Patent Publication Number: US-11041608-B2

Title: Luminaire

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of co-pending U.S. patent application Ser. No. 16/401,895, filed May 2, 2019, which claims the benefit of U.S. Provisional Application No. 62/665,804, filed May 2, 2018, and to U.S. Provisional Application No. 62/745,499, filed Oct. 15, 2018. The entire contents of these applications are incorporated herein by reference. 
    
    
     BACKGROUND 
     The present disclosure relates to a luminaire, and more specifically to a luminaire housing supporting an optic such as a lens. 
     SUMMARY 
     In one independent aspect, a luminaire includes a housing including a pair of sides and a base extending between the sides; a lens removably coupled to the housing, the lens including side portions; a mounting bracket directly coupled to the base and including a chamber, a driver coupled to the base and positioned within the chamber; a plurality of light emitters coupled to a surface of the mounting bracket and in communication with the driver; a first portion including a pocket and a protuberance positioned on either a side portion of the lens or a side of the housing; and a second portion including a projection and a curved portion positioned on the other of the side portion of the lens and the side of the housing, the protuberance engageable with the pocket to couple the lens to the housing. 
     In another independent aspect, a luminaire includes a housing including a pair of sides having an S-shaped portion that includes a pocket and a protuberance; a mounting bracket coupled to the housing and supporting at least one light emitter; and a lens removably coupled to the housing, the lens including side portions having a portion including a projection and a curved portion, the curved portion engageable with the protuberance and the projection engageable with the pocket to create a snap-fit engagement. 
     In yet another independent aspect, a luminaire includes a housing including a base and a first side and a second side extending from the base; a mounting bracket directly coupled to the base and including a chamber, a driver coupled to the base within the chamber; a plurality of light emitters supported on a surface of the mounting bracket; an end cap coupled to the housing, the end cap configured to limit light emitted from the light emitters from passing through the end cap; and a lens removably coupled to the housing at a terminal end of the housing without the use of additional fastening members, the lens configured to at least partially cover the light emitter. 
     Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a luminaire. 
         FIG. 2  is an exploded view of the luminaire of  FIG. 1 . 
         FIG. 3  is an end view of a housing of the luminaire of  FIG. 1 . 
         FIG. 4  is an end view of a lens of the luminaire of  FIG. 1 . 
         FIG. 5  is a perspective view of an end cap of the luminaire of  FIG. 1 . 
         FIG. 6  is a cross-sectional view of the luminaire of  FIG. 1 , viewed along section  6 - 6 . 
         FIG. 7  is an enlarged view of portion  7 - 7  of the cross-sectional view of  FIG. 6 . 
         FIG. 8  is a perspective view of a luminaire according to another embodiment. 
         FIG. 9  is an exploded view of the luminaire of  FIG. 8 . 
         FIG. 10  is an end view of a lens of the luminaire of  FIG. 8 . 
         FIG. 11  is a perspective view of an end cap of the luminaire of  FIG. 8 . 
         FIG. 12  is a cross-sectional view of the luminaire of  FIG. 8 , viewed along section  12 - 12 . 
         FIG. 13  is an enlarged view of portion  13 - 13  of the cross-sectional view of  FIG. 12 . 
         FIG. 14  is a perspective view of a luminaire according to another embodiment. 
         FIG. 15  is an exploded view of the luminaire of  FIG. 14 . 
         FIG. 16  is a perspective view of an end cap of the luminaire of  FIG. 14 . 
         FIG. 17  is a cross-sectional view of the luminaire of  FIG. 14 , viewed along section  17 - 17 . 
         FIG. 18  is an exploded view of two luminaires of  FIG. 14  coupled together. 
         FIG. 19  is a perspective view of a coupler bracket. 
         FIG. 20  is a perspective view of a lens bracket. 
         FIG. 21  is a perspective view of a luminaire according to another embodiment. 
