Patent Abstract:
A high lumen output illumination device includes a light source secured on a ballast housing and a reflector. At least one reflective element redirects light emanating from the source along a direction of interest. At least one support element gives the reflective element a useful optical shape and aids in the retention of the optical shape. The reflector is capable of being transitioned between two orientations, an open orientation, where the reflector is functional, and a collapsed orientation, where the reflector occupies a greatly reduced amount of space. The reflector includes a fastening means that allows the reflector to be removed from the ballast housing, and re-attached to the ballast housing when desired.

Full Description:
BACKGROUND OF INVENTION  
         [0001]    The present invention relates to the artificial illumination arts. It finds particular application in high lumen output luminaries that include reflectors which are packaged and shipped and will be described with particular reference thereto. It is to be appreciated, however, that the present invention is not limited to the aforementioned application.  
           [0002]    Typical reflectors used in conjunction with high intensity discharge (HID) lamps are bulky constructions, consuming space, yet having an actual volume that is relatively small. The shape of a reflector is often dictated by required optical characteristics, rather than size and shape requirements. As a result, bulky reflectors are often desired, and it is necessary to ship the bulky reflectors to the consumer. Packaging a reflector often involves putting the reflector in a box, the box being a standard shipping means. Since the box and the reflector are such different shapes, and the box must be big enough so the reflector can fit inside, much of the room in the box is unoccupied, making shipment of an assembled reflector in a box rather inefficient.  
           [0003]    One known alternative is to ship the reflector in disassembled sections, reducing the amount of empty space in a packaging box. While this method holds the advantage of making more efficient use of packaging space, the reflectors require assembly upon arrival to the consumer. Either the consumer assembles the reflectors, or the retailer employs personnel to assemble the reflectors upon arrival to the consumer.  
           [0004]    Umbersols such as the type used in photography flash fixtures, and described in EP 0 964 291 A1 to Whittle utilize collapsible reflectors. This type of reflector includes a sheet of reflector element that is supported by a plurality of legs. This type of reflector is typically assembled and disassembled before and after each use, the legs being folded or removed from the light socket. Moreover, this type of reflector is used in conjunction with a low average wattage lamp, making its use with HID light fixtures improbable.  
         SUMMARY OF INVENTION  
         [0005]    In accordance with one aspect of the present invention, a lighting fixture is provided. A light source is fixed onto a ballast housing. A collapsible reflector is fixedly attached to the ballast housing with at least one fastener. At least one reflective element focuses and directs light emanating from the light source, and at least one support element aids in the retention of an optically useful shape of the reflective element.  
           [0006]    In accordance with another aspect of the present invention, a method of packaging a reflector is provided. The reflector is collapsed into a form that occupies less space than its expanded form. The reflector is inserted into a shipping medium in its collapsed form, there being substantial room left in the shipping medium. 
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0007]    The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.  
         [0008]    [0008]FIG. 1 is a cross sectional view of a concentric ring embodiment of an HID reflector, in accordance with the present invention.  
         [0009]    [0009]FIG. 2 is a sectional view of a spirally wound embodiment of the HID reflector, in accordance with the present invention.  
         [0010]    [0010]FIG. 3 is a sectional view of a plate mail embodiment of the HID reflector, in accordance with the present invention.  
         [0011]    [0011]FIG. 4 is a collapsed view of a stacked plate embodiment of the present invention.  
         [0012]    [0012]FIG. 5 is a top-down view of the embodiment of FIG. 4 in an open configuration.  
         [0013]    [0013]FIG. 6 is a sectional view of a rib-supported embodiment of the reflector, in accordance with the present invention.  
         [0014]    [0014]FIG. 7 is a depiction of multiple reflectors of FIG. 1 packaged into a shipping container.  
         [0015]    [0015]FIG. 8 is a depiction in partial section of multiple reflectors of FIG. 2 packaged into a shipping container. 
     
    
     DETAILED DESCRIPTION  
       [0016]    With reference to FIG. 1, a light source  10  is mounted on a ballast housing  12 . A collapsible reflector  14  focuses and re-directs light emanating from the light source. A reflective element  16  is supported by a plurality of support elements  18 . The support elements  18  are concentric rings that are smaller in radius near the ballast housing  12 , and larger in radius extending downward away from the ballast housing  12 . Preferably, the ballast housing is mounted vertically with respect to ground so gravity naturally extends the reflector  14  away from the ballast housing  12 . Alternately, the ballast housing  12  can be mounted in an orientation other than vertical and additional securements used to hold the reflector  14  in its extended position.  
         [0017]    The reflective element  16  is preferably a flexible material, such as a heat resistant material with a reflective coating applied. Thin sheets of reflective plastics such as Mylar, Polyimide, Kapton, and Teflon are preferred. In general, the reflective element  16  is a material that can be manufactured in the form of a sheet, is flexible, and can be coated or is inherently reflective. The reflective element is secured to the rings  18  such that the reflective element  16  is extended to the same orientation each time the rings  18  are extended. One preferred method of securing the rings  18  is to laminate them within the reflective element. Two layers of reflective material are fused around the rings  18 , by heating, or other adhesive means well known in the art. Another preferred method is securing the rings  18  to the reflective element  16  using an additional bonding agent or adhesive. The rings  18  could be either inside or outside of the reflective element  16  with respect to the light source  10 .  
