Patent Publication Number: US-9404636-B1

Title: Lighting apparatus with a reflective surface

Description:
TECHNICAL FIELD 
     This disclosure relates to lighting apparatuses, and more particularly to lighting apparatuses for high mast applications, and even more particularly to lighting apparatuses with a reflective surface for more efficiently directing light from the lighting apparatuses to areas surrounding the lighting apparatuses. 
     BACKGROUND OF THE DISCLOSURE 
     The misdirection and/or uneven distribution of light from a lighting mechanism can decrease the overall efficiency of the lighting mechanism and require additional equipment in order to illuminate a desired area. For example, in many current high mast lighting mechanisms, excessive light is directed to an area directly below the lighting mechanism (i.e., around the base of the pole that supports the lighting mechanism) instead of being directed to outlying areas that are desired to be illuminated. Current attempts to efficiently direct light away from an area directly below the lighting mechanism include complex and expensive reflective shrouds that encase the lighting element. In the case of outdoor high mast lighting, the complex and expansive shrouds are exposed to environmental influences such as rain, failing debris, snow and hail that can damage the shroud and cause light to be misdirected from damaged portions of the shroud. It would be beneficial to have a lighting mechanism, suitable for all conditions of service that, among other things, more efficiently directs light from the lighting mechanism and in particular, is capable of effectively directing light away from an area directly below the lighting mechanism. 
     SUMMARY 
     In a first aspect, there is provided a high mast lighting apparatus that includes a shroud having a reflective surface, the shroud configured to receive a lighting element therein. The reflective surface may include a reflective cone extending between a top portion of the shroud and the lighting element for directing light generated by the lighting element toward an open end of the shroud. 
     In certain embodiments, the reflective surface is coupleable to the shroud. 
     In other embodiments, the shroud is supported on a post. 
     In yet another embodiment, the reflective surface includes a plurality of segments, wherein at least one of the segments is in the shape of an annulus. 
     In still another embodiment, the plurality of segments include fold lines for selectively bending the segments. 
     In some embodiments, the reflective surface is located within the shroud and is spaced from the shroud. 
     In another embodiment, the shroud further includes an annular protrusion and the reflective surface is connected to the shroud at the annular protrusion. 
     In certain embodiments, the reflective surface includes an opening at a center of the reflective surface to receive the lighting element. 
     In certain other embodiments, the reflective cone encircles the lighting element. 
     In a second aspect, there is provided a reflective surface that includes a main reflective body and a reflective cone. The main reflective body may include a first segment and a second segment, wherein the second segment is in the shape of a truncated dome. The reflective cone may be disposed within the truncated dome of the second segment. The reflective cone and the main reflective body may include rows of planar portions, wherein a top row planar portion of the reflective cone is at an angle of between about 80 and about 100 degrees to an adjacent planar portion of a top row of the main reflective body. 
     In certain embodiments, the reflective cone includes an opening to receive at least a portion of the lighting element. 
     In other embodiments, the planar portions are formed of aluminum. 
     In yet other embodiments, the reflective cone includes at least one opening in the top portion of the reflective cone for the passage of heated air from a lighting element. 
     In still another embodiment, the main reflective body includes a first segment that is couplable to a second segment. 
     In some embodiments, the first segment includes a plurality of forming segments connectable to form an annulus and the second segment includes a plurality of forming segments connectable to form an annulus. 
     In other embodiments, the forming segments comprise fold lines. 
     In a third aspect, there is provided a lighting apparatus that includes a shroud and a reflective surface. The shroud may include an annular protrusion on an internal surface of the shroud. The reflective surface may be disposed within the shroud, wherein the reflective surface is spaced from the shroud and is couplable to the shroud at the annular protrusion. 
     In certain embodiments, the shroud is concave in shape and the reflective surface includes a concave main reflective body and a convex reflective cone. 
     In other embodiments, the convex reflective cone is located at a central axis of the shroud and encircles a lighting element. 
     In yet other embodiments, the annular protrusion is located near an open end of the shroud. 
     In still another embodiment, the reflective surface is made by physical vapour deposition. 
     In other embodiments, the reflective surface is 98 percent reflective. 
     Other aspects, features, and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of the inventions disclosed. 
    
    
     
       DESCRIPTION OF THE FIGURES 
       The accompanying drawings facilitate an understanding of the various embodiments. 
         FIG. 1  is a cutaway front view of a lighting apparatus with a reflective surface. 
