Patent Abstract:
Embodiments of the disclosure relate to retrofitting LED light bars into fluorescent tubular style lamp fixtures as well as integrating LED light bars into new lamp fixtures. In various embodiments a single light bar may be utilized with multiple style base ends to allow it to retrofit into a variety of existing fixtures. Some embodiments offer multiple mounting options on an LED light bar for existing lamp fixtures so that electrical utilities&#39; rebate requirements can be met with a single LED light bar assembly.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 62/329,862 filed Apr. 29, 2016, the entire contents and disclosure of which are hereby incorporated by this reference. 
     
    
     TECHNICAL FIELD 
       [0002]    Embodiments described in this application relate generally to lighting products, their mechanical features for attachment, and associated means and methods, and more specifically, retrofitting fluorescent tubular style fixtures as well as integrating the disclosed device(s) into new fixtures with a light-emitting diode (“LED”) light bar, in particular linear tubes. 
       BACKGROUND 
       [0003]    Current light bar technologies for retrofit applications cause businesses to maintain inventory for a multitude of lighting configurations. Cost incurred range from maintaining inventory of similar light bars, sans the mechanical end style for mounting in existing fixtures, can be costly and difficult. 
         [0004]    When upgrading fluorescent tubular lamps to LED tubes or fixtures, there are many electrical utility rebates that offer a wide range of financial benefits to help reduce energy consumption. Many of these rebates have requirements stipulating how the replacement lighting is installed. Depending upon the utility and/or the rebate the requirements of the retrofit vary. For instance, some rebates mandate that the retrofitting lamp cannot utilize the existing receptacle, (i.e., tombstone). 
         [0005]    This wide range of installation requirements (e.g., fluorescent light tombstone socket options) and selection of different lighting options makes it cumbersome for electrical supply houses, distribution centers, installers, etc., to have all the needed items readily available. 
         [0006]    In applications where new lighting is being installed and no longer require the tombstone sockets, a mounting clip can be used instead. 
         [0007]    Overall, it would be advantageous to have a means for variations in mounting option applications such that a single light bar can qualify for different financial rebates in retrofits or reduce inventory while allowing variations in product offerings. 
       BRIEF SUMMARY 
       [0008]    The disclosed embodiments and device(s) overcome these above-described requirements by offering a single light bar that can easily transform to fit the requirements of both the rebates and function of retrofitting/installing a fixture or light source. 
         [0009]    Having the ability to utilize the same fixture for a multitude of needs provides a larger variety of rebate and use offerings. For instance, a vapor tight fixture, utilizing the clips and/or rotatable end cap base adaptors can distribute the light in various patters based upon the angle of the mounting application. The variation in angle can allow the same fixture to be used in multiple applications. 
         [0010]    Embodiments of the disclosure generally relate to retrofitting LED light bars into fluorescent tubular style lamp fixtures as well as integrating LED light bars into new lamp fixtures. A single light bar can be utilized with multiple style base ends that allows it to retrofit into a variety of existing fixtures. This results in a method for offering multiple mounting options on an LED light bar for an existing lamp fixture so that electrical utilities&#39; rebate requirements can be met with a single LED light bar assembly. 
         [0011]    A major advantage of the disclosed device(s) is offering a single LED light bar source that has the capability of utilizing any existing fixture receptacle and/or can be mounted independent of the receptacle. Electrical Utilities offer rebates for adoption of LED lighting to reduce energy consumption. These rebates have a myriad of technical requirements regarding how the existing lamp receptacle is utilized when the LED light bar replaces a fluorescent light. In some instances, the fluorescent lamps&#39; tombstone receivers must stay in place but in some instances the tombstones can be removed. Removal of the tombstones in a lighting retrofit is sometimes regarded as less labor intensive since the fluorescent ballast, its high voltage wiring, and tombstones can all be removed as a single assembly. These components are then replaced by LED light bars, the LED power supply and dedicated direct current (DC) wiring. When the tombstones must remain in place, the high voltage wiring is cut and the fluorescent lamp ballast is removed. The interchangeability of the end base adaptors allow for either adaptation and installation to the existing fixture. Moreover, if the rebate requirements state that the tombstones must remain in place but the end base adaptors cannot be used, this invention will allow the light bar to fit in between the existing fixture receptacles with the interchangeable base adaptors removed. This ability of the invention helps reduce the additional labor and inventory needed by businesses to meet the rebate requirements in different localities. 
