Patent Publication Number: US-11041595-B2

Title: High mast luminaire

Description:
RELATED APPLICATIONS 
     The present application is a continuation application of and claims priority to U.S. Non-Provisional patent application Ser. No. 15/964,880 (now U.S. Pat. No. 10,422,494 issued on Sep. 24, 2019), titled “High Mast Luminaire,” and filed on Apr. 27, 2018, which claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 62/500,743, titled “High Mast Luminaire”, and filed on May 3, 2017. The entire contents of the forgoing applications are incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     Embodiments described herein relate generally to light fixtures, and more particularly to systems, methods, and devices for a high mast luminaire. 
     BACKGROUND 
     When compared to conventional lighting technologies, such as incandescent, fluorescent, halogen, metal halide, or high pressure sodium light sources, light emitting diodes (LEDs) offer substantial benefits associated with their energy efficiency, light quality, and compact size. However, new technologies can help to realize the full potential benefits offered by light emitting diodes. For example, technologies that allow control over the direction of light emitted from LEDs would be beneficial. Additionally, technologies for handling the heat emitted by LEDs would also be beneficial. 
     SUMMARY 
     In one example embodiment, a luminaire comprises a light emitting diode module with a plurality of optics, each optic covering one or more LEDs, and each optic separated from the other optics by a vent. The luminaire further comprises a driver housing comprising a driver and a rotatable cap for rotating the LED module and a hollow connector for connecting the LED module and the rotatable cap of the driver housing. 
     In another example embodiment, a luminaire comprises a driver housing with a driver, a rotatable cap, and a mounting assembly. The luminaire further comprises an LED module with a plurality of optics wherein each optic of the plurality of optics covers one or more LEDs. The LED module and the driver housing are connected by a hollow connector wherein the hollow connector and the LED module are rotatable by the rotatable cap. 
     These and other aspects, objects, features, and embodiments, will be apparent from the following description and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings illustrate only example embodiments of high mast luminaires and are therefore not to be considered limiting of its scope and may admit to other equally effective embodiments. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Additionally, certain dimensions or positions may be exaggerated to help visually convey such principles. In the drawings, reference numerals designate like or corresponding, but not necessarily identical, elements. 
         FIG. 1  shows a top perspective view of a high mast luminaire in accordance with certain example embodiments. 
         FIG. 2A  shows a bottom perspective view of a high mast luminaire in accordance with certain example embodiments. 
         FIG. 2B  shows a cross-sectional view of a portion of the LED module of a high mast luminaire in accordance with certain example embodiments. 
         FIGS. 3A and 3B  show a high mast luminaire with a shroud in accordance with certain example embodiments. 
         FIG. 4  shows an interior view of the driver housing of a high mast luminaire in accordance with certain example embodiments. 
         FIG. 5  shows another interior view of the driver housing of a high mast luminaire in accordance with certain example embodiments. 
         FIG. 6  shows a partial cross-sectional view of a high mast luminaire in accordance with certain example embodiments. 
         FIG. 7  shows a partial exploded view of a high mast luminaire in accordance with certain example embodiments. 
         FIG. 8  shows a partial cross-sectional view of a high mast luminaire in accordance with certain example embodiments. 
         FIG. 9  shows another cross-sectional view of a high mast luminaire in accordance with certain example embodiments. 
         FIG. 10  is an inverted enlarged partial cross-sectional view of an optic and LED in accordance with certain example embodiments. 
         FIG. 11  is an inverted enlarged partial exploded view of the LED module of a high mast luminaire in accordance with certain example embodiments. 
     
    
    
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS 
     The example embodiments discussed herein are directed to high mast luminaires such as the luminaires mounted above roadways. While the example embodiments described herein are in the context of high mast luminaires, it should be understood that the embodiments described herein can apply to a variety of luminaires. For example, the embodiments can be used with luminaires located in any environment (e.g., indoor, outdoor, hazardous, non-hazardous, high humidity, low temperature, corrosive, sterile, high vibration). Further, the luminaires described herein can use one or more of a number of different types of light sources, including but not limited to various light-emitting diode (LED) light sources such as discrete LEDs, LED arrays, chip on board LEDs, and organic LED light sources, as well as other types of light sources. Therefore, the example luminaires described herein, should not be considered limited to a particular type of light source. 
