Patent Publication Number: US-6905222-B1

Title: Thermal isolation luminaire and wall mount system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of U.S. Provisional Application No. 60/369,269, filed Apr. 2, 2002. 

   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not applicable. 
   BACKGROUND OF THE INVENTION 
   1. Technical Field of the Invention 
   The present invention relates generally to a landscape luminaire. More particularly, the invention relates to a landscape luminaire having a wall mount system which supports the weight of the luminaire during installation, has thermal isolation characteristics, and a modular hinged ballast tray. 
   2. Description of the Related Art 
   Landscape luminaires are typically used to illuminate landscaping and building facades to provide an aesthetically pleasing appearance. Landscape luminaires may be situated on churches, office buildings, malls, hospitals, schools, and the like to illuminate the structure walls and adjacent landscaping. However, these building mounted landscape luminaires generally have several problems associated therewith. First, these lights are often quite large in order to effect a desired lighting level and therefore may be extremely heavy. This makes installation very difficult, sometimes requiring two-men. Second, the weight also makes servicing and cleaning very difficult, especially when the fixture must be opened and supported. Third, larger luminaires produce significant amounts of heat which may be damaging to the fixture and electrical components therein over the life of the fixture. 
   Older light designs have attempted to overcome the weight problems associated with outdoor landscaping luminaires. Various shapes and sizes have been developed; however, these designs often ship fully assembled yet must be disassembled to effectuate installation of lightweight manageable parts. This disassembly and re-assembly in the field can lead to water leaks, incorrect time-consuming installation, or even lost parts. 
   In view of the deficiencies in known landscape luminaires, it is apparent that a landscape luminaire is needed wherein a mounting system supports the weight of the luminaire during installation and subsequent servicing, and the luminaire has a modular design allowing thermal isolation of the lamp and electronic components to allow better heat dissipation of the light fixture and electrical components therein. 
   SUMMARY OF THE INVENTION 
   It is an object of the present invention to provide a landscape luminaire. 
   It is a further object of the present invention to provide a landscape luminaire having a wall mounting system which supports the weight of the luminaire during installation and servicing. 
   It is an even further object of the present invention to provide a landscape luminaire having a modular design which may allow for separate mounting of reflector housing and ballast housing. 
   Specifically, the present invention provides a landscape luminaire having a wall mount and thermal isolation system comprising a wall mount plate having parallel opposed arm slots, and a substantially U-shaped wireform having a first, a second and a third arm. The first and second arms are slidably connected to the wall mount plate within the parallel opposed arm slots. The third arm of the wireform is pivotably connected to a fixture mount plate. The wireform first and second arms have elbows therein which contact the wall mount plate and dispose a reflector housing away from a building wall when the fixture is open during installation or service. The wall mount plate has a knock-out plate where wires enter providing power to the fixture electronic components. 
   The landscape luminaire further comprises a reflector or optics housing. In a first embodiment the reflector or optics housing may be directly connected to the fixture mount plate. Within the reflector housing may be a modular hinged ballast tray. Mounted on the modular ballast tray may be a power supply, a ballast, a lamp socket, and lamp. Above the modular ballast tray is a reflector. Between the reflector and a lens tray mounted lens is the lamp and the lamp socket which may also be mounted on the modular ballast tray. In electrical communication with the lamp and lamp socket are the power supply and the lamp ballast. With this modular configuration, the modular hinged ballast tray, which contains the reflector, power supply, ballast, lamp socket and lamp, may be easily replaced during servicing if a component fails thereby removing the need for the service technician to replace individual components within the reflector housing and making servicing simplified. 
   In an alternative embodiment, the reflector or optics housing also comprises a reflector therein and a lens tray connected to a lower peripheral edge of the reflector housing. The lens tray has a lens seated therein. Between the reflector and lens is a lamp. The lamp is preferably a HID lamp, for instance, a metal halide lamp, but may be any other lamp known to one of ordinary skill in the art. The lamp is operably connected to a lamp socket, the lamp socket being mounted in a electronics or ballast housing. The ballast housing may be a plurality of shapes and has a modular ballast tray mounted therein. The modular ballast tray has a power supply and ballast mounted thereon. The ballast housing may have a plurality of vents for heat dissipation along a top semi-circular surface. On a first side of the ballast housing is a fixture bracket allowing the lamp socket to be attached on a first side thereof and the reflector housing to be attached on a second side thereof. On a second side of the ballast housing may be the fixture mounting plate which is pivotably attached to the wireform. The wall mount plate may further comprise a level bubble thereon for assisting in mounting. The wall mount plate may be of similar design to the other embodiment such that the installations are interchangeable. 
