Patent Publication Number: US-7914198-B2

Title: Modular luminaire system

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This divisional application claims benefit under 35 USC 120 of U.S. application Ser. No. 11/122,596, filed May 5, 2005, which will issue as U.S. Pat. No. 7,513,675 on Apr. 7, 2009, which application claims benefit under 35 USC 119(e) of U.S. Provisional Application No. 60/568,831, filed May 7, 2004, the entire disclosures of which are incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention is directed towards a modular luminaire system and in particular to a modular lighting system which has a luminaire unit, the luminaire unit electrically connected to a remote ballast housing by a removable and pluggable cord, the luminaire unit electrically connected to the ballast housing through this flexible cord and plug system. 
     REVIEW OF THE PRIOR ART 
     Luminaire systems of the prior art which require ballast electronics have typically had the ballast electronics integrated with the luminaire unit itself. With such a system, the ballast is hardwired to the luminaire directly thereby mandating that all ballast electronics be incorporated within the luminaire unit. Alternatively, the luminaire ballast electronics were typically combined into a single unit for placement or mounting along a ceiling or wall surface for later use. Commonly in such situations where ballast electronics are required, high intensity discharge lamps, metal-halide lamps and ceramic metal-halide lamps, to name a few, require ballast electronics for the requisite starting voltage as well as for continued electrical power. These prior art systems, however, have a significant drawback in that the luminaire unit must be combined with the ballast electronics thereby limiting the nature and aesthetic value of the prior art luminaires. 
     In these prior art systems, it was common to require the electronics for the ballast to be integrated within the electrical connections of the luminaire itself, therefore increasing the size of the luminaire as well as increasing the heat produced within the luminaire unit. In alternative constructions where the luminaires were combined with the ballast or ballast electronics, additional manufacturing steps were thus required and again, the aesthetic appearance of the luminaire was minimized due to the necessary size, which may be considerable, of the ballast electronics. 
     It is therefore desirable to have modular system wherein high intensity discharge lamps and the like, may be connected remotely to a ballast housing or ballast electronics thereby fully separating the luminaire unit and the ballast electronics in a fully modular system. 
     SUMMARY OF THE INVENTION 
     The present invention is directed towards a high intensity discharge modular lighting system which has a luminaire unit which is remotely and removably electrically connected to a remote ballast housing, the remote ballast housing being separate from the luminaire unit. The modular lighting system of the present invention utilizes a luminaire unit which has a cord and plug being insulated, the plug being received within a receptacle on the ballast housing. The ballast housing may be kept separate and remote from the luminaire unit thereby allowing the ballast electronics to be separated from the luminaire. 
     One of the benefits of the present invention is that the luminaire system may be a number of different illumination sources, such as high intensity discharge lamps, metal-halide or ceramic metal-halide while also allowing significantly different configurations to the luminaire and ballast combination. Thus, the luminaire unit may be designed such that it is not dependent upon the electronics of the ballast within the luminaire housing or directly affixed thereto. 
     Therefore, one object of the present invention is to provide a modular lighting system wherein the lighting system is comprised of a luminaire unit being electrically, but remotely connected by a cord and plug system to a remote ballast housing, the remote ballast housing providing the necessary starting pulse and power for various illumination lamps. 
     Another object of the present invention is to provide a modular lighting system wherein the luminaire is a high intensity discharge illumination luminaire connectable by a cord and plug system to a remotely positioned ballast unit, the remote ballast housing being one of a number of varying ballast electronics dependent upon the specific lamp or luminaire being utilized. 
     Another object of the present invention is utilization of a high intensity discharge modular illumination system having a separated remote ballast housing and a luminaire, the luminaire removably connected by a cord and plug system to the ballast, the ballast being configurable to and electrically connected with a track lighting system or alternative power source. The remote ballast unit may be removably attached to a track lighting system thereby contacting the electrical contacts on the track while providing the necessary electrical systems to a high intensity discharge illumination source on the luminaire unit. 