         FIG. 22A  is a perspective view of the luminaire of  FIG. 14  coupled to a ceiling using a first attachment mechanism. 
         FIG. 22B  is a perspective view of the luminaire of  FIG. 14  including a second attachment mechanism. 
         FIG. 22C  is a perspective view of the luminaire of  FIG. 14  including a third attachment mechanism. 
         FIG. 22D  is a perspective view of the luminaire of  FIG. 14  including a fourth attachment mechanism. 
         FIG. 22E  is a perspective view of the luminaire of  FIG. 14  including a fifth attachment mechanism. 
         FIG. 23  is a perspective view of the luminaire of  FIG. 14  including uplights. 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Use of “including” and “comprising” and variations thereof as used herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Use of “consisting of” and variations thereof as used herein is meant to encompass only the items listed thereafter and equivalents thereof. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. 
     In general, the present disclosure relates to a lens that is removably coupled to a housing of a luminaire in order to selectively cover light emitters. The lens is coupled to the housing without the use fasteners. 
     As shown in  FIG. 1 , a luminaire  10  includes a housing  14  with an elongated body that extends along a longitudinal axis  18 . A lens  22  is coupled to the housing  14 . The lens  22  extends in a direction parallel to the axis  18  along a length of the housing  14 . In the illustrated embodiment, a first end cap  26  is coupled to a first end  28  of the housing  14  and a second end cap  30  is coupled to a second end  32  of the housing  14 . In the illustrated embodiment, the end caps  26 ,  30  define an end surface of the luminaire oriented orthogonal to the axis  18 . 
     As shown in  FIGS. 2 and 3 , in the illustrated embodiment, the housing  14  has a somewhat V-shaped cross section, including two inclined side portions  34  and a base portion  38  that extends between the side portions  34 . The base portion  38  can be secured to a support surface (e.g., a wall or ceiling). The V-shaped section forms a channel  42  that extends in a direction parallel to the axis  18 . The housing  14  also includes apertures  46  and removable sections or knockouts  50  disposed along the base portion  38  and/or side portions  34 . The apertures  46  permit communication (e.g., for wires) between an external environment and the channel  42  through a portion of the housing  14 . Alternatively, or in addition to the apertures  46 , he knockouts  50  can be detached from the housing  14  as desired to create apertures (not shown). 
     As shown in  FIG. 3 , in the illustrated embodiment, the side portions  34  are substantially linear and terminal ends of the side portions  34  include an S-shaped feature (i.e., a concave section adjacent a convex section). The S-shaped feature includes a pocket  39  and a protuberance  40 . In the illustrated embodiment, the pocket  39  is disposed at the terminal end of the respective side portion  34  and opens away from the longitudinal axis  18 . The pocket  39  also extends orthogonally with respect to the axis  18 . In the illustrated embodiment, the protuberance  40  is disposed between the respective pocket  39  and the linear section of the side portion  34 . The protuberances  40  protrude away from one another and away from the axis  18 . In the illustrated embodiment, the protuberance  40  is larger than the pocket  39 . 
     As shown in  FIGS. 2 and 4 , the lens  22  is open on three sides (e.g., a first end, a second end, and a bottom). In the illustrated embodiment, the lens  22  has a substantially curvilinear profile that extends at least partially around a longitudinal axis  52 , and a passage  54  extends between the ends of the lens  22 . In other embodiments, the lens  22  may have a substantially planar profile. An external surface  58  is disposed proximate the external environment, and an internal surface  62  faces inwardly, opposite the external surface  58  and proximate the passage  54 . In the illustrated embodiment, the external surface  58  is substantially smooth and the internal surface  62  includes ridges ( FIG. 4 ); in other embodiments, the external surface may have surface formations such as ridges, and/or the internal surface may be substantially smooth. Projections  70  protrude from the sides of the internal surface  62  into the passage  54 . In the illustrated embodiment, the projections  70  are orthogonal with respect to the longitudinal axis  52 . Curved portions  74  are positioned on either side of the passage  54  and a terminal end of each of the curved portions  74  slopes inwardly toward the longitudinal axis  52 . Pockets  78  are formed on each side of the passage  54  along the surface of the curved portions  74  between the respective projection  70  and the terminal end of the curved portion  74 . In the illustrated embodiment, the projections  70 , curved portions  74 , and pockets  78  form an E-shape. In some embodiments, the lens  22  may include an S-shaped feature and the side portions  34  may include an E-shaped feature. 