   All of the above outlined objectives are to be understood as exemplary only and many more objectives of the invention may be learned from the disclosure herein. Therefore, no limiting interpretation of the objectives noted is to be understood without further reading of the entire specification, claims, and drawings included herewith. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The aspects and advantages of the present invention will be better understood when the detailed description of the preferred embodiment is taken in conjunction with the accompanying drawings, in which: 
       FIG. 1  shows a perspective view of a first embodiment of the wall mount luminaire of the present invention; 
       FIG. 2  shows a perspective view of the luminaire of  FIG. 1  upon partial installation with the wall mount in the open position; 
       FIG. 3  shows a rear perspective view of the wall mount system of the present invention in the open position; 
       FIG. 4  shows a side perspective view of the wall mount system of the present invention in the open position; 
       FIG. 5  shows a perspective view of a modular housing tray used with the first embodiment of  FIG. 1 ; 
       FIG. 6  shows a bottom view of the wall mount luminaire of  FIG. 1 ; 
       FIG. 7  shows a perspective view of an alternative embodiment of wall mount luminaire with thermal isolation system of the present invention; 
       FIG. 8  shows an assembly view of the wall mount luminaire with thermal isolation of  FIG. 6 ; and, 
       FIG. 9  shows a perspective view of the fixture of  FIG. 1  in an open position revealing the wire shield door. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Wall Mount System 
   The present invention will now be described in conjunction with the drawings, referring initially to  FIGS. 1 and 2 , a wall mount landscape luminaire fixture  10  is shown. The luminaire fixture  10  includes a reflector or optics housing  12  having three rounded sides surfaces  13  and preferably a flat top portion  14  wherein a translucent lens  15  may be disposed for various desired uptight characteristics. Of course, uptight and downlight characteristics may be readily modified with interchanging of various components hereof and no limitation is to be interpreted from the specific light output characteristics described as they are used only for exemplary purposes only. 
   The reflector housing  12  is formed preferably of heavy duty die cast aluminum having a corrosion resistant finish, however various other materials may be used preferably being corrosion resistant. The bottom of the reflector housing  12  is open wherein various light components are positioned. Fastened along a lower edge  16  of the reflector housing  12  is a lens tray  18  wherein a lens  20  is preferably disposed, as shown in FIGS.  1 , 6 , 7 . Moreover, the lens tray  18  is preferably hingeably connected to the reflector housing  12  as shown in  FIG. 9  to provide easy servicing. A gasket  17  may be disposed between the lens tray  18  and the reflector housing  12  to prevent water, dirt, and other contaminants from entering the housing  12  as shown in  FIG. 8 . 
   As shown in  FIGS. 2 and 5 , a back side of the reflector housing  12  has a fixture mount plate  22  connected thereto having a substantially square shape however, one skilled in the art will recognize that the fixture mount plate  22  may be a plurality of shapes. The fixture mount plate  22  is preferably connected to the reflector housing  12  by a plurality of screws extending through the fixture plate  22  and reflector housing  12 . The fixture mount plate  22  has a plurality of tabs  24  extending from a peripheral edge thereof providing a portion of a splice chamber between the fixture mount plate  22  and wall mount plate  40 . The reflector housing  12  also preferably comprises an aperture or knock-out therein through which wire may extend from within the reflector housing  12  or ballast housing  80 . The wire then extends through an opening formed by a beveled edge of a wire shield door  56  and fixture mount plate  22 . 
   As shown in FIGS.  2 , 4 , 9  the wire shield door  56  has a bent leg  57  extending therefrom and a ledge  58  along a lower edge of the wire shield door  56 . The door  56  is positioned between the fixture mount plate  22  and the ballast housing  80  or reflector housing  12  such that the ledge  58  rests on an opening of either of the housings  12 , 80  depending on which embodiment is being used. The wire shield door allows access to an integral splice chamber without opening the fixture mount plate  22  from the wall mount plate  40 . As shown in  FIG. 9 , the leg  57  is depressed providing clearance so that the wire door shield  56  may be removed. 