     In certain example embodiments, the example luminaires are subject to meeting certain standards and/or requirements. For example, the National Electric Code (NEC), the National Electrical Manufacturers Association (NEMA), the International Electrotechnical Commission (IEC), the Federal Communication Commission (FCC), and the Institute of Electrical and Electronics Engineers (IEEE) set standards as to electrical enclosures (e.g., light fixtures), wiring, and electrical connections. As another example, Underwriters Laboratories (UL) sets various standards for light fixtures, including standards for heat dissipation. Use of example embodiments described herein meet (and/or allow a corresponding device to meet) such standards when required. 
     Any luminaires, or components thereof (e.g., housings or heat sinks), described herein can be made from a single piece (e.g., as from a mold, injection mold, die cast, 3-D printing process, extrusion process, stamping process, or other prototype methods). In addition, or in the alternative, a luminaire (or components thereof) can be made from multiple pieces that are mechanically coupled to each other. In such a case, the multiple pieces can be mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to epoxy, welding, fastening devices, compression fittings, mating threads, and slotted fittings. One or more pieces that are mechanically coupled to each other can be coupled to each other in one or more of a number of ways, including but not limited to fixedly, hingedly, removeably, slidably, and threadably. 
     A coupling feature (including a complementary coupling feature) as described herein can allow one or more components and/or portions of an example heat sink or other component of a light fixture to become coupled, directly or indirectly, to another portion of the example heat sink or other component of a light fixture. A coupling feature can include, but is not limited to, a snap, Velcro, a clamp, a portion of a hinge, an aperture, a recessed area, a protrusion, a slot, a spring clip, a tab, a detent, and mating threads. One portion of an example heat sink can be coupled to a light fixture by the direct use of one or more coupling features. 
     In addition, or in the alternative, a portion of a luminaire can be coupled using one or more independent devices that interact with one or more coupling features disposed on a component of the heat sink. Examples of such devices can include, but are not limited to, a pin, a hinge, a fastening device (e.g., a bolt, a screw, a rivet), epoxy, glue, adhesive, tape, and a spring. One coupling feature described herein can be the same as, or different than, one or more other coupling features described herein. A complementary coupling feature (also sometimes called a corresponding coupling feature) as described herein can be a coupling feature that mechanically couples, directly or indirectly, with another coupling feature. 
     Terms such as “first”, “second”, “top”, “bottom”, “side”, “distal”, “proximal”, and “within” are used merely to distinguish one component (or part of a component or state of a component) from another. Such terms are not meant to denote a preference or a particular orientation, and are not meant to limit the embodiments described herein. In the following detailed description of the example embodiments, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. 
     Referring to  FIGS. 1 and 2A , perspective top and bottom views of an example high mast luminaire  100  are shown. The example high mast luminaire  100  comprises a driver housing  105  connected to an LED module  115  by a hollow connector  110 . The example high mast luminaire  100  is attached to a pole  112  for mounting, for example, above a roadway. The driver housing comprises a driver housing top  106  and a driver housing base  107 . The hollow connector  110  can vary in length depending on the application. For example, in embodiments where the LEDs and the drivers produce a relatively large amount of heat, a longer hollow connector  110  can be used to further separate the driver housing  105  from the LED module  115  so that heat produced by each component does not adversely affect the other component. A longer hollow connector  110  also promotes increased air flow between the driver housing  105  and the LED module  115  to improve cooling. In one example, the length of the hollow connector  110  can vary between 2 and 8 inches. 
       FIG. 2B  is an enlarged cross-sectional partial view of the LED module  115 .  FIGS. 2A and 2B  show vents  118  passing through the LED module  115  to promote cooling of the LED module  115 . In the example of  FIGS. 2A and 2B , an LED plate  155  covers a majority of the bottom surface of the LED module  115  to minimize light being directed towards the sky, for example, to comply with “dark sky” regulations. An additional feature of the example in  FIGS. 2A and 2B  is that many of the vents  118  are staggered to further prevent light being directed towards the sky. In other words, the staggered vents  118  have an opening in the LED plate  155  and an offset corresponding opening in the LED casting  160 . As such, the vent openings  118  in the LED plate  155  are covered by the LED casting  160  in the area directly above the opening in the LED plate  155  so that light cannot easily pass through the LED module  115  towards the sky. 