     As shown in  FIGS. 2 and 5 , the end caps  26 ,  30  has a main surface  82  with a profile substantially similar to a combined profile of the housing  14  coupled to the lens  22 . In other words, the end caps  26 ,  30  inclined side portions formed between a rounded portion and a base surface. In the illustrated embodiment, each end cap  26 ,  30  also includes a side wall  86  extending along a perimeter of the end cap  26 ,  30  and oriented orthogonally relative the main surface  82 . In the illustrated embodiment, the side wall  86  partially encloses a cavity  90  with the main surface  82  ( FIG. 5 ). 
     As shown in  FIG. 5 , the end cap  26  includes projections  94 . In the illustrated embodiment, the projections  94  are disposed within the cavity  90  and protrude from the main surface  82  in the same direction as the side wall  86 . The projections  94  are spaced apart from one another. In the illustrated embodiment, the projections  94  are cylindrical in shape. The end cap  30  includes substantially similar projections (not shown). 
     Returning to  FIG. 2 , a mounting bracket  98  is coupled to the base portion  38  of the housing  14 . In the illustrated embodiment, the mounting bracket  98  has a substantially rectangular profile and includes a hollow central portion that defines a chamber  102  ( FIG. 6 ). Control drivers  106  (e.g., current drivers) and a power source  110  (e.g., a battery pack— FIG. 2 ) are coupled to the base portion  38  within the chamber  102 . Light boards  114  containing light emitters (e.g., light emitting diodes or LEDs) are coupled to the mounting bracket  98  and configured to emit light in a direction outwardly and away from the chamber  102 ). The light boards  114  are in electrical communication with the control drivers  106  and the power source  110 . In other embodiments, the light boards may be in electrical communication with an external power source (e.g., a wall outlet—not shown) either instead of, or in addition to, the power source  110 . In the illustrated embodiment, the light boards  114  span a length of the mounting bracket  98 . In other embodiments, the light boards may have a different length, and/or the luminaire may include fewer or more light boards. 
     As shown in  FIGS. 6 and 7 , the lens  22  is coupled to the housing  14  so that the longitudinal axis  52  is parallel to the axis  18 . The pockets  78  of the lens  22  are similar in shape to the protuberances  40  of the side portions  34 , which allows one of the pockets  78  to engage or nest with an associated one of the protuberances  40 . The lens  22  snaps onto the housing  14  in order to couple the two together. The pocket  78  receives the protuberance  40  so that a portion of the lens  22  wraps around the protuberance  40 . The projections  70  abut upper portions of the protuberances  40  (e.g., portions of the side portions  34  that include both the pocket  39  and the protuberance  40 ) and the curved portions  74  abut lower surfaces of the protuberance  40  (e.g., transition areas of the side portions  34  between the linear section and the S-shaped section), thereby securing the protuberance  40  within the associated pocket  78 . In the illustrated embodiment, the projections  70  include rounded edges, allowing the projections  70  to engage the protuberances  40 . The curved portions  74  include a similar radius of curvature as the protuberances  40 , allowing the curved portions  74  and the lower surfaces of the protuberances  40  to substantially mate (i.e., the curved portions  74  and the lower surfaces substantially contact each other along their length). 
     The projections  70  are also received within the pockets  39 . In some embodiments, the rounded edges of the projections  70  have a similar radius of curvature to the associated pocket  78 , allowing the projections  70  and surfaces of the pockets  39  to substantially mate (i.e., the projections  70  and the pockets  39  contact each other along their length). 