     One benefit of the present invention is that the remote placement of the ballast housing from the luminaire unit reduces the heat generated by the luminaire unit and also allows the luminaire unit, while being a high intensity discharge illumination source, from necessarily incorporating all of the ballast electronics within the luminaire. 
     The modular lighting system of the present invention provides a removable mounting mechanism allowing the luminaire unit to be attached to an unpowered track on the remote ballast housing or to an alternative mounting position. The remote ballast housing of the present invention may be electrically connected to a power track lighting system or may be a canopy mount or other various mounting positions. Such modularity between the luminaire unit and the remote ballast housing allows a number of configurations for high intensity discharge illumination while alternate placements of the remote ballast housing may be utilized, the two elements of the illumination system of the present invention being separated but electrically releasably connected by a removable cord and plug system allowing the luminaire to be plugged into the ballast housing. 
     The modular system of the present invention allows both the remote ballast housing and the luminaire unit to be removably attached or mounted in multiple positions while also making the luminaire unit aesthetically pleasing by removal of the ballast electronics from the luminaire. 
     These and other benefits of the present invention will be directly apparent after review of the drawings attached herewith along with the description and claim set forth herein. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the modular lighting system of the present invention incorporating both the remote ballast housing and the luminaire unit electrically connected together; 
         FIG. 2  is a bottom view of the remote ballast housing of the present invention; 
         FIG. 3  is a top perspective view of the remote ballast housing of the present invention; 
         FIG. 4  is a perspective and close-up view of the track lighting system for use with the remote ballast unit of the present invention; 
         FIG. 5  is a close-up view of one embodiment of the luminaire unit of the present invention; 
         FIG. 6  is a close-up view of the cord and plug electrical connection between the luminaire unit and the remote ballast unit of the present invention; 
         FIG. 7  is a view of the remote ballast unit electrically connected and receiving the cord and plug from the luminaire unit; 
         FIG. 8A  is a side view of an alternative remote ballast housing of the present invention; 
         FIG. 8B  is a bottom perspective view of the remote ballast housing of  FIG. 8A ; 
         FIG. 9A  is a separated view of the remote ballast housing and the mounting mechanism of the luminaire unit of the present invention; 
         FIG. 9B  is a connected view the luminaire unit mounting mechanism directly affixed to the track within the remote ballast unit; 
         FIG. 10A  is a close-up view of the luminaire unit mounting mechanism with a track lighting system of the present invention; 
         FIG. 10B  is the connected track assembly fitting of the luminaire unit with the track lighting system; 
         FIG. 11  is a close-up end view of the remote ballast unit of the present invention; 
         FIG. 12  is a side sectional view of the track system in use with the present invention; 
         FIG. 13  is a side view of a luminaire unit of the present invention; 
         FIG. 14  is a lower perspective view of a remote ballast housing having a canopy attachment of the present invention; 
         FIG. 15  is a perspective view of an exemplary modular lighting system of the present invention; 
         FIG. 16  is a side view of an exemplary modular lighting system embodiment of the present invention; and, 
         FIG. 17  is a close-up side view of an alternative embodiment mounting for the luminaire unit of the present invention. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The modular lighting system of the present invention is shown in  FIG. 1  wherein the remote ballast housing  30  is non-electrically connected to the luminaire unit  20  through the use of an attachment arm  15  and track attachment fitting  14 . The luminaire unit  20  has a lamp socket cup  18 , a reflector housing  17  and luminaire face  16  as depicted. The luminaire unit  20  of the present invention is electrically connected to the remote ballast housing  30  by the cord  22  and the plug  24  which is received within a receptacle of the remote ballast housing  30 . By separating the remote ballast housing  30  and the luminaire unit  20  and allowing for a cord and plug electrical connection system, flexibility for high intensity discharge metal-halide track lighting is provided, among the various embodiments set forth herein. The modular lighting system of the present invention allows for flexibility in matching luminaire units with various remote ballast housings depending upon the particular illumination required and dependent upon the specific lamp utilized. Various aspects of the elements of the modular luminaire system of the present invention will be set forth herein. 