         FIG. 2  is a close-up, perspective view of the lighting apparatus of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 1 and 2 , a lighting apparatus  100  is shown that includes a reflective surface  140  for directing light generated by a lighting element  106  away from an area directly below the lighting apparatus  100  (i.e., around the base of the pole that supports the lighting mechanism) to outlying areas where additional light is desired and/or necessary. In addition, the lighting apparatus  100  includes a lighting element housing  104  that protects the reflective surface  140  and is spaced from the reflective surface  140  so that damage to the lighting element housing  104  (i.e., dents/bending/etc. from hail, wind and rain) does not affect the reflective surface  140 . The lighting apparatus  100  is inexpensive and simple to manufacture and can be economically shipped, as will be described in more detail below. 
     In general, the lighting apparatus  100  includes a connector  102 , such as a ballast housing  128 , to connect the lighting apparatus  100  to a support structure, such as, for example, a pole, building wall, or ceiling structure. The lighting apparatus  100  further includes a lighting apparatus housing  104  that is connected with the connector  102  and includes a protective shroud  116 , and a reflective surface  140  located within the protective shroud  116  for directing light from a lighting element  106  that is positioned within the protective shroud  116 . 
     The connector  102  may be any suitable linking mechanism used to secure the apparatus  100  to a support structure. In some embodiments, the connector  102  is a ballast housing  128  that may also include elements for powering and controlling the apparatus  100 , such as, for example, a power cord and ballast (not shown). 
     The lighting element housing  104  is connected to the connector  102  and includes the protective shroud  116 , the reflective surface  140  and the lighting element  106 . The protective shroud  116  may be in the form of any suitable shape and made of any suitable material, such as, for example, metal or plastic. In some embodiments, the protective shroud  116  is formed of a rigid material that protects the elements within the shroud  116 , such as the reflective surface  140  and the lighting element  106 . In some embodiments, the protective shroud  116  is positioned around the reflective surface  140  so that the reflective surface  140  is completely encircled by the protective shroud  116  to protect the reflective surface  140  from external elements, such as, for example, hail, rain, falling debris and dirt. 
     In the embodiments illustrated in  FIGS. 1 and 2 , the protective shroud  116  is generally dome-shaped and is slightly larger than the reflective surface  140  disposed therein. However, the protective shroud  116  may be any suitable shape that is slightly larger than the reflective surface  140 . In some embodiments, for example, the protective shroud  116  is cone-shaped. In some embodiments, the protective shroud  116  is rectangular in shape. In some embodiments, the protective shroud  116  is dome-shaped and is made of 0.1 inch thick spun aluminum. 
     According to some embodiments, the protective shroud  116  includes a transparent cover  118  disposed on a bottom surface  156  of the protective shroud  116  to further protect the reflective surface  140  from the outside environment. The cover  118  may form an airtight seal to the protective shroud  116  such that the volume within the protective shroud  116  is completely closed off and sealed from the ambient air. Thus, the volume between the protective shroud  116  and the cover  118  may be closed off from airborne contaminants in the ambient air which could contaminate a surface of the lighting element  106 , an internal surface  234  of the cover  118  and/or the reflective surface  140 , thereby increasing the luminaire dirt deprecation and decreasing the overall efficiency of the lighting apparatus  100 . The cover  118  may also prevent intrusion from living organisms, such as insects and small animals, which may damage or otherwise decrease the efficiency of the lighting apparatus  100 . The cover  118  is formed of any suitable material, such as, for example, glass or plastic, and is attachable to the protective shroud  116  by any suitable attachment mechanism(s). 
     According to some embodiments, the apparatus  100  can be constructed without a cover  118  thus exposing the lighting element  106  to the environment. In other embodiments, rather than forming an air-tight connection, the cover  118  is for example, a mesh-type material that prevents entry of contaminants over a certain size into the volume between the protective shroud  116  and the cover  118 . In some embodiments, the cover  118  need not be made of sag glass and need not include light baffles due to the light spreading caused by the reflective surface  140 , as will be discussed in more detail below. 
     In the embodiment illustrated in  FIG. 1 , the protective shroud  116  includes an annular protrusion  134  located near a bottom surface  156  of the protective shroud  116  and an annular protrusion  146  located above the annular protrusion  134 . In some embodiments, the reflective surface  140  is connectable to the protective shroud  116  at one or more of the annular protrusions  134  and  146 . The reflective surface  140  may be attached to the protective shroud  116  at one or more of the annular protrusions  134  and  146  by any suitable attachment mechanisms, for example, by screws, bolts or the like. Thus, in the embodiment illustrated in  FIGS. 1 and 2 , the reflective surface  140  may be easily attached and/or removed from the protective shroud  116 . 