         [0012]    Accordingly, various embodiments of the disclosure and disclosed device(s) have a base cap on both sides. This base cap has a receiving adaptor end base that can either not have any adaptor and be used as a traditional light bar with separate mounting clips or can use an interchangeable base adapter. The interchangeable base offers several adaptors that will fit in the existing light fixtures receptacle. Standard receptacles in the field are G13 for 4-foot tubes and Fa8 for 8-foot tubes. Other standard receptacle options can easily be created to this interchangeable adapter base system. 
         [0013]    Embodiments of the disclosure and device(s) also generally relate to offering the interchangeable base to any size length of light bar. This will allow for the reduction of inventory but create a large array of offerings. Further, they provide the ability to offer an interchangeable and removable end base adaptor which greatly increases the number of stock keeping units (SKU) that can be offered while reducing the quantity of lamps needed to be in stock. These novelties pass the same benefits of additional flexibility in product offerings to distributors. Other advantages, benefits and applications may exist. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    Advantages of the various embodiments described in this disclosure will be apparent to those of ordinary skill in the art from the following detailed description and the appended drawings: 
           [0015]      FIG. 1  shows a broken view of an embodiment of the lamp assembly; 
           [0016]      FIG. 2  shows an exploded view of an embodiment of the lamp assembly and various convertible base adapters; 
           [0017]      FIG. 3  shows a side view A-A of an embodiment of adapter base  16 ; 
           [0018]      FIG. 4  shows a perspective broken view of t an embodiment of the lamp assembly along with depicting cutting planes for sections B-B and C-C; 
           [0019]      FIG. 5  shows Section B-B from  FIG. 4 ; 
           [0020]      FIG. 6  shows Section C-C from  FIG. 4 ; 
           [0021]      FIG. 7  shows an exploded top view of embodiments of the end base and metal extrusion; 
           [0022]      FIG. 8  shows an exploded side view of embodiments the end base and metal extrusion; 
           [0023]      FIG. 9  shows a perspective view of the end base and metal extrusion assembled according to an embodiment of the disclosure; 
           [0024]      FIG. 10  shows the end view of two light bars assembled with an angular mounting clip according to an embodiment of the disclosure; 
           [0025]      FIG. 11  shows a front view of a rotating head of an embodiment of a rotating base adapter; 
           [0026]      FIG. 12  shows a side view of an embodiment of a rotating base adapter; 
           [0027]      FIG. 13  shows an embodiment of the locking feature of the rotating base adapter; 
           [0028]      FIGS. 14 and 15  show an existing light fixture being retrofitted with the LED light bars disclosed herein; 
           [0029]      FIG. 16  shows a front view of a light fixture including an embodiment of an angled clip; 
           [0030]      FIG. 17  shows a right side view of an embodiment of an angled clip; 
           [0031]      FIG. 18  shows a perspective view an embodiment of an angled clip; 
           [0032]      FIG. 19  shows a front view of a light fixture having an embodiment of a vertical clip; 
           [0033]      FIG. 20  shows a right side view of an embodiment of a vertical clip; 
           [0034]      FIG. 21  shows a perspective view of an embodiment of a vertical clip; 
           [0035]      FIGS. 22A and 22B  show the insertion of an angled clip into a fixture according to an embodiment of the disclosure; and 
           [0036]      FIG. 23  shows a new light fixture fitted with embodiments of angled and vertical clips supporting light bars. 