     Contact between the projections  70 , the curved portions  74  and the respective surfaces of the protuberances  40  limit movement of the lens  22  relative to the housing  14  in directions that are non-parallel to the axis  18  (e.g., in a vertical direction as shown in  FIG. 6 ). Contact between the pockets  39  and the projections  70  further limits movement of the lens  22  in directions that are non-parallel to the axis  18 . In the illustrated embodiment, the nesting arrangement forces direct contact between the projections  70 , the curved portions  74 , and the respective surfaces of the protuberances  40  while the lens  22  is coupled to the housing  14 . The nesting arrangement also forces direct contact between projections  70  and the pockets  39 . The direct contact between these features  39 ,  40 ,  70 ,  74  provides a snap-fit. 
     The snap-fit between the lens  22  and the housing  14  facilitates quick coupling of the lens  22  and housing  14  together. Additionally, the snap-fit arrangement eliminates the need for tabs, lances, brackets and other connective hardware (not shown) required in conventional lens couplings. Eliminating connective hardware/features eliminates, or substantially reduces, dark spots and shadows caused by the connective hardware/features blocking light from exiting the lens. A user may also remove the lens  22  by applying a force proximate either curved portion  74  of the lens  22  to move the curved portion  74  away from the lower surface of the protuberance  40 , thereby allowing the lens  22  to be separated from the housing  14 . 
     Once the lens  22  is coupled to the housing  14 , the end caps  26 ,  30  are coupled to the housing  14 . In the illustrated embodiment, an outermost surface of the end caps  26 ,  30  is wider than the housing  14  and the lens  22  (i.e., along the side wall  86 ). The outermost surfaces of end caps  26 ,  30  slide over the housing  14  and the lens  22  so that ends of the housing  14  and lens  22  are received within the cavity  90  of the respective end cap  26 ,  30 . The projections  94  are disposed on the main surface  82  a distance apart from the outermost surface, and are closer to the axis  18  than the side portions  34 . The projections  94  slide along an inner surface of the side portions  34  (i.e., proximate the channel  42 ) when the cavity  90  receives the housing  14  and lens  22 . Upper projections  94  slide against inner surfaces of the protuberances  40  (i.e., along a pocket adjacent the channel  42  that mirrors the shape of the protuberance  40 ) and lower projections  94  slide against an interface between the side portions  34  and the base portion  38 . The projections  94  limit movement in directions that are non-parallel to the axis  18 , while still allowing translational movement in one direction along the axis  18 . 
     When the luminaire  10  is fully assembled, the control drivers  106  regulate current from the battery pack  110  (or the external power source) to the light board(s)  114 . Current from the battery pack  110  causes the LEDs on the light board(s)  114  to output light. The lens  22  may be transparent or translucent and allow light to pass through. The side walls  86  of the end caps  26 ,  30  act as light seals and limit the emission of light proximate the ends of the lens  22 . Additionally, the main surface  82  of the end caps  26 ,  30  is solid and prevents light from being emitted from the housing in a direction along the axis  18 . 
     In the illustrated embodiment, the luminaire  10  also includes sensors  117  and  118  in communication with at least one module  122  ( FIG. 2 ). The sensor  117  is disposed on the end cap  26  and sensor  118  is disposed in an opening  123  of the end cap  30 . The sensors  117 ,  118  may be occupancy sensors, motion sensors, or ambient light sensors. The module  122  is coupled to the mounting bracket  98 . In the illustrated embodiment, the sensors  117 ,  118  communicate with the module  122  through radio waves; although in other embodiments the sensor  118  and the module  122  may communicate via Bluetooth, Wi-Fi, or a wired connection. The module  122  is in communication with the drivers  106 , so that a signal sensed by the sensors  117 ,  118  controls the light output from the light board(s)  114 . The sensors  117 ,  118  may send signals to the drivers  106  via the module  122  to only provide current to the light board(s)  114  when movement is sensed in a given room. The sensors  117 ,  118  may also send a signal to the drivers  106  via the module  122  to output a different level of current based on an amount of light sensed that is not emitted from the luminaire  10  (e.g., natural light) 
       FIGS. 8-13  illustrate another embodiment of a luminaire  1010 . Common elements include the same reference number, plus 1000. The luminaire  1010  is substantially similar to the luminaire  10 , although the lens  1022  includes a smaller radius of curvature than the lens  22 . Thus, the lens  1022  has a more rounded profile than the lens  22 . 