     When the reflective surface  140  is connected to the protective shroud  116 , the reflective surface  140  is spaced apart from an inner surface  158  of the protective shroud  116  so that damage to the protective shroud  116  does not affect and/or otherwise impact the reflective surface  140 . The distance between the reflective surface  140  and the protective shroud  116 , for example, the distance shown by the arrow labeled  244  in  FIG. 1 , provides a buffer area between the protective shroud  116  and the reflective surface  140 . Thus, for example, if a projectile contacts and dents the protective shroud  116 , the dent may extend into the buffer area between the protective shroud  116  and the reflective surface  140  without damaging the reflective surface  140 . 
     The reflective surface  140  is configured to efficiently direct light from the lighting element  106  through an open end  240  of the protective shroud  116 . Specifically, the reflective surface  140  is configured to direct light away from an area directly below the lighting apparatus  100 , typically where a support pole is located. In general, the reflective surface  140  includes a main reflective body  164  and a reflective cone portion  142 . The main reflective body  164  includes a first segment  160  and a second segment  162 , each of which is generally in the shape of a convex truncated dome that may be similar to the convex shape of the protective shroud  154 . The first segment  160  is located adjacent to the bottom surface  156  of the protective shroud  116  and is coupled to the second segment  162 . The second segment  162  is coupled to the first segment  160  on a lateral end of the second segment  162  and to the reflective cone  142  on an opposite lateral end of the second segment  162 . In some embodiments, the reflective cone  142  is located within a truncated portion of the second segment  162 , as shown in  FIG. 1 . The first segment  160 , second segment  162  and reflective cone  142  may be one integral piece or, in the alternative, may be separate pieces that are coupled together by known fastening mechanisms. 
     The first segment  160 , the second segment  162  and the reflective cone  142  are each formed of rows of interconnected, planar portions  166  made of a reflective material, such as, for example, high reflectivity aluminum that is 98 percent reflective. In some embodiments, the planar portions  166  are made by physical vapour deposition in which the base material is aluminum which is coated by 99.99 percent pure silver. In some embodiments, the planar portions  166  include a protective layer, a reflective layer, a silver layer which is applied using physical vapour deposition, a bonding layer and an anodized aluminum substrate. 
     The first segment  160 , second segment  162  and reflective cone  142  include fold lines  210  at the intersection of the planar portions  166  which allow for selectively bending the first segment  160 , the second segment  162  and the reflective cone  142  at the fold lines  210 . The fold lines  210  may be, for example, scored portions of the first segment  160 , the second segment  162  and the reflective cone  142  that allow for bending of the first segment  160 , the second segment  162  and the reflective cone  142  in an area between the planar portions  166  so that the first and second segments  160  and  162  may be formed into the shape of an annulus and the reflective cone  142  may be formed into the shape of a cone  142 , as shown in  FIG. 1 . 
     In some embodiments, the first segment  160 , the second segment  162  and the reflective cone  142  are each formed of one or more forming segments, which are sheets of one or more interconnected, adjacent planar portions  166 . For example, in some embodiments, the planar portions  166  of the first segment  160  that are labeled  166   a  in  FIG. 1  together form a forming segment that may be linked to other forming segments to create the first segment  160 . When assembled, the forming segments are connected so that an end of one forming segment is connected to an end of an adjacent forming segment. The fold lines  210  of the forming segments provide an axis upon which the forming segments bend to form the generally annular shape of the first segment  160 , the second segment  162  or the cone shape of the reflective cone  142 . The forming segments are attached together by any suitable attachment mechanism. For example, in some embodiments, pliable metal tabs are included on one end of the forming segments and corresponding openings are included on an opposite end of the forming segments so that the metal tabs of a forming segment can be attached to the openings of an adjacent forming segment. 
     The forming segments are substantially planar until they are selectively bent along the fold lines  210  and attached to adjacent forming segments to form the shapes of the first segment  160 , the second segment  162  and/or the reflective cone  142 . Thus, the parts that form the reflective surface  140 , specifically the first segment  160 , the second segment  162  and the reflective cone  142 , may each be manufactured as substantially flat pieces, shipped as flat pieces and then easily assembled into the appropriate shapes upon delivery. 
