Abstract:
Retrofitting lighting fixtures (e.g., HID based lighting fixtures) using a pin mounted PL style fluorescent based energy efficient light assembly and methods of installing retrofitting lighting fixtures are disclosed.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 11/873,264, filed Oct. 16, 2007, which claims the priority of U.S. Provisional Application No. 60/877,033, filed Dec. 26, 2006, and titled “Fluorescent-based Parking Garage Lighting Retrofit Kit.” The contents of both applications are incorporated in their entirety by reference. 
     
    
     FIELD OF INVENTION 
       [0002]    The present description relates to retrofits of existing high intensity discharge based lighting fixtures using fluorescent based lighting assemblies. 
       BACKGROUND 
       [0003]    As energy costs have risen, some commercial, industrial and municipal customers are removing existing older lighting fixtures (e.g., high intensity discharge (HID) and/or older T12 fluorescent lighting fixtures) and replacing them with newer, more energy efficient lighting fixtures. These more energy efficient lighting fixtures can be based on multiple lamp types including high intensity linear fluorescent (HIF), screw-in compact fluorescent (CFL), pin mounted photoluminescence fluorescent (PL), induction lamps (IL), and/or light emitting diodes (LED). 
         [0004]    While the cost of installing entirely new fixtures using such energy efficient lamps can be returned over time based on the energy savings, the process can be time consuming, includes the purchase of a completely new fixture and hence delivers a proportionally lower economic return. In addition, newer highly efficient IL and LED based fixtures have extremely high initial capital costs. 
         [0005]    Retrofitting an existing HID fixture using a screw-in CFL style lamp(s) without a light reflector has been performed, but the light output performance associated with the screw-in CFL type of lamp has delivered poor performance versus the pre-existing HID style lamps. 
         [0006]    Retrofitting an existing HID fixture with a higher performance PL lamp and ballast without a light reflector has been performed, but the light output performance associated with this retrofit has delivered poor performance versus the pre-existing HID style lamps. 
         [0007]    Retrofitting an existing HID fixture with PL lamp(s) and an optically efficient light reflector optimized for the PL lamp and a backing plate designed for easy mounting enables the best balance of sufficient light output with high energy savings and a low total cost of installation. 
       SUMMARY 
       [0008]    This disclosure relates to retrofitting lighting fixtures (e.g., HID based lighting fixtures) using a PL based energy efficient light assembly. 
         [0009]    In some aspects, a lighting retro-fit system can be used for mounting one or more PL lamps within an existing external housing of a light fixture. The existing external housing can include a light reflector mount. The retro-fit system can include a light reflector for reflecting light from a PL lamp(s) in a direction away from the reflector. The retro-fit system can also include a one piece adapter backing plate. The one piece adapter backing plate can include one or more arms configured to support the one or more PL lamps and one or more openings, screw holes or tabs configured to enable attachment of the one piece adapter plate to a plurality of fixture designs. The adapter plate can be configured to surround a periphery of the light reflector and can be configured to mount the light reflector within the existing external housing of the fixture. The retro-fit system can also include a mechanical connector configured to attach the light reflector to a reflector mount on the one piece adapter. The retro-fit system can also include at least one lamp connection configured to receive the lamp and configured to be attached one of the one or more arms. The adapter plate can include a plurality of openings to accommodate wiring from the lamps to the ballast, mounted inside of the existing fixture housing. 
         [0010]    Embodiments can include one or more of the following. 
         [0011]    The adapter can include a plurality of adapters. Each of the adapters can be configured to receive the light reflector along an inner periphery of the adapter and have a different outer periphery for mounting to a different external fixture housing. The existing fixture can also include at least one HID lamp. The HID lamp and existing reflector can be replaced with a retro-fit system including PL lamp(s) in combination with an optically efficient light reflector optimized for the PL lamps(s). The retro-fit system can also include a ballast. The light reflector can have a conical shape. 
         [0012]    In some aspects, a method for retrofitting a lighting system can include removing a light assembly having a first HID lamp and a first light reflector from an external fixture housing. The method can also include selecting one of a plurality of backing plate adapters that is associated with the external housing. The method can also include attaching the selected one of the backing plate adapters to a periphery of an existing fixture housing or backing plate. The method can also include attaching a second PL lamp to the backing plate and using the same light reflector for reflecting light from the second lamp in a direction away from the reflector. The method can also include attaching the light reflector to a reflector mount on the backing plate. 