     The Luminaire Unit 
     The luminaire unit  20  depicted in  FIG. 1  may be a number of different constructions and designs. High intensity discharge (HID), metal-halide and ceramic metal-halide lighting may be utilized with the remote ballast housings. The luminaire unit  20 , as is shown in  FIG. 1 , is more clearly shown in  FIG. 5 , in one embodiment, as well as  FIG. 13  and  FIGS. 15 ,  16  and  17 , depicting the various embodiments utilized with the modular luminaire system of the present invention. 
     As can be seen from the embodiment depicted in  FIG. 1 , the luminaire unit  20  shown has a socket cup  18  having a lamp socket contained therein for retention of a lamp  27  shown in  FIG. 5 , the lamp  27  being any of a number of the varying high intensity discharge or other illumination sources. The luminaire unit  20  may be a number of different luminaire systems such as spot lighting, wall washing or other modular lighting units required for the particular environment to which the luminaire unit is being installed. The flexibility of the modular lighting system of the present invention is provided by the luminaire unit  20  incorporating into the design a cord and plug system, the cord  22  being in electrical communication with the lamp  27 . The lamp  27  may be a number of different lamps available for use with similar high intensity discharge characteristics, such as T4 or T6. The lamps, commonly referred to as high intensity discharge, metal-halide or ceramic metal-halide lighting, typically offers significant performance enhancements over normal incandescent and fluorescent lighting sources. However, as is known, such high intensity lighting resources require different power supplies, therefore the need for the remote ballast housing utilized with the present invention. 
     Returning to the luminaire unit  20  of the present invention and depicted in  FIG. 5 , the luminaire unit  20  has, as mentioned, socket cup  18  which retains the mounting mechanism for lamp  27 . Further, lens  25  may be utilized for covering of the illumination source, tinting or other desired illumination modification. Also, as is readily apparent from the depiction of the embodiment in  FIG. 5 , the luminaire unit  20  has a track attachment fitting  14  which is affixed to an attachment arm  15  for fixation of the luminaire unit  20  to a track. However, the track attachment fitting  14  as depicted is not required for electrical connection purposes and is provided to removably mount the luminaire to one of a number of mounting locations. 
     As is apparent from the construction of the track attachment fitting  14 , shown in  FIG. 13 , as well as is shown in  FIGS. 9A ,  9 B,  10 A and  10   b , the track attachment fitting  14  has an attachment arm  14   a  thereby allowing the attachment fitting  14  to be removably and non-electrically attached to a track, such as the track  39  shown in  FIG. 9A . Thus, the luminaire unit  20  is attachable to the remote ballast housing track  39  through the use of the track attachment fitting  14 , shown in  FIGS. 9A and 9B , where it is shown as being removably affixed to the remote ballast housing track  39 . 
     Alternatively, as is seen in  FIGS. 10A and 10B , the luminaire unit  20  may be affixed to a track  50  having a track bead  51  as is shown, the track attachment fitting  14  having a locking lever  14   a  and support  14   b . The track attachment fitting  14  may be a molded polycarbonate allowing for rotation of the lever and attachment mechanism into the track for removable attachment therein. 
     While it is shown that the luminaire unit  20  is affixed to a track unit, the modular luminaire system of the present invention is designed for a number of removable attachment mechanisms for each luminaire unit  20  and the examples shown herein are not to be considered to be limiting as they are exemplary only. 
     Returning to the example luminaire units shown in the figures, the luminaire unit  20  has incorporated an attachment arm  15  which extends upward to a track attachment fitting  14 . The track attachment fitting  14  is a standard track attachment unit as is shown much more closely in  FIGS. 9A ,  9 B,  10 A and  10 B. The track attachment fitting has a lever  14   a  for rotation of slide or attachment mechanism  14   b . The attachment arm  15  and track attachment fitting  14  allows for the luminaire unit  20  to be directly affixed to a track  30 . The track may be a track directly formed in a remote ballast housing unit, such as is shown in  FIG. 1 . Of course, the track attachment fitting  14 , shown in the examples, allows for the luminaire unit  20  to be directly affixed to a track located on either a remote ballast housing, external track assembly or other peripheral device. Of note, however, is that luminaire unit  20  of the present invention is not utilizing the track attachment fitting  14  for electrical connection but is merely using it as a releasable mounting mechanism for releasably affixing the luminaire unit to the appropriate overhead assembly. Thus, the specific mounting arrangement shown in the drawings is not considered limiting. 