     The reflective cone  142  is generally in the shape of a truncated cone and is convex compared with the concave shape of the main reflective body  164  and the protective shroud  116 . The reflective cone  142  encircles the lighting element  106  and/or a socket  168  connected to the lighting element  106  and includes an opening  148  to receive the lighting element  106  and/or the socket  168 . As such, the reflective cone  142  extends between a top portion  242  of the protective shroud  116  and the lighting element  106  for directing light generated by the lighting element  106  toward the open end  240  of the protective shroud  116 . As shown in  FIG. 1 , the reflective cone  142  is located at a central axis of the protective shroud  116 . 
     In some embodiments, the reflective cone  142  protrudes from an inner surface  158  of the protective shroud  116  such that an angle, labeled  220  in  FIGS. 1 and 2 , between a planar portion  166  of a first row  216  of planar portions  166  of the reflective cone  142  and an adjacent planar portion  166  of a first row  218  of planar portions  166  of the second segment  162  is between about 80 and 100 degrees. In some embodiments, the angle  220  is about 87 degrees. In some embodiments, the angle  220  is about 87.8 degrees. 
     Referring now specifically to  FIG. 2 , the reflective cone  142  includes a first row  216 , a second row  222 , a third row  224  and a fourth row  226  of planar portions  166 . The angle between the first row  216 , second row  222 , third row  224  and fourth row  226  of planar portions  166  determines the direction of light that is reflected from the planar portions  166  of the reflective cone  142 . In some embodiments the first row  216  of planar portions  166  of the reflective cone  142  is at an angle  228  to the second row  222  of planar portions  166  of the reflective cone  142  that is about 170 degrees. In some embodiments, the second row  222  of planar portions  166  is at an angle  230  to the third row  224  of planar portions  166  that is about 178 degrees. In some embodiments, the third row  224  of planar portions  166  is at an angle  232  to the fourth row  226  of planar portions  166  that is about 178 degrees. 
     In operation, the reflective surface of the planar portions  166  of the first segment  160 , the second segment  162  and the reflective cone  142  spreads and/or otherwise disperses light generated by the lighting element  106 . Referring specifically to  FIG. 1 , light that is emitted from the lighting element  106  in a direction such as that of the arrow labeled  212  in  FIG. 1 , may be directed in a direction such as that of the arrow labeled  214 . Light that is emitted from the lighting element  106  away from the open end  240  of the protective shroud  116 , such as in the direction of the arrow labeled  236  in  FIG. 1 , may also be directed in a direction away from an area directly below the lighting apparatus  100 , such as that of the arrow labeled  238 . Thus, light is directed away from an area directly below the lighting apparatus  100 , typically where the pole supports the lighting apparatus above the ground, to outlying areas to more efficiently light a given area. 
     In use, the apparatus  100  may be coupled to a post, building wall, ceiling element or some other support and may be directed toward an area that is to be illuminated. The open end  240  of the lighting apparatus  100  is directed toward a ground, or downwardly, or may be directed in another direction, for example, toward a ceiling, or upwardly. Terms such as top, bottom, above, below, upward and downward, and similar terms, are used with reference to  FIGS. 1 and 2  to conveniently describe the apparatus  100 , and it will be understood that those terms are to be adjusted depending on the orientation of the lighting apparatus  100 . Thus, for example, if the lighting apparatus  100  is directly upwardly (i.e., opposite of the orientation shown in  FIG. 1 ), the top portion  242  of the protective shroud  116  would be located towards a lower end of the apparatus  100 . 
     The lighting element  106  produces light which either escapes directly through the open end  240  of the protective shroud  154  or is reflected by the reflective surface  140  to exit through the open end  240 . Light that contacts the reflective cone  142  is generally directed away from a location directly below the lighting apparatus  100  due to the protruding, convex shape of the reflective cone  142  and the concave shape of the first segment  160  and the second segment  162 . As such, light from the lighting apparatus  100  is more efficiently spread and the overall efficiency of the lighting apparatus  100  may be improved. 
     In some additional embodiments, heated air from the lighting element  106  travels through the opening  148  in the reflective cone  142  or otherwise become positioned inside the reflective cone  142 . Furthermore, in order to permit the escape of heated air from the reflective cone  142 , the first row of  216  of planar portions  166  of the reflective cone  142  may include one or more openings (not shown) to allow heated air to pass through the openings and out of the reflective cone  142 . 
     As described above, in the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. As stated above, terms such as “top”, “bottom”, “above”, “below”, “upward” and “downward” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms. 
     In this specification, any use of the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear. 
     In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive. 
     Furthermore, invention(s) have been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention(s) are not to be limited to the disclosed embodiments, but on the contrary, are intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.