         [0013]    Embodiments can include one or more of the following. 
         [0014]    The method can also include bending at least one light assembly support arm included in the backing plate to a position about perpendicular to the backing plate. Removing the light assembly having the first lamp and the light reflector from the external housing and can include removing a fixture diffuser lens, removing the first lamp, removing a lamp socket, and optionally removing a ballast. Removing the light assembly having the first lamp and the first light reflector from the external housing can further include optionally removing a base plate, reflector, starter, and a restrike lamp. The method can also include inserting fish paper into a slot area. 
         [0015]    In some aspects, a fluorescent lighting retro-fit system can be configured for mounting a PL lamp(s) within one of a plurality of external housings of a lamp assembly that includes a reflector mount. The retro-fit system can include a light reflector for reflecting light from at least one fluorescent lamp in a direction away from the reflector. The light reflector can include a mechanical connector for attaching the fluorescent light reflector to the reflector mount. at least one lamp connection configured to receive the fluorescent lamp, and a plurality of adapters, each configured to surround the periphery of the light reflector and each configured to mount the light reflector within a corresponding one of the plurality of external housings. 
         [0016]    The lighting assembly enables the retrofitting of an existing HID based fixture with a set of components that optimize light output while reducing the energy consumed by the lamps during the product&#39;s useful life. 
         [0017]    In some embodiments, retrofitting an existing HID fixture with a CFL lamp in combination with an optically efficient light reflector optimized for the CFL lamp increases the light output performance significantly when compared to retrofitting with only a CFL lamp and no light reflector, hence providing higher energy savings. 
         [0018]    Other features and advantages of the invention are apparent from the following description, and from the claims. 
     
    
     
       DESCRIPTION OF DRAWINGS 
         [0019]      FIG. 1  shows a lighting assembly in a parking garage setting. 
           [0020]      FIG. 2  shows an exploded view of a light assembly. 
           [0021]      FIG. 3  shows an isometric view of a backing plate. 
           [0022]      FIG. 4  shows an exemplary backing plate. 
           [0023]      FIG. 5  shows an exemplary backing plate. 
           [0024]      FIG. 6  shows a cross-sectional side view of a light reflector. 
           [0025]      FIG. 7  shows a side view of the reflector of  FIG. 6 . 
           [0026]      FIG. 8  shows a view of a portion of the light reflector of  FIG. 6 . 
           [0027]      FIG. 9  shows a view of a portion of the light reflector of  FIG. 6 . 
           [0028]      FIG. 10  is a flow chart of a light assembly installation process. 
           [0029]      FIG. 11  is a flow chart of a lamp attachment process. 
           [0030]      FIGS. 12A and 12B  show a shoebox style lighting assembly. 
           [0031]      FIGS. 13A and 13B  show a sign-light style lighting assembly. 
           [0032]      FIG. 14  shows an exemplary backing plate. 
       
    
    
     DETAILED DESCRIPTION 
       [0033]      FIG. 1  shows a parking garage  10  and a light assembly  20  used to provide light for the parking garage  10 . A parking garage  10  (e.g., a parking garage attached to a building or a stand alone parking garage) often includes multiple lighting fixtures that, due to security concerns, often burn 24 hours a day, 7 days a week. Since the lights in the parking garage  10  are illuminated for such lengthy time periods, lighting often represents a majority of the parking garage&#39;s utility bill. As such, retrofitting the parking garage  10  with higher efficiency lighting fixtures can result in substantial savings for the parking garage  10 . 
         [0034]    In addition to the extended use of the lighting in a parking garage setting, lighting used in a parking garage  10  must be able to withstand varying weather conditions. For example, the lighting must perform in wide range of ambient temperatures including temperatures below zero degrees Fahrenheit and as high as 120 degrees Fahrenheit. While traditional fluorescent light sources have been significantly affected by such extreme temperatures, recent advances in fluorescent lamp and ballast technology have allowed fluorescent lamps to strike and run at below zero degrees Fahrenheit with high efficacy. As such, retrofitting a parking garage  10  with higher efficiency lighting fixtures that can withstand the temperature ranges and extended periods of use can result in substantial savings for the parking garage. 