         [0018]    The reflector  14  is collapsible to occupy less volume. The rings  18  are stacked forming a “bull&#39;s eye” orientation in a single plane. The reflective element  16  folds into the spaces between the rings  18 . The reflector  14  can remain attached to the ballast housing  12  when compressed, or it can be removed and stored separately. The reflector  14  is preferably fixedly attached to the ballast housing. Inscribed within and attached to the uppermost ring is a base plate  20 , which is used to attach the reflector  14  to the ballast housing  12 . The base plate  20  includes a large central aperture through which the light source  10  is fixed to the ballast housing  12 . The base plate also includes a plurality of generally keyhole shaped apertures that fit over an equal number of bolts  22  in the ballast housing  12 . The reflector  14  is twisted slightly such that the bolt shafts fit into the narrow portions of the keyhole shaped apertures. The bolts  22  are then tightened to secure the reflector  14  in place relative to the ballast housing  12 . Alternately, the base plate  20  may be bolted directly to the ballast housing.  
         [0019]    In a variation of the above disclosed embodiment, the support is a single helical construction rather than a plurality of concentric rings. In this variation, the support can be biased to the open position so the lighting fixture can be oriented in a position other than vertical. Additionally, a locking mechanism or clamp is included to keep the reflector in a collapsed position, as it would tend to open.  
         [0020]    In an alternate embodiment, and with reference to FIG. 2 a  light source  30  is carried on a ballast housing  32 . A reflector  34  focuses and re-directs light emanating from the light source. A reflective element  36  includes a thin, elongated strip that is coiled in a spiral, forming a desirable optical shape of the reflector  34 . Transverse edges of the elongated strip  36  include support elements  38  that aid the strip  36  in retaining its optical shape. The preferred support elements  38  are interlocking hooks made from the edges of the strip  36  that have been folded over. The elongated strip  36  is biased toward an open position, and the hooks  38  prevent the strip  36  from over extending. To achieve a collapsed position, pressure is applied to the reflector, (in an upward direction in FIG. 2) compressing the helical shape into a spiral. Preferably, a latch or other locking device holds the reflector in the collapsed form. Alternately, rather than a single helical strip, a plurality of helical strips can be utilized to form the reflector.  
         [0021]    The uppermost portion of the reflector  34  includes a flange portion  40  by which the reflector  34  is secured to the ballast housing  32 . Screws, rivets, interlocking tabs, or other well known securing devices  42  are used to hold the flange portion  40  secure relative to the ballast housing  32 . Simple, non-permanent attachment means are preferred to permanent attachment means to allow the ballast housing  32  and the reflector  34  to be shipped as one unit, or separately, depending the needs and desires of the consumer. Optionally, the reflector can be flangeless, with portions of the reflective element  36  secured to the ballast housing  32 .  
         [0022]    The reflective element  36  is preferably biased to the open, extended orientation, that is, helical reflective element  36  acts much like a spring. Thus, the reflector may be positioned in orientations other than vertical with respect to the ground. However, the preferred bias is not so great to render collapsing the reflector difficult. The hooks  38  are preferably made utilizing a roll-forming method, or other well known, equivalent machining method. The reflective element is preferably constructed of aluminum, steel, or any material having a ‘shape memory’ that can be finished with a reflective coat. The interior portion of the reflective element  36  used for reflection is preferably finished with a high reflectance mirror surface or other useful optical finish, such as a high reflectance matte, white glossy paint, or a semi-bright finish. Ultimately, the reflective finish depends on the desired application. The reflective element  36  is preferably between 0.5 and 1.0 mm thick, to provide the reflective element  36  with the needed flexibility to comfortably transition between open and closed reflector orientations.  
         [0023]    In an alternate embodiment of the present invention, and with reference to FIG. 3, a light source  50  is carried on a ballast housing  52 . A reflector  54  includes a plurality of reflective elements  56  that are held in position with respect to one another with support elements. The reflective elements  56  are plates having reflective surfaces facing inward towards the light source. The reflective elements  56  are shaped according to their position in the reflector  54 . The reflective elements  56  are arranged in tiers, each tier forming a horizontal zone, there being six shown in FIG. 3.  
         [0024]    Along horizontal intersections of the reflective elements, that is, the horizontal barriers between zones, horizontal hinges  58  secure the vertical positions of the various zones relative to each other. Control hinges  60  secure radial positions, that is, distance from the light source  50 , of the reflective elements. In a six zone embodiment as depicted in FIG. 3, three sets of control hinges  60  are utilized. One set is between the first and second zones, a second set is between the third and fourth zones, and a third set is between the fifth and sixth zones. The control hinges are preferably used between every other zone to allow collapsibility of the reflector  54 . In the preferred embodiment, the reflective elements  56  fold onto one another, the horizontal zone intersections with control hinges folding away from the light source, and the zone intersections without control hinges folding towards the light source  50 . Preferably, gravity is used to keep the reflector  54  in an open orientation when the light source  50  is in operation. Alternately, latches at the intersections are utilized to keep the reflector  54  in an open orientation so the light source  50  may be oriented other than vertical with respect to the ground.  
