Patent Publication Number: US-10782005-B2

Title: Coupler for light fixture

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of prior-filed U.S. Provisional Patent Application No. 62/592,898, filed Nov. 30, 2017, the entire contents of which are incorporated by reference. 
    
    
     BACKGROUND 
     The present disclosure relates to light fixtures, and more specifically to a bracket that is removably coupled to a light fixture. 
     SUMMARY 
     In one independent aspect, a bracket is removably connectable to a housing of a luminaire. The bracket includes a first planar portion, a second planar portion, and an intermediate portion coupled between the first planar portion and the second planar portion. The first planar portion includes at least one first aperture, and the first aperture is enclosed within a first peripheral edge. An oblique portion of the first peripheral edge is oriented at an oblique angle relative to at least one other portion of the first peripheral edge. The second planar portion is parallel to the first planar portion. The second planar portion includes at least one second aperture, and the second aperture is enclosed within a second peripheral edge. An oblique portion of the second peripheral edge is oriented at an oblique angle relative to at least one other portion of the second peripheral edge. 
     In another independent aspect, a luminaire includes a housing, a bracket, a projection, and an aperture. The housing includes an end and an inner surface. The bracket is positioned adjacent the end of the housing. The projection is positioned on one of the inner surface of the housing and the bracket. The aperture is positioned on the other of the inner surface of the housing and the bracket. The aperture receives the projection, and the aperture is enclosed within a peripheral edge. An oblique portion of the peripheral edge is oriented at an oblique angle relative to at least one other portion of the peripheral edge. The oblique portion engages the projection to bias the bracket toward the end of the housing. 
     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 housing. 
         FIG. 2  is an exploded view of the luminaire housing of  FIG. 1 . 
         FIG. 3  is a cross-sectional view of the luminaire housing of  FIG. 2  viewed along section  3 - 3 . 
         FIG. 4  is an enlarged view of a portion of the luminaire housing of  FIG. 3 . 
         FIG. 5  is a cross-sectional view of the luminaire of  FIG. 2  with housing portions coupled together, viewed along section  3 - 3 . 
         FIG. 6  is a cross-sectional view of the luminaire of  FIG. 2  with housing portions coupled together, viewed along section  3 - 3 . 
         FIG. 7  is an exploded view of the luminaire housing according to another embodiment. 
         FIG. 8  is a perspective view of an intermediate coupler. 
         FIG. 9  is a perspective view of an end coupler. 
         FIG. 10  is a perspective view of an intermediate coupler according to another embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments of the disclosure 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 coupler, such as a bracket, for connecting a luminaire housing to other components, such as another luminaire housing or to an end cover. The coupler provides a visibly continuous surface between the luminaire housing and the connected component. 
     As shown in  FIGS. 1-5 , a light fixture (e.g., a luminaire  10 ) includes a first housing  14  and a second housing  18 . In the illustrated embodiment, the housings  14 ,  18  have substantially the same length, are arranged in an end-to-end relationship, and have a rectangular transverse cross-section. In other embodiments, the housings may have different lengths, may be positioned in a different manner, and/or the housing profile may be another shape. Also, in the illustrated embodiment, the luminaire  10  includes a first coupler or intermediate coupler or central bracket  22  and second couplers or end brackets  26 . The central bracket  22  is positioned between adjacent, facing ends of the first housing  14  and the second housing  18 . Fastening members  30  couple the central bracket  22  to the housings  14 ,  18 . Each end bracket  26  is positioned adjacent a distal end of the first housing  14  or the second housing  18 . A plurality of fastening members (not shown) couple the end bracket  26  to the associated end of the first housing  14  or the second housing  18 . 
     As shown in  FIG. 8 , the central bracket  22  has a first planar extension or first face  34  and a second planar extension or second face  38 . The faces  34 ,  38  are parallel to one another and are substantially rectangular in shape, although in other embodiments, the faces  34 ,  38  may be another shape. The first face  34  and the second face  38  are connected by a bar  42  that is integrally formed with the faces  34 ,  38 . The bar  42  is positioned above the faces  34 ,  38  and a space between the faces  34 ,  38  is open. 