       FIGS. 14-18  illustrate a further embodiment of a luminaire  2010 . Common elements include the same the reference number, plus 2000. The luminaire  2010  is substantially similar to the luminaire  10 , and only differences will be described below. 
     As shown in  FIGS. 15 and 16 , the end caps  2026 ,  2030  have a main surface  2082  with a profile substantially similar to a combined profile of the housing  2014  coupled to the lens  2022 . In the illustrated embodiment, each end cap  2026 ,  2030  also includes a side wall  2086  spaced apart from a peripheral edge of the end cap  2026 ,  2030 . The side wall  2086  includes a first portion  2086   a  that is substantially similar in shape to the housing  2014 , and a second portion  2086   b  that has a curved shape similar to the profile of the lens  2022 . In the illustrated embodiment, a gap between the first side portion  2086   a  and the peripheral edge is less than a gap between the peripheral edge and the second side portion  2086   b . The side wall  2086  is oriented orthogonally relative the main surface  2082 . In the illustrated embodiment, the side wall  2086  forms a substantially enclosed shape on the main surface  2082  ( FIG. 16 ). 
     As shown in  FIG. 16 , the end cap  2026  includes protuberances  2150  and pockets  2154 . In the illustrated embodiment, the protuberances  2150  and the pockets  2154  are formed as part of the second portion  2086   b , and one protuberance  2150  and one pocket  2154  are positioned adjacent each side of the second portion  2086   b . In the illustrated embodiment, each protuberance  2150  is shaped similarly to the protuberance  2040 , and each pocket  2154  is shaped similarly to the pocket  2039 . The end cap  2030  includes substantially similar projections (not shown). 
     The end caps  2026 ,  2030  may be coupled to the housing  2014  before or after the lens  2022  is coupled to the housing  2014 . In the illustrated embodiment, a width of the side wall  2086  is narrower than a width of the housing  2014  and the lens  2022 . The housing  2014  and the lens  2022  slide over the end caps  2026 ,  2030  so that the side wall  2086  is received within the channel  2042  of the housing  2014  and within the passage  2054  of the lens  2022 . The first portion  2086   a  slides along an inner surface of the side portions  2034  (i.e., proximate the channel  2042 ). As shown in  FIG. 17 , the protuberances  2150  slide against inner surfaces of the protuberances  2040  (i.e., along a pocket adjacent the channel  2042  that mirrors the shape of the protuberance  2040 ) and the pockets  2154  slide against inner surfaces of the pockets  2039  (i.e., along a projection adjacent the channel  2042  that mirrors the shape of the pocket  2039 ). The protuberances  2050  and the pockets  2054  limit movement in directions that are non-parallel to a longitudinal axis  2018  ( FIG. 14 ) of the luminaire  2010 , while still allowing translational movement in one direction along the axis  2018 . Positioning the side wall  2086  within the channel  2042  and the passageway  2054  allows the lens  2022  to be removed without first requiring removal of the end caps  2026 ,  2030 . 
     As shown in  FIG. 18 , multiple housings  2014  may be connected together in an end-to-end manner and provide the appearance of a single elongated housing. To connect two housings  2014 , a coupler bracket  2158  is positioned within the channel  2042  against the base portion  2038 , overlapping both of the housings  2014 . A lens bracket  2174  is coupled to both housings  2014  between the lenses  2022 . 