         [0035]      FIG. 2  shows an exploded view of the lighting assembly  20  for retrofitting an existing light fixture with a higher efficiency assembly including two PL fluorescent lamps, a light reflector and a backing plate. Not shown, but included in the system is a new ballast which powers these new PL lamps. For example, this lighting assembly  20  can mount into an existing high intensity discharge (HID) based low ceiling height fixture (e.g., low bay) The lighting assembly  20  can be used to retrofit a variety of fixture designs with this including low bay fixtures from manufacturers such as Hubbell Kim which has a place of business at 701 Millennium Blvd, Greenville, S.C. 29607, Cooper Lighting which has a place of business at 1121 Highway 74 South, Peachtree City, Ga. 30269, and Genlyte Group LLC which has a place of business at 10350 Ormsby Park Place Suite 601, Louisville, Ky. 40223. In so doing, this common assembly design substantially reduces the operating and maintenance costs while preserving the required illumination levels of these fixtures. 
         [0036]    The lighting assembly  20  includes a backing plate  52 , lamp holders  42  and  44 , lamps  34  and  38 , a ballast, and a light reflector  32 . The backing plate  52  mounts inside an existing light fixture housing to allow retrofitting of the existing light fixture. The lamps  34  and  38  are connected to the backing plate  52  by lamp sockets  36  and  40  which are attached to the lamp holders  42  and  44  connected to the backing plate  52 . Openings  28  and  30  in the light reflector  32  allow the reflector to fit over the lamp holders  42  and  44 . The light reflector  32  is formed of a highly reflective material and increases the amount of light directed to the target from the PL lamp. The light reflector  32  is secured to the backing plate  52  by screws or other attachment devices. After installation of the light reflector  32 , lamps  34  and  38  are inserted into the lamp sockets  36  and  40  so that a portion of the light emitted by the lamps  34  and  38  is reflected out of the light assembly  20  by the light reflector  32 . 
         [0037]      FIG. 3  shows an exemplary backing plate  52 . The exterior shape (e.g., the size and shape) of the backing plate  52  can vary to allow the backing plate  52  to fit into an existing fixture&#39;s base housing which itself is attached to an electrical connection and roof bracket. The backing plate  52  provides a standardized interior shape that accommodates a common light reflector design so that the same light reflector  32  can be used with multiple backing plates  52  having different exterior shapes. For example, the size and placement of the lamp holders  42  and  44  in the interior portion of the backing plate  52  is the same for backing plates of different sizes and shapes. 
         [0038]    The backing plate  52  has an integrated design for lamp holder brackets  42  and  44  which protrude from the interior portion of the backing plate  52 . The lamp holder brackets  42  and  44  allow the backing plate and arms to be manufactured from a single piece of metal. During installation the lamp holder arms are bent to about a ninety degree angle with respect to the surface of the backing plate  52 . The lamp holder brackets  42  and  44  include openings  43  and  45  through which a high voltage insulation tube can be fed. Lamp sockets  36  and  40  can be attached to the lamp holder brackets  42  and  44  and socket leads from the lamp sockets  36  and  40  can be inserted into the high voltage insulation tube prior to feeding the high voltage insulation tube through the openings  43  and  45 . 
         [0039]    The backing plate  52  also includes multiple air holes  54  that provide ventilation into the lighting assembly  20 . The air holes  54  are openings stamped into the backing plate  52 . The air holes  52  allow improved thermal efficiency for the ballast, and reduce the high temperature characteristics of the cavity. In the embodiment shown in  FIG. 3 , the air holes  52  are small circular openings arranged in a grid-like fashion. However, other arrangements and shapes of the air holes  54  are possible. 
         [0040]    The backing plate  52  also includes multiple clips  48 ,  49 ,  50  and  51  for attaching an electrical insulation material such as fish paper  46  to the backing plate  52 . The fish paper  46  provides a cover between the lamp area and the interior of the fixture housing (e.g., for UL approval). 
         [0041]    In some embodiments, the backing plate  52  is produced from a single piece of metal. For example, the backing plate  52  can be stamped from non coated aluminum and the lamp arms  42  and  44  are bent to be perpendicular to the backing plate surface. Lamp sockets  36  and  40  are mounted to the interior lamp arms  42  and  44  on the backing plate  52 . 