     Returning to the examples shown in the Figures, the luminaire unit  20  additionally has the lens  25 , lamp  27  and luminaire face  16 , all of which may be modified according to user preference and design necessities. A significant number of variations are allowable for design of the particularized luminaire unit  20  used. The particular constructions shown are exemplary only. 
     Cord and Plug Assembly 
     The luminaire unit  20  also has shown extending outward from the socket cup  18  a cord and plug assembly which is comprised of the cord  22  and attachment plug  24 . Interior of the cord  22  are conductors which are three each individually wrapped in adequate insulation, the entirety of the three insulated conductors then enclosed in additional silicone insulation material. As is known, the conductors include one ground and two live conductors for completion of the appropriate circuit. Each of the conductors terminate at the insulated conductors ends  24   b . As can be seen, the conductive ends  24   b  extend outward from the plug  24  and are utilized to electrically connect the luminaire unit  20  with pins in plug receptacle  32  and the electronics within the remote ballast housing  30 . 
     The three conductor system utilized allows for the luminaire unit  20  to be removably and electrically connected to the remote ballast housing  30 , regardless of the location of the remote ballast housing  30  or the mounting of the luminaire unit  20 . However, due to the necessary starting pulse for activation of the high intensity discharge lamps, the cord  22  and plug  24  must necessarily be properly insulated to withstand and adequately insulate up to a 5 KV starting pulse or more. This starting pulse may be as low as 4 KV dependent upon the particular electronics or lamps utilized. However, the cord and plug as well as the insulated conductors  24   b  are adequately insulated to prevent electrical shock and meeting all necessary standards for insulation. Also of note is that the plug  24  may incorporate a locking lever  24   a  to maintain the plug in position within the plug receptacle  32  of the remote ballast housing  30 . The locking tab merely positions into a slot adjacent to the plug receptacle  32  and prevents the plug from being removed from the remote ballast  30  without depression of the locking tab  24   a . Thus, the design of the modular illumination system of the present invention allows for the electrical connection of the luminaire unit  20  through the use of the cord and plug system described independent of the actual luminaire unit and the remote ballast housing. Further, because of the design, the luminaire unit  20  may be significantly separated from the remote ballast housing  30  wherein an insulated extension cord, such as is shown in  FIGS. 16 and 17  may be utilized to electrically connect the luminaire unit  20  to the remote ballast housing  30  even when there is considerable distance between the two. Also of note is that the mounting mechanism utilized for the luminaire unit  20  may vary such that the user may decide where or in what environment the luminaire unit  20  of the present invention may be utilized as long as the luminaire unit  20  is combined with an adequate remote ballast housing  30  necessary for supplying adequate power to the lamp. 
     Remote Ballast Housing 
     The remote ballast housing utilized in the present invention may be one of a number of designs and may incorporate either an electronic ballast or a magnetic ballast. The remote ballast housing depicted in the drawing is electrically connected to the luminaire unit  20  and may itself be electrically connected to a live track assembly  50 , such as is shown in  FIG. 4 , or may be electrically connected to a junction box as in a canopy mount, shown in  FIG. 14 . The ballast may be 39 Watts or 100 Watts depending upon the necessary lamp or illumination electronics utilized. Thus, the power provided by each of the various remote ballast housings  30  may be modified depending upon the particular usage and connected luminaire unit. 