   Referring to  FIGS. 2–4 , rotatably connected between the fixture mount plate  22  and surrounding brackets  27  is a wireform  28  having first and second arms  30 ,  32  and a third arm  34  making the wireform  28  substantially U-shaped. More specifically, a bracket  25  is connected to the fixture mounting plate  22  and within surrounding brackets  27  such that the third arm  34  is disposed between the bracket  25 , the surrounding bracket  27 , and the fixture mount plate  22  which in combination form a conduit wherein the third arm  34  is rotatably received. First and second arms  30 ,  32  preferably each have an elbow  36  therein bent at least about five degrees and inwardly extending fingers  38 , opposite the third arm  34 . 
   As best seen in  FIG. 3 , opposite the fixture mount plate  22  is a wall mount plate  40  having a substantially square shape and having an area slightly smaller than the fixture mount plate  22 . Extending from parallel vertical edge  41  of the wall mount plate  40  are finger brackets  42 . Each finger bracket  42  and the adjacent vertical edge  41  form a vertically disposed slot  44  wherein fingers  38  are slidably positioned. The vertically disposed slots  44  preferably have an open upper portion wherein the fingers  38  may be “started” in the slots  44 . In a closed position, the fingers  38  move upward such that the wall mount plate  40  fits within the fixture mount plate  22 . 
   Along a top surface of the wall mount plate  40  is a level bubble  46  which aids in installation of the wall mount plate  40 . A knock-out plate  48  is located in the wall mount plate  40  through which, when removed, wire can pass from a wall conduit or junction box. Extending from an inner surface of the wall mount plate  40  is a gasket  50 , as depicted in  FIG. 2 . The gasket  50  is preferably formed from foam, rubber, plastic, or some other water resistant material. The gasket  50  extends preferably parallel to three sides of the wall mount plate  40  to prevent weather elements from entering a splice chamber created when the wall mount plate  40  and fixture mount plate  22  are disposed in a closed position. Also disposed in the wall mount plate  40  is a plurality of bolt apertures  52 , shown in  FIG. 3  for fixably attaching the wall mount plate  40  to a building facade. 
   With the wall mount plate  40  mounted to a building wall the wireform fingers  38  are placed in upper portions of slots  44 . The wireform  28 , which is rotatably connected to the fixture mount plate  22  and reflector housing  12 , is pulled to the bottom of the slot  44  by the weight of the reflector housing  12 . When the fixture  10  is opened during initial wiring or installation, the elbows  36  of wireform  28  support the weight of reflector housing  12  in a manner such that the reflector housing  12  does not contact the building facade. This protects the lens  20 , finish of the reflector housing  12 , as well as the electrical components therein. When the luminaire  10  is initially wired, the reflector housing  12  is hung by the fixture mount plate  22  and wireform  28  to the wall mount  40 . Moreover, this design provides support for the reflector housing  12  so that an installer&#39;s hands are free to connect the wall conduit wires and power supply wires. When the fixture  10  is closed, the wireform fingers  38 —remain positioned at the bottom of the channel  44  and the arms  30 ,  32  rotate upwards such that they are parallel with the slots  44 , vertically disposing the wireform  28  such that the fixture mount plate  22  encloses the wall mount plate  40  compressing the gasket  50  and creating the integral splice chamber therebetween. Wire connectors or wire-nuts may be disposed in the splice chamber eliminating the need for a junction box. With the fixture  10  in the closed position, screws  54  may be disposed through the top surfaces of the wall mount plate  40  and fixture mount plate  22  to lock the fixture  10  in the closed position. 
   Hinged Ballast Tray 
   In a first embodiment, the fixture mount plate  22  is directly attached to the reflector housing  12  as depicted in  FIGS. 2 ,  4 . Within the reflector housing  12  is a hinged ballast tray  60  shown in  FIGS. 5 ,  6  having a power supply  62 , ballast  64 , reflector  66 , lamp socket  68 , lamp  70 , and plurality of wires  72 . The power supply  62  is in electrical communication via wires  72  with the ballast  64 , the lamp socket  68  and lamp  70 . The lamp  70  is preferably a HID lamp comprising a metal halide bulb but may be any other type of lamp known to those skilled in the art. The reflector  66  is substantially bowl shaped and preferably formed of polished and/or segmented specular aluminum reflectors. However, various other materials may be used to form the reflector  66 . The hinged ballast tray  60  is hinged along a side to provide easy access to technicians. However, it is anticipated that due to the modular design of the hinged ballast tray  60 , the entire tray  60  may be replaced when a component located thereon fails. 