     Each face  34 ,  38  includes four apertures  46 . In other embodiments, the faces  34 ,  38  may include fewer or more apertures. In the illustrated embodiment, the apertures  46  are positioned proximate corners of the first face  34  and the second face  38 . Each aperture  46  is at least partially enclosed by a peripheral edge, and a portion of the peripheral edge includes an inclined surface  48 . In the illustrated embodiment, the inclined surfaces  48  slope downwardly, away from the bar  42  and away from the axis of insertion of the projections  122 . Each inclined surface  48  slopes from an edge of the face  34 ,  38  proximate the aperture  46  and parallel to a first face axis  126  and a second face axis  130 , toward the first or second axes  126 ,  130  and forms an oblique angle relative to the adjacent portions of the peripheral edge. In the illustrated embodiment, the oblique angle is between 0° and 90°, and the oblique portion of the peripheral edge is neither parallel nor perpendicular relative to the adjacent portions of the peripheral edge, and is neither parallel nor perpendicular relative to the face axes  126 ,  130 . Each face  34 ,  38  is symmetric about the respective axis  126 ,  130 . 
     Bent portions  50  are positioned adjacent an edge of each face  34 ,  38 . The bent portions  50  are formed integrally with and positioned at corners of the faces  34 ,  38 . In the illustrated embodiment, the bent portions  50  are formed proximate the bar  42 , with a single bent portion  50  positioned on either side of the bar  42 . The bent portions  50  are oriented orthogonally to the faces  34 ,  38  and extend towards the opposite face  34 ,  38 . In other words, the bent portions  50  on the first face  34  extends towards the second face  38  and the bent portions  50  on the second face  38  extends towards the first face  34 . Each bent portion  50  has one hole  54 , although in other embodiments, the bent portions  50  may include more holes  54 . 
     As shown in  FIG. 9 , each end bracket  26  includes an end surface  58  and a top surface  60  orthogonal to the end surface  58 . In the illustrated embodiment, the end surface  58  is rectangular in shape, although in other embodiments, the end surface  58  may have a different shape. A first planar portion or first side face  62  and a second planar portion or second side face  66  are integrally formed on the end surface  58  and extend orthogonally away from the end surface  58 . The side faces  62 ,  66  are generally rectangular in shape. 
     In the illustrated embodiment, each side face  62 ,  66  includes two apertures  70 . One aperture  70  is positioned on either end of each side face  62 ,  66 , although in other embodiments, the apertures  70  may be positioned elsewhere on the side faces  62 ,  66 . Each aperture  70  includes a peripheral edge having an oblique or inclined portion or surface  68 . In the illustrated embodiment, the inclined surfaces  68  slope downwardly, away from the top surface  60 . Each inclined surface  68  slopes from an edge of the face  62 ,  66  distal the end surface  58  and parallel to an end face or end bracket axis  134 , toward the end bracket axis  134 . In the illustrated embodiment, the oblique angle is between 0° and 90°, and the oblique portion of the peripheral edge is neither parallel nor perpendicular relative to the adjacent portions of the peripheral edge, and is neither parallel nor perpendicular relative to the face axes  126 ,  130 . The apertures  70  on the first side face  62  are mirrors of the apertures  70  on the second side face  66  about the end bracket axis  134 . 
     A bent section  74  is positioned adjacent an edge of the side face  62 , and another bent section  74  is positioned adjacent an edge of the side face  66 . The bent sections  74  are formed integrally with and positioned at an end of the side faces  62 ,  66 . In the illustrated embodiment, the bent sections  74  are formed proximate the top surface  60 . The bent sections  74  are oriented orthogonally to the side faces  62 ,  66  and extend towards the opposite side face  62 ,  66 . In other words, the bent sections  74  on the first side face  62  and the bent sections  74  on the second side face  66  each extend towards the end bracket axis  134 . Each bent section  74  has one hole  78 , although in other embodiments, the bent sections  74  may include more holes  78 . 
     Referring now to  FIG. 3 , an inner surface  120  of the first housing  14  and the second housing  18  include a plurality of projections or hooks  122 . In the illustrated embodiment, each housing  14 ,  18  has eight hooks  122 , four hooks  122  on each end. One hook  122  is positioned proximate each corner of each housing  14 ,  18 , although in other embodiments, the hooks  122  may be positioned elsewhere on the inner surface  120 . As shown in  FIG. 4 , the hooks  122  extend towards an interior and a lower end of the housing  14 ,  18 . In the illustrated embodiment, the hooks  122  have a right angled bend. 
     As shown in  FIG. 5 , the central bracket  22  is positioned between the first housing  14  and the second housing  18  and the apertures  46  are aligned with the hooks  122 . As the central bracket  22  moves toward an upper surface of the housings  14 ,  18 , the inclined surfaces  48  pull the hooks  122  of the first housing  14  and the second housing  18  toward one another. The slope of the apertures  46  draws the hooks  122  toward the face axes  126 ,  130  (i.e., toward the center of the central bracket  22 ), and therefore biases the housings  14 ,  18  toward one another. Each aperture  46  mates with a respective hook  122  in order to couple the housings  14 ,  18  together. 