         [0042]    A variety of exterior sizing and shapes for the backing plate  52  are defined for different commercially available fixtures.  FIGS. 4 and 5  show two exemplary sizes of the backing plate  52 . More particularly,  FIG. 4  shows a large backing plate that would be suitable for use with, for example, Cooper fixtures or other similarly sized fixtures.  FIG. 5  shows a small backing plate that would be suitable for use with, for example, Hubbell Kim PGL fixtures or other similarly sized fixtures. In general, different backing plates can be similar in shape such that the different sizes of backing plates can be used with the various external dimensions inside different fixture housings. 
         [0043]      FIGS. 6 and 7  show a cross-sectional side view and a side view of the light reflector  32 , respectively. The light reflector  32  optimizes light output generated from two cross mounted opposed PL lamps. The light reflector  32  has conical shape which provides optimized reflection and light dispersion from a variety of different wattage PL&#39;s, while accounting for their similar form factors and range of lengths. The slope of the light reflector is greater near the center  33  of the reflector and decreases with increased distance from the center  33 . The slope decreases with increased distance from the center  33  in order to maximize the fixture efficiency as well as improved dispersion of light, a key element in low bay fixtures. The shape of reflector  32  allows the reflector to perform in a variety of fixtures and especially allowing high angle light to pass thru the clear windows in some models for lighting the ceiling. In addition, the shape of reflector  32  allows for use with a variety of lamp wattages and sizes. 
         [0044]    As shown in  FIG. 8 , the light reflector  32  includes an outer rim  25  that is flat and does not slope. The flat rim  25  allows for easier installation and attachment of the reflector  32  to the backing plate  52 . The reflector  32  includes screw holes  24   a ,  24   b , and  24   c  ( FIG. 9  shows an expanded view of a screw hole in the reflector  32 ) to secure the reflector  32  to the backing plate  52  after the backing plate  52  is inserted into the fixture. 
         [0045]    The light reflector  32  also includes rectangular holes  28  and  30  which allow attachment of the reflector  32  after the backing plate  52  has been secured to the fixture housing potentially reducing installation time for the light assembly  20 . 
         [0046]    The light reflector  32  can be manufactured from a number of metal materials. One exemplary material for manufacture of the reflector  32  is a highly reflective Alanod Mo 4 aluminum material. For example, the reflector  32  can be fabricated from Alanod coated aluminum sheet through a spun metal process. 
         [0047]    As described above, the lighting assembly  20  retrofits into existing HID based fixture housings, converting the existing fixture into a more energy-efficient fluorescent PL-based design. The assembly design is cost efficient in that it (i) leverages a common light reflector design which increases the lamp(s) performance (ii) can be installed very quickly utilizing a universal backing plate which accommodates multiple fixture designs and (iii) integrates the lamp holders into the backing plate which allows for a lower cost of manufacturing. 
         [0048]      FIG. 10  shows a process  100  for installing the lighting assembly  20 . Process  100  includes two main portions; first a portion of the old light fixture is removed including the lamp and subsequently the new light assembly is installed in the existing fixture housing. More particularly, the process for installing the new lighting assembly includes removing the current fixture diffuser lens ( 102 ). The process also includes removing the existing HID lamp ( 104 ), removing the HID lamp socket, and optionally the base plate and existing reflector ( 106 ). The process also includes potentially removing the existing ballast, starter, and restrike lamp ( 108 ). After these portions of the existing lamp structure have been removed, the lighting assembly  20  is used to install a new, more efficient light. The process for installing the lighting assembly  20  includes attaching the new ballast to the fixture housing ( 110 ) and attaching the incoming electrical wiring to the new ballast ( 112 ). The process also includes bending the lampholder brackets to approximately a 90 degree angle from the baseplate ( 114 ). After the lampholder brackets are bent into place, the process includes attaching pre-wiring in the lampholders to the new ballast ( 116 ) and attaching the baseplate to the fixture assembly ( 118 ). The process for installing the lighting assembly  20  also includes inserting fish paper into the pre-designed slot area ( 120 ). The process for installing the lighting assembly  20  also includes attaching the light reflector over the baseplate and lampholder assembly ( 122 ) and inserting two PL-lamps into lampholders ( 124 ). After the lamps have been inserted, the process includes re-attaching the existing fixture diffuser lens ( 126 ). 
