them together or squeeze them together or depress to bias the one or more latches150inward so that they can disengage the one or more recesses250,250′ in the socket200,200′, thereby allowing the user to remove the cartridge100from engagement with the socket200,200′.

In another embodiment, the user need not grip the one or more gripping members10to bias the one or more latches150inward, and can simply advance the cartridge100(in the correct orientation) relative to the socket200,200′, where the one or more latches150have an angled surface that allows the one or more latches150to be biased inward as the cartridge100is advanced relative to the socket200,200′ so that the one or more latches150clear the side walls246,246′ and248,248′ to engage the one or more recesses250,250′. In still another embodiment, the one or more resilient members50can be excluded, and the one or more gripping members10can be an integral part (e.g., one piece) with the top portion20of the cartridge100. The cartridge100housing can be made of a material that allows some flexion, so that the user can apply a force to the one or more gripping members10to bias the one or more latches150inward, thereby allowing the one or more latches150to clear the side walls246,246′ and248,248′ of the socket200,200′ for engagement and disengagement with the recesses250,250′ during installation and removal of the cartridge100.

FIGS. 12 and 13show an exploded view of the cartridge100and socket200, and the motion of the cartridge100relative to the socket200(see arrow M) to couple the cartridge100to the socket200.

Advantageously, the cartridge100and socket200,200′ system disclosed herein elegantly simplifies the process of replacing a power supply cartridge, which can be done by a user without any tools, without the need to cut or strip electrical wires when replacing the cartridge, and without the need to keep track of fasteners that need to be removed or replaced to replace the power supply. Additionally, the cartridge100and socket200,200′ allow the user to easily replace the power supply (e.g., in a down lighting system) where space to the electrical components of the lighting system is very limited.

Of course, the foregoing description is that of certain features, aspects and advantages of the present invention, to which various changes and modifications can be made without departing from the spirit and scope of the present invention. Moreover, the field replaceable power supply cartridge need not feature all of the objects, advantages, features and aspects discussed above. Thus, for example, those skilled in the art will recognize that the invention can be embodied or carried out in a manner that achieves or optimizes one advantage or a group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein. In addition, while a number of variations of the invention have been shown and described in detail, other modifications and methods of use, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. For example, the embodiments of the field replaceable power supply cartridge discussed above can be used with many different types of lighting assemblies or form factors, such as recessed down lights, pendants, sconces, chandeliers, exterior lighting, high-bay warehouse fixtures, landscape lighting, cove lighting, linear lighting, under-cabinet lighting, ceiling mounted fixtures, track lighting, etc. It is contemplated that various combinations or subcombinations of the specific features and aspects between and among the different embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the discussed field replaceable power supply cartridge.