     As shown in  FIG. 19 , the coupler bracket  2158  includes two inclined side portions  2162  and a base portion  2166  that extends between the side portions  2162 . The cross section of the coupler bracket  2158  has a profile substantially similar to the profile of the housing  2014 . The inclined portions  2162  engage the inclined portions  2034  of an end portion of each of the housings  2014 . The coupler bracket  2158  includes holes  2170  spaced apart along the base portion  2166  and the side portions  2162 . The holes  2170  receive fasteners (e.g., threaded screws—not shown) and couple each housing  2014  to the coupler bracket  2158 . Positioning the coupler bracket  2158  within the channel  2042  so that the base portion  2166  of the coupler bracket  2158  contacts the base portion  2038  of each housing provides a smooth engagement surface between the housings  2014 . 
     As shown in  FIG. 20 , the lens bracket  2174  includes projections  2178 , curved portions  2182 , and pockets  2186  similar to the projections  70 , curved portions  74 , and pockets  78  described with respect to  FIG. 4 , and the lens bracket  2174  is coupled to the housings  2014  in a similar manner as the lens  2022 . The lens bracket  2174  also includes a rib  2190 . The lens bracket  2174  is positioned between the two lenses  2022  so that each lens  2022  contacts one side of the rib  2190 . The lens bracket  2174  and substantially prevents light from escaping at an interface or gap between the lenses  2022 . 
     As shown in  FIG. 21 , multiple housings  2014  can be connected together in an end-to-end manner using a coupler bracket  2194  that is positioned against an outer surface of the base portion  2038 , overlapping both of the housings  2014 . The cross section of the coupler bracket  2194  has a profile substantially similar to an outer profile of each housing  2014 . The coupler bracket  2194  can be coupled to the housings  214  using fasteners (e.g., threaded screws—not shown). A lens bracket  2174  is coupled to both housings  2014  between the lenses  2022 . The coupler bracket  2194  is removable from the housings  2014  independently of the lenses  2022  (i.e., the lenses  2022  can remain coupled to the housings  2014  while the housings  2014  are uncoupled from each other). 
     As shown in  FIGS. 22A-22E , the luminaire  2010  including a variety of coupling mechanisms that can be used to secure the luminaire  2010  to a ceiling C. For example the luminaire  2010  may be secured directly to the ceiling C with fasteners (not shown) so that the base portion  2038  of the housing  2014  is proximate to, or in contact with the ceiling (see e.g.,  FIG. 22A ). The luminaire  2010  may also be spaced away from the ceiling C. In some embodiments, posts  2198  may be coupled to either end of the luminaire  2010  (see e.g.,  FIG. 22B ), or may be coupled to a center of the luminaire  2010  (see e.g.,  FIG. 22C ). In other embodiments, cables  2202  may be coupled to longitudinal edges of the luminaire  2010  (see e.g.,  FIG. 22D ), or may be coupled along a central axis of the luminaire  2010  (see e.g.,  FIG. 22E ). Although not shown, the luminaire  10  and the luminaire  1010  may be coupled to the ceiling C in any of these ways. 
     As shown in  FIG. 23 , uplights  2210  are coupled to the base portion  2038  of the luminaire  2010 . The uplights  2210  direct light in a substantially opposite direction relative to the light boards  2114 . In the illustrated embodiment, four uplights  2210  are coupled to the base portion  2038 , and each uplight  2210  includes at least one LED. The uplights  2210  may be specifically incorporated into the embodiments of  FIGS. 22B-22E , where the base portion  2038  is spaced from the ceiling C. The uplights  2210  assist in preventing shadows from forming above the luminaire  2010 . 
     The embodiment(s) described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present disclosure. As such, it will be appreciated that variations and modifications to the elements and their configuration and/or arrangement exist within the spirit and scope of one or more independent aspects as described.