         [0049]      FIG. 11  shows a process  130  for attaching the lamp to the lamp holder. Process  130  includes sliding plastic sleeves over socket arms ( 132 ) and inserting wires into the sockets ( 134 ). The attachment process  130  also includes feeding the wires through the socket bracket holes and sleeves ( 136 ) and attaching wire ties to each side around wires and sleeve ( 138 ). After the wires have been fed through the brackets and the wire ties attached, the process includes attaching the socket to the socket bracket ( 140 ) and packing the assembly ( 142 ). 
         [0050]    It is to be understood that the foregoing description is intended to illustrate and not to limit the scope of the invention, which is defined by the scope of the appended claims. 
         [0051]    Other embodiments are within the scope of the following claims. For example, while the lighting assembly  20  has been described for retrofitting the HID based lighting fixtures in a parking garage  10 , the lighting assembly  20  can also be used to retrofit other HID based lighting fixtures typically used in warehouse, industrial or commercial applications. 
         [0052]    Other embodiments can include a specifically designed PL based retrofit assembly that accommodates a variety of HID based outdoor lighting fixtures such as box shaped street lights from manufacturers such as Hubbell, wall washer fixtures, billboard lighting fixtures from various manufacturers and cobra head street light fixtures. The assemblies for these fixtures would include of a different shaped light reflector which was parabolic instead of conical and has a similar integrated backing plate with lamp arms. The design would accommodate multiple fixture sizes and multiple wattage PL lamps depending on the light level performance necessary for the application. 
         [0053]    For example,  FIGS. 12A and 12B  show an exemplary use of a retrofit assembly with a shoebox style light fixture  150 . The shoebox style light fixture  150  includes a housing  151  that is substantially box shaped (e.g., rectangular). A retrofit light assembly can be used for retrofitting an existing light fixture with a higher efficiency assembly including two PL lamps  154 , a light reflector  156  and a backing plate  160 . The exterior shape (e.g., the size and shape) of the backing plate  160  can vary to allow the backing plate  160  to fit into the existing base housing  151  of the shoebox style light fixture  150 . In addition, the light reflector  156  can be shaped to optimize light output from the shoebox style light fixture  150 . The retrofit light assembly for the shoebox style light fixture would be suitable for use with, for example, Genlyte fixtures, Lithonia fixtures, Hubbell fixtures or other similarly sized fixtures. 
         [0054]    In another example  FIGS. 13A and 13B  show an exemplary use of a retrofit assembly with a sign-light style light fixture  170 . The sign-light style light fixture  170  includes a housing  182  and a cover  174  located on top of the housing  182 . The housing  182  is wider at a back end of the housing than at a front end of the housing (e.g., as indicated by heights  178  and  180  respectively) such that the cover  174  is sloped with respect to a bottom surface  179  of the housing  182 . A retrofit light assembly can be used for retrofitting an existing sign light fixture with a higher efficiency assembly including two PL lamps  172 , a light reflector  176  and a backing plate  184 . The exterior shape (e.g., the size and shape) of the backing plate  184  can vary to allow the backing plate  184  to fit into the existing housing  182  of the sign-light style light fixture  170 . In addition, the light reflector  176  can be shaped to optimize light output from the sign-light style light fixture  170 . The retrofit light assembly for the sign-light style light fixture would be suitable for use with, for example, Cooper fixtures, Hubbell fixtures, Lithonia fixtures or other similarly sized fixtures. 
         [0055]    In another example,  FIG. 14  shows an exemplary backing plate  200 . The exterior shape (e.g., the size and shape) of the backing plate  200  can vary to allow the backing plate  200  to fit into an existing fixture&#39;s base housing. The backing plate  200  can be attached to the existing fixture&#39;s base housing by inserting screws into apertures  206   a ,  206   b , and/or  206   c . Additionally or alternatively, the backing plate  200  includes bendable tabs  208   a ,  208   b , and  208   c  which can be used to attach the backing plate  200  to the existing fixture&#39;s base housing. The tabs  208   a ,  208   b , and  208   c  can be bent out from the surface of the backing plate  200  to allow mounting of the backing plate  200  to the sides of a reflector or external fixture housing. The backing plate  200  also includes lamp holders  202  and  204  which protrude from the interior portion of the backing plate  200  and multiple air holes  210  that provide ventilation into the lighting assembly. The backing plate  52  also includes multiple clips  212 ,  214 ,  216 , and  218  for attaching an electrical insulation material such as fish paper  46  to the backing plate  52 . 
         [0056]    Other embodiments are within the scope of the following claims.