   Connected beneath the reflector housing  12  is the lens tray  18 . The lens tray  18  is preferably rectangular shaped with a plurality of screw holes disposed about the perimeter of the tray  18 . The lens tray  18  further has a lens aperture  19  which is preferably rectangular in shape. As seen in  FIG. 6 , disposed within the lens aperture  19  is a lens ledge  74  upon which a lens  20  is positioned, as shown in  FIGS. 6 and 8 . The lens  20  is preferably formed of a prismatic glass or tempered flat glass and, in combination with reflector  66  directs light from the HID metal halide lamp  70 . Although  FIG. 8  depicts an alternative embodiment utilizing the inventive design hereof, the modular characteristics and construction of the reflector housing  12  and lens tray  18  may be shared such that the reflector housing and lens tray may be used with or without a ballast housing, described in the second embodiment. 
   Thermal Isolation System 
   Copious amounts of heat may be generated by the lamp and power supply of landscape luminaires, especially when the lamp is a large lamp, for example a 400 watt lamp. The considerate amounts of heat created by larger lamps can be harmful to the electronic components of the lamp and can, under some circumstances, lead to failure of those components. 
   In order to deal with this problem a second embodiment of the present invention comprises a thermal isolation system wherein a modular housing design is used to separate the reflector housing and lamp from the electronic components within a ballast or electronics housing. Thus, heat from the reflector housing and lamp therein is isolated from electrical components in the ballast housing. 
   Referring to  FIGS. 7 and 8 , an electronics or ballast housing  80  has a substantially extruded semi-circular surface  81  with a flat top portion  82 . Along the rounded surfaces  81  of the housing  80  are a plurality of vents  84  for dissipating heat. The housing  80  has a first and a second side  86 ,  88  forming an enclosed area within the housing area  80 . Extending from the semi-circular surface  81  and flat top portion  82  adjacent the edge of the first side  86  is a flange  94 . The flange  94  operably connects with reflector housing  12  and provides a seal therebetween. 
   On the first side  86  of the ballast housing  80  is an aperture  90  which may be a plurality of shapes so long as the lamp  70  may fit therethrough. Disposed about the aperture  90  is a fixture bracket  92  which may be a plurality of shapes so long as the lamp  70  fits therethrough. Preferably, the bracket  92  fully encloses the aperture  90  to better seal the components within the ballast housing  80 . The bracket  92  may also have a plurality of screw apertures extending inward from the bracket sides through which screws  171  may be placed to hold the lamp socket  169  and reflector housing  12 . It is to be noted that the overall design of the embodiment shown herein incorporates similar design characteristics for the bracket and aperture  92 ,  90  as that of the wall mount plate  40  and fixture plate  22  so that they are interchangeable and truly modular in design. 
   The first and second sides  86 ,  88  and the semi-circular housing surface  81  define an opening which may be rectangular and wherein a ballast tray  96  may be disposed. The ballast tray  96  has a plurality of apertures wherein screws maybe positioned to attach the ballast tray  96  to the ballast housing  80 . Disposed between the ballast tray  96  and the ballast housing  80  may be a gasket  17  which provides a seal therebetween. 
   Positioned on the ballast tray  96  may be a power supply  162 , a ballast  164 , and a plurality of wires not shown. The wires provide electrical communication between the power supply  162 , the ballast  164 , and a lamp socket  168 . The lamp socket  168  is connected to a socket bracket  169  and the fixture bracket  92  from an inner portion of the ballast housing  80  by a plurality of fasteners, such as threaded screws  171 . The wires preferably extend through the second side  88  of the ballast housing  80  and fixture mount plate  22  and are connected to wires extending from a building wall. Also preferably located on the second side  88  of the ballast housing is a fixture mount plate  22 . As described above the fixture mount plate  22  has a wireform  28  extending therefrom being slidably and pivotably connected a wall mount plate  40  connected to a building facade. The wires in the ballast housing  80  and the power wires extending from the building may be connected by connectors or wire-nuts disposed in the splice chamber defined by the fixture mount plate  22  and wall mount plate  40  when the fixture  10  is in the closed position. A lamp  70  disposed in the lamp socket  168  passes through the ballast aperture  90  and into a reflector housing  112 . Within the reflector  166  may be a lens tray  18 , a lens  20 , and a gasket  17  providing a seal between the reflector housing  12  and lens tray  18 . The housing  12  and lens tray  18  are preferably of the same design as the first embodiment wherein the housing  12  may be interchangeable between the low wattage design of the first embodiment and the higher wattage design of the second embodiment. 
   The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom for modifications will become obvious to those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the invention and scope of the appended claims.