     The remote ballast housing  30  shown in the Figures incorporate various connection mechanisms such as the track attachment fittings  35 , shown in  FIG. 8A , for the larger magnetic remote ballast housing  300 , and as previously indicated, may incorporate a plug receptacle  32  on the bottom end thereof. The plug receptacle  32  may have three conduits or electrical contact pins for contacting the insulated conductor ends  24   b  of the plug  24 . The remote ballast housing  30 ,  300 , or  310  shown in  FIG. 14 , may also have on the lower surface thereof a ballast housing mounting  39  which allows for removably and non-electrically mounting the luminaire unit  20 . Thus, the luminaire unit  20  may be directly and non-electrically connected to the remote ballast housing through the track so that it is kept in somewhat close proximity to the remote ballast housing. Alternatively, the luminaire unit  20  may be mounted remotely therefrom. As is also shown in the Figures, the remote ballast housing embodiments depicted also incorporate a power switch  34  for turning on and off the power provided by the remote ballast housing. This may be necessary for connecting of the power cord  22  after the remote ballast housing has been electrically connected to a power source. The power source may be a live track assembly  50 , as is shown in  FIG. 4  and  FIG. 12 , or may be a junction box by a canopy mount  311 , as shown in  FIG. 14 . As is known in the art and as shown in the figures, the track attachment fittings  35  for the remote ballast housing may include the necessary metalized contacts  35   a  to appropriately contact the active tracks of the track assembly  50 , shown in  FIG. 12  as being upper circuit  53 , lower circuit  54  and neutral track  55 . Thus, the remote ballast housing depicted in the Figures may be electrically connected to the track  50  or to an alternative electrical source. 
     EXAMPLES 
     As is readily apparent, the ability of modularizing the luminaire units and the ballast electronics as is done in the present invention is through the use of a plug and cord assembly allows for significant variations in design and use of high intensity lamp illumination. Of the examples shown in  FIGS. 15 ,  16  and  17 , as well as throughout the rest of the Figures, it is apparent that the luminaire unit  20  may be remotely positioned away from the remote ballast housing and mounted on a number of mounting surfaces. 
     As is shown in  FIG. 15 , the luminaire unit  20  is mounted directly to a track  50 , but is not electrically connected thereto. The luminaire unit  20  is electrically connected through the cord  22  and plug  24  to the remote ballast housing  30  which is electrically connected to the energized track  50 . The modular HID luminaire unit  60 , shown in  FIG. 15 , therefore depicts the luminaire unit adjacent to and electrically connected to the remote ballast housing but not mounted or affixed thereto. 
     Alternatively, as is shown in  FIG. 16 , the modular HID luminaire unit  62  depicted therein incorporates the use of a remote ballast housing  30  affixed to a track  50  and, dependent from the ballast housing track  39 , is an extension wand  64  for remote placement of the luminaire unit  20 . An electrical cord extends from the luminaire unit  20  to the remote ballast housing and the luminaire unit  20 , by virtue of the extension wand  64  and is directly mechanically affixed to the remote ballast housing but is removably attached therefrom for alternative placement. Additionally, as is apparent from both  FIGS. 16 and 17 , the cord  22  may incorporate a remote extension cord  22   a , as shown in  FIG. 17  for extending the distance between the luminaire unit  20  and the remote ballast housing. Also, as shown in  FIG. 17 , the luminaire unit  20  is remotely mounted from the remote ballast housing and, as is shown in this example, the modular luminaire unit  66  is removably mechanically attached to a mounting bar  68  completely separate from the remote ballast housing. 
     As is readily apparent, a number of variations due to modularity of the modular HID luminaire unit system of the present invention allows for a number of various mechanical attachments between the luminaire unit and the remote ballast housing. The luminaire unit may be directly attached to the remote ballast housing through the use of a remote ballast housing track mounting system or may be mounted separate therefrom. Also, as is readily apparent, the luminaire unit  20  is readily and easily removably attached to any position and is also removably electrically connected to the remote ballast housing. Thus, the luminaire unit  20  may be matched to an appropriate remote ballast housing depending upon the electrical needs of the illumination system and the particularized ballast utilized.