     In the embodiment illustrated in  FIGS. 2A and 2B , at least one vent  118  is disposed between each pair of optics  116  to dissipate the heat generated by the one or more LEDs covered by each optic  116 . In the example shown in  FIGS. 2A and 2B , an additional vent  118  is located along the perimeter of the LED module  115 , between the rim  119  and the LED plate  155 , and encircling the optics  116 . As also shown in the example in  FIG. 2B , one or more heat sink fins  120  are disposed across each vent  118  to further assist in dissipating heat generated by the LEDs. As will be readily understood, the number and positions of optics  116 , vents  118 , and heat sink fins  120  can be varied to accommodate different applications. In one example embodiment, each LED (e.g., the LED  150  shown in  FIGS. 10 and 11 ) consumes between 25 and 80 watts and the arrangement of the vents  118  and heat sink fins  120  reduces the average temperature of the LED module  115  from approximately 120 degrees C. to approximately 94 degrees C. It should also be understood that in other embodiments, the LED plate  155  can have other configurations and may cover less of the bottom surface of the LED module  115 . 
       FIGS. 3A and 3B  illustrate an alternate embodiment of a high mast luminaire  300 . The alternate high mast luminaire  300  comprises a driver housing  105 , an LED module  115 , and a hollow connector  110  similar to those described in connection with  FIGS. 1 and 2 . However, the alternate embodiment illustrated in  FIGS. 3A and 3B  also comprises a shroud  309  that covers the hollow connector  110 , for example, for aesthetic purposes. 
       FIGS. 4 and 5  illustrate top plan and top perspective views, respectively, of the driver housing  105  of an example high mast luminaire.  FIG. 4  shows three drivers  125  located in the driver housing base  107 . The drivers  125  receive power (e.g., line power) via a terminal block  172  and a surge protector  174 . In alternate embodiments, the luminaire may have fewer or more drivers and they may be mounted in other positions. As illustrated in the example in  FIGS. 4 and 5 , the driver housing base  107  comprises three side walls  126 ,  127 , and  128  wherein the interior surface of the sidewall is flat so that each of the drivers  125  can be mounted directly against the flat interior surface of each sidewall  126 ,  127 , and  128  to optimize the transfer of heat from the drivers  125  to the driver housing base  107 . This arrangement can also be seen in the cross-section view shown in  FIG. 9 . As illustrated in  FIG. 5 , the outer surface of the three side walls  126 ,  127 , and  128  of the driver housing base  107  comprise heat sink fins to assist with heat dissipation. 
       FIGS. 4 and 5  also show an example mounting assembly  101  of the LED module  115 . The mounting assembly  101  comprises an aperture  108  in the side of the driver housing base  107 , the aperture  108  for receiving a mounting component such as the pole  112 . The mounting assembly  101  also comprises a pair of clamps  102  and  103  and a receiving end  104 . The receiving end  104  has a series of step features designed to receive mounting components, such as pole  112 , having varying dimensions. 
       FIG. 5  illustrates the driver housing base  107  with the drivers removed.  FIG. 5  shows an example rotatable cap  130 . Rotatable cap  130  comprises a first set of apertures for receiving hexagonal bolts  132  which are used to fasten the rotatable cap  130  to the hollow connector  110 . Rotatable cap  130  also comprises a second set of apertures for receiving rotational set screws  134 . Rotatable cap  130  further comprises one or more third apertures for receiving a tamper-proof security screw  136 . Lastly, rotatable cap  130  further comprises one or more fourth apertures for receiving one or more wiring grommets  138 . It should be understood that the different types of fasteners described and shown in connection with the rotatable cap  130  are simply examples and that in alternate embodiments other types of fasteners can be used. 