       
    
    
     DETAILED DESCRIPTION 
       [0037]    In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those of ordinary skill in the art to practice the disclosure. It should be understood, however, that the detailed description and the specific examples, while indicating examples of embodiments of the disclosure, are given by way of illustration only and not by way of limitation. From this disclosure, various substitutions, modifications, additions rearrangements, or combinations thereof within the scope of the disclosure may be made and will become apparent to those of ordinary skill in the art. 
         [0038]    In accordance with common practice the various features illustrated in the drawings may not be drawn to scale. The illustrations presented herein are not meant to be actual views of any particular method, device, or system, but are merely idealized representations that are employed to describe various embodiments of the disclosure. Accordingly, the dimensions of the various features may be arbitrarily expanded or reduced for clarity. In addition, some of the drawings may be simplified for clarity. Thus, the drawings may not depict all of the components of a given apparatus (e.g., device) or method. In addition, like reference numerals may be used to denote like features throughout the specification and figures. 
         [0039]    Information and signals described herein may be represented using any of a variety of different technologies and techniques. For example, data, instructions, commands, information, signals, bits, symbols, and chips that may be referenced throughout the above description may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles, or any combination thereof. Some drawings may illustrate signals as a single signal for clarity of presentation and description. 
         [0040]    Disclosed is a multi-use light bar to ease installation and assembly. More particularly, but not by way of limitation, the disclosure relates to a multi-use light bar that includes interchangeable base adaptors that are designed to be fastened to existing lamp receptacles, e.g., G13 (bi-pin), Fa8 (single pin), R17D (protruding end cap). This allows for a single light bar to readily emulate different mechanical mounts. Other embodiments of the end cap adaptors include rotatable bases, connectors linking one light bar to the next and/or other mounting methods to existing receptacles in fixtures or to ease assembly in new fixtures. 
         [0041]    Also disclosed are mounting clips that may be used if the light bar is not utilizing the existing fixture receptacles. The LED light bar is supportable with mounting clips and/or a receptacle that readily attach to a fixture and/or location via, e.g., self-tapping screws or other affixing methods. Such mounting clips snap into the light bar&#39;s (or bars&#39;) longitudinal grooves to hold it in place either between the existing receptacles or in other such locations. Additionally, for new fixtures the disclosed device(s) can be easily mounted in the grooved clips or receptacle for the light bar. Light bars may be installed at fixtures to change light output, change beam pattern, or change kelvin options, using the existing fixtures. For example, if an existing fixture is adhered to a specific location and light is provided to a specific target (e.g., a refrigerator door light, a closet light, an oven light a car light, etc.), the devices and techniques described herein may be used to install a light bar that distributes light at different intensities, beam patterns, with more efficient power consumption characteristics, etc. 
         [0042]    With reference to  FIG. 1 , an LED light bar  1  is shown that is depicted having a breakaway within its length. Light bar  1  consists of end base  2 ,  3 , lens  5 , metal extrusion  9 , and circuit card assembly  11 . In some embodiments, metal extrusion  9  can be of materials other than metal such as plastics. 
         [0043]    Depicted on circuit card  11  and along its length are LEDs  12  that are commonly arranged in a linear pattern. Dimension “L”  8  indicates that the overall length, which can be nearly any practical length required for this type of lighting design. A pair of base adapters  14 ,  17  are utilized at each end of light bar  1  enabling it to fit standard light fixtures. Lens  5  is typically a translucent plastic usually of a white color, but could be created in other colors or made water clear. 