         [0025]    The reflective elements  56  are preferably pre-formed polyhedral constructions that are coated with a useful optical coating on their interior faces. Trapezoidal reflective elements are preferred, but any polyhedral sections that form a useful optical shape are possible. The horizontal hinges  58  can be separate hinges, or they can be integrated within the reflective elements. In a separate hinge embodiment, apertures are provided in the reflective elements to accept the hinges. In an integral hinge embodiment, alternating edges are equipped with hinges  58 , while the edges adjacent to the hinges are provided with apertures to accept the hinges. Similarly, either integral or separate control hinges could be used.  
         [0026]    In an alternate embodiment, with reference to FIG. 4, a light source  70  is fixed on a ballast housing  72 . A reflector  74  includes a plurality of reflective elements  76 . The reflective elements  76 , as seen in a collapsed configuration in FIG. 4, are stackable, petal shaped segments of the reflector  74 . With reference to FIG. 5, when the reflector  74  is in an open position, support elements  78  hold the reflective elements  76  in position relative to each other. The reflector  74  is opened by rotating a first element  76  around a track  80 . When the first element has been translated approximately its own width around the track  80 , the support element  78  of the first element couples with the support element  78  of a second element, towing the second element along the track  80 . A support element of the second couples with a support element of the third, etc. The first element is translated around the track  80  until it abuts a last, preferably immobile element. A latch  82  is used to fixedly connect the first and last elements to keep the reflector in an open position.  
         [0027]    In an alternate embodiment of the present invention, with reference to FIG. 6, a light source  90  is carried on a ballast housing  92 . A reflector  94  includes a reflective element  96  that is supported by a plurality of support elements  98  or ribs, extending from a track  100 . The reflective element  96  is preferably a flexible material with a reflective coating on the interior of the reflector  94 , facing the light source. The ribs  98  are attached at regular intervals along an outer surface of the reflective element  96 .  
         [0028]    In a collapsed orientation of the reflector  94  the ribs  98  are closely spaced together, with the reflective element  96  folded in-between the ribs  98 . The reflector  94  is transitioned to an open orientation by translating a first rib around the track  100 . The first rib tows the reflective element  96  and the remaining ribs  98  therewith, forming a surface with optically useful properties around the light source. A latch  102  secures the first rib with a preferably immobile last rib, holding the reflector  94  in its open orientation.  
         [0029]    All of the above-disclosed embodiments provide an optically useful reflector that is collapsible into a form that occupies less space than its open orientation. The reflector is then capable of being packaged and shipped with the ballast housing, or packaged and shipped with multiple copies of itself. If the reflector and ballast housing are shipped together, the reflector can be pre-attached to the ballast housing, leaving the consumer little or no manipulation of the product aside from taking the product out of the box.  
         [0030]    The ballast housing can be packaged and shipped with the reflector pre-attached, as illustrated in FIGS. 7 and 8. Preferably, the ballast housing  12 ,  32  and the reflector  14 ,  34  together occupy little room over and above what the ballast housing occupies alone. Preferably, the ballast housing  12 ,  32  and reflector  14 ,  34  are packaged without the light source  10 . This reduces occupied space and lessens the sensitivity of the package to impact. Packaging insulation  110  is used to protect the ballast housings during shipment, as well as to prevent physical contact between ballast housings. The packaging insulation can be any of well known insulation devices, such as Styrofoam peanuts, Styrofoam blocks, air bags, bubble wrap, and others. The ballast housings  12 ,  32 , reflectors, and shipping insulation  110  are packaged into a shipping container  112 , one preferably selected for its safety and security.  
         [0031]    The preferred packaging method, in addition to providing added space in shipping containers, and protection of the lighting fixtures, lessens the need for assembly by the consumer. In the embodiments shown in FIGS. 7 and 8, the container  112  lid is opened, any packaging material  110  on top is removed, and the lighting assembly is lifted straight upwards by the ballast housing  12 ,  32 . Gravity extends the reflector  14 ,  34  as the ballast housing  12 ,  32  is lifted from the container. At this point, the light source  10  is attached to the ballast housing  12 ,  32  and the lighting assembly is ready to be hung and connected to a power supply.  
         [0032]    Alternately, instead of shipping multiple assembled fixtures in the same shipping container, the ballast housing  12 ,  32  and reflector  14 ,  34  can be shipped separately. The preferred embodiment has been described using a detachable reflector. It is to be understood that a thermoplastic seal or other permanent attachment means can be utilized to permanently attach the reflector  14 ,  34  to the ballast housing  12 ,  32 . It is to be understood, that although packaging has been described in detail with reference to the first two embodiments, similar packaging is applicable to the remainder of the embodiments.  
         [0033]    The invention has been described with reference to the preferred embodiment. Modifications and alterations will occur to others upon a reading and understanding of the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

Technology Classification (CPC): 5