     Referring to  FIGS. 5, 6, 7, and 8 , the installation of the high mast luminaire using the rotatable cap can be further described. As illustrated in  FIG. 2 , each of the optics  116  is biased to direct light at a particular angle. In other words, each optic  116  is asymmetric and is designed to direct at least a majority of light from an LED towards the side of the optic that has a wider rounded surface. Because each of the optics  116  is oriented in the same direction, it is advantageous to be able to rotate the LED module  115  to direct light in the desired direction, for example towards a roadway on one side of the luminaire. During installation or maintenance of the luminaire, the rotatable cap  130  permits rotation of the hollow connector  110  and the LED module  115  to direct light in the desired direction while the driver housing  105  remains attached to a pole  112  and does not rotate. The apertures in the rotatable cap  130  are asymmetric so that the rotatable cap  130  can only be installed in the correct position. 
     During installation or maintenance, the hexagonal bolts  132  and the rotational set screws  134  are loosened so that the rotatable cap  130  can be rotated to position the LED module  115  at the desired angle. As shown in the example in  FIG. 8 , the rotatable cap  120  rests on an inner wall  109  of the driver housing base  107 . As further shown in the example of  FIGS. 6 and 8 , the hexagonal bolts  132  and the tamper-proof security screws  136  fasten to the hollow connector  110 , while the rotational set screws  134 , located closer to the perimeter of the rotatable cap  130 , fasten to the top of the inner wall  109 . Although the hexagonal bolts  132  and the rotational set screws  134  are loose, the tamper-proof security screws  136  can only be partially unfastened and serve as a safety feature. The tamper-proof security screws  136  are designed so that they are fastened during the manufacturing process and cannot be completely unfastened without the proper tool. The tamper-proof security screws  136  are designed so that the rotatable cap  130  cannot be completely separated from the hollow connector  110  and the LED module  115  when the hexagonal bolts  132  and the rotational set screws  134  are loosened. As can be seen in  FIG. 8 , the tamper-proof security screws  136  are designed such that when they are partially loosened there is a gap  140  between the head of the tamper-proof screw  136  and the rotatable cap  130  thereby permitting enough flexibility to rotate the rotatable cap  130  on the inner wall  109  to the desired angle. 
     Arrows and angle measurement markings are included on the rotatable cap  130  and the driver housing base  107  to assist the installer in selecting the desired angle of rotation. Once the rotatable cap  130  is placed at the desired angle so that light is emitted from the LED module  115  in the designated direction, the hexagonal bolts  132  attached to the hollow connector  110  are tightened. Lastly, the rotational set screws  134  are tightened against the top of the inner wall  109  as an additional measure to ensure the rotatable cap  130  will not rotate. 
     Additional advantages of the example embodiments of high mast luminaires are shown in  FIGS. 9-11 . In particular, the LED module  115  is designed to optimize heat transfer from the LEDs  150  located under each optic  116 . The LEDs  150  are mounted on an LED plate  155  as shown in  FIGS. 9 and 10 . The LED plate  155  is attached to the LED casting  160  of the LED module  115 . The LED casting  160  comprises mounting pads  164  and wiring cavities  162 . The mounting pads  164  are positioned directly behind the LEDs  150  to facilitate the transfer of heat from the LEDs  150  across the LED plate  155  and to the mounting pads  164 . The LED casting  160  absorbs the heat via the mounting pads  164  and dissipates the heat via the vents  118  and heat sink fins  120 . 
     The wiring cavities  162  accommodate grommets  166  on each side of the mounting pad  164  so that the two lead wires from the LED  150  can pass through a grommet  166  on each side of the mounting pad  164  without interfering with the direct contact of the LEDs to the mounting pad  164  and the desired heat transfer.  FIG. 11  shows the aforementioned features, but with the LED plate  155  hidden from view to illustrate the mounting pad  164  and the wiring cavities  162 . The lead wires from the LED  150  connect to conductors in the wiring cavities  162  and the conductors extend through the hollow connector  110  and through the grommets  138  to the driver housing  105  to provide power from the one or more drivers  125 . 
     Many modifications and other embodiments set forth herein will come to mind to one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the example embodiments are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of this application. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.