     The end bracket  26  is positioned proximate an end of either housing  14 ,  18  so that the apertures  70  are aligned with the hooks  122 . Each aperture  70  mates with a respective hook  122  in order to couple the end bracket  26  to a housing  14 ,  18 . In the illustrated embodiment, as the end bracket  26  is moved toward the upper surface of the housings  14 ,  18 , the inclined surfaces pull the hooks  122  toward the surface  58  of the end bracket  26 . 
     As shown in  FIG. 6 , the fastening members  30  are inserted through the holes  54  ( FIG. 8 ) to couple the central bracket  22  to the housings  14 ,  18 . While not shown, fastening members are also inserted into holes  78  to couple the end bracket  26  to either the first housing  14  or the second housing  18 . 
     The central bracket  22  creates a close connection between the first housing  14  and the second housing  18 , providing a nearly seamless appearance. When the first housing  14  and the second housing  18  are connected, fasteners  30  are not visible on an external surface of either housing  14 ,  18 . The bracket  22  also creates a seal that substantially limits water and other unwanted particles from entering through the interface between the housing portions  14 ,  18  and into the inner surface  120  of the housings  14 ,  18 . The end bracket  26  also creates a seal that limits water and other unwanted particles from entering through the ends of the housings  14 ,  18 . 
     The open area between the first face  34  and the second face  38  provides clearance to avoid interfering with internal lighting components (not shown). The same is true for the end bracket  26 , which also does not extend substantially into the housing  14 ,  18 . 
     As shown in  FIG. 10 , a second embodiment of an intermediate coupler or corner bracket  82  includes a body  86 . In the illustrated embodiment, the body  86  has a rectangular profile, although in other embodiments, the body  86  may have a different shape. The body  86  is solid and includes a first connecting surface  90  and a second connecting surface  94 . The first connecting surface  90  and the second connecting surface  94  are oriented orthogonally with respect to one another. 
     Each connecting surface  90 ,  94  includes a first planar portion or first side face  98  and a second planar portion or second side face  102  which are integrally formed on the connecting surfaces  90 ,  94  and extend orthogonally away from the connecting surfaces  90 ,  94 . In some embodiments, the side faces  98 ,  102  are generally rectangular in shape. 
     In the illustrated embodiment, each side face  98 ,  102  includes two apertures  106 . One aperture  106  is positioned on either end of each side face  98 ,  102 , although in other embodiments, the apertures  106  may be positioned elsewhere on the side faces  98 ,  102 . Each aperture  106  includes an inclined surface  108 . In the illustrated embodiment, the inclined surfaces  108  slope downwardly, away from the top surface  112 . Each inclined surface  108  slopes from an edge of the face  98 ,  102  distal the connecting surface  90 ,  94  and parallel to a central face or corner bracket axis  138 , toward the corner bracket axis  138 . In the illustrated embodiment, the oblique angle is between 0° and 90°, and the oblique portion  108  of the peripheral edge is neither parallel nor perpendicular relative to the adjacent portions of the peripheral edge, and is neither parallel nor perpendicular relative to the corner bracket axis  138 . The apertures  106  on the respective first side faces  98  mirror the apertures  106  on the second side faces  102  about the corner bracket axis  138 . 
     A bent section  110  is positioned adjacent an edge of the side face  98  and a bent section  110  is positioned adjacent an edge of the side face  102 . The bent sections  110  are formed integrally with and positioned at an end of the side faces  98 ,  102 . In the illustrated embodiment, the bent sections  110  are formed proximate the same end of the body  86 . The bent sections  110  are oriented orthogonally to the side faces  98 ,  102  and extend towards the opposite side face  98 ,  102 . In other words, the bent sections  110  on the first side face  98  and the bent sections  110  on the second side face  102  extend towards a center of the body  86 . Each bent section  110  has one hole  114 . 
     The connecting surfaces  90 ,  94  each include an electrical connector  118 . In the illustrated embodiment, the electrical connector  118  has a circular shape and is positioned between the side faces  98 ,  102  and proximate the bent sections  110 , although in other embodiments, the electrical connectors  118  may be positioned elsewhere on the connecting surfaces  90 ,  94 . 
     As shown in  FIG. 7 , the corner bracket  82  couples the first housing  14  and the second housing  18  in substantially the same manner as the central bracket  22 . Instead of forming a continuous housing in a linear direction as the central bracket  22  does, the corner bracket  82  connects the housings  14 ,  18  at a right angle. The electrical connectors  118  ( FIG. 10 ) provide electrical connection through the body  86  allowing the corner bracket  82  to create a seal between the housings  14 ,  18  while also providing electrical connection between the internal lighting components in the housings  14 ,  18 . 
     Although aspects have been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope of one or more independent aspects as described.