         [0044]    Now referring to  FIG. 2 , is shown more detail of the end of light bar  1 . Particularly are shown connecting adapters  14 ,  15 , and  16 . Each of the adapters have their own respective pins  26 ,  27 , and  28 , which are both standard sizes to the lighting industry and are all made of electrically nonconductive materials. End pins  26  could be made of metal, but would not be connected to any electrical circuit. Pins  26 ,  27 , and  28  are meant to be both an adaptive element in order to adapt to existing electrical hardware while also forming a structural element to hold the light bar  1  in an existing lamp fixture (not shown). Dovetail  21  is a common geometric detail of end adapters  14 ,  15 , and  16  and can be received in the direction of arrow  25  by a mating dovetail  20  which is part of base adapter  2 ,  3 . The open side of dovetail  20  is always radially located to the same side as lens  5  so as to maintain the securest attachment when light bar  1  is located overhead using base adapters  14 ,  15 ,  16 . Base adapters  14 ,  15 , and  16  are meant to be used as respective pairs when used with light bar  1 . Light bar  1  is also meant to be used independent of base adapters  14 ,  15 ,  16  in another embodiment. 
         [0045]    Referring now to  FIG. 3 , shown is a side view A-A of adapter base  16 . Common geometry to all interchangeable base adapters  14 ,  15 ,  16  are dovetail  21  locking boss  22 . As any one of base adapters  14 ,  15 ,  16  are a mated with base end  2 ,  3  via dovetail  20 ,  21  locking feature  22  received by notch  27 . Locking feature  22  and notch  27  are created such that the adapter base  14 ,  15 ,  16  can be released again from end base  2 ,  3  by finger pressure pushing them apart. 
         [0046]    Referring now to  FIGS. 4, 5, and 6 , shown is a perspective view of LED light bar  1  along with its respective SECTION VIEWS B-B and C-C. Mounting of light bar  1  to an existing light fixture (not shown) is accomplished by the use of mounting clip  6 ,  8  in two positions along with threaded fasteners  53 ,  54 . Now with regards to  FIG. 5 , SECTION B-B is showing geometric details of metal extrusion  9  which embodies symmetric and opposite grooves  31 ,  32  and  35 ,  36  the purpose of which are then shown in  FIG. 6 , SECTION C-C. Clip  6  has legs,  40 ,  41 , which can flex slightly in direction of arrow  49 . The flexure of legs  40 ,  41  allows these to open as they slide over metal extrusion  9 . Legs  40 ,  41  are then biased allowing feet  33 ,  34  to engage into grooves  31 ,  32  and hold light bar,  1  in place. Grooves  31 ,  32  run the length of light bar  1  and allow a pair of mounting clips  6 ,  8  to be positioned in any practicable position along metal extrusion  9  in the directions of arrow  50 . Flexibility of legs  40 ,  41  also allow for the light bar  1  to be detached from clip  6 ,  8  without having to remove threaded fasteners  53 ,  54 . To ease overhead installation, holes  108 ,  109  in clips  6 ,  8 , have a geometric star pattern  110  that protrudes within holes  108 ,  109 . Pattern  110  allows fasteners  53 ,  54  to be started into holes  108 ,  109  and held by their threads as a self-holding method. 
         [0047]    Now referring to  FIGS. 7, 8, 9  are shown only the metal extrusion  9  and base cap  2 . Base cap  2 ,  3  are used to close the entire light bar assembly  1  without adhesives or threaded fasteners. Fastening of end base  2  to extrusion  9  or end base  3  to extrusion  9  is accomplished using snap geometric features. Legs  63 ,  64 ,  65  are flexible members allowing them some bias ability. Boss features  60 ,  66 ,  67  communicate and are received in extrusion holes  61 ,  68 , and  69  ( 69  not shown, but exactly opposite of hole  68 ,  FIG. 8 ) when moved together in the direction shown by arrow  70 . Biasing from legs  63 ,  64 ,  65  keep boss features  60 ,  66 ,  67  in their respective holes. Completed mate of end base  2  and extrusion  9  is shown in perspective view  FIG. 9 . Opposite end of extrusion  9  of light bar  1  is assembled in exactly the same way between extrusion  9  and end base  3 . 
         [0048]    Referring to  FIG. 10 , what is shown in  FIG. 10  is multi-clip adapter  90  holding a pair of light bars  1  on angles relative to one another and base feature  96  (end base  2  is not shown on the right side of  FIG. 10 ). In one embodiment, the multi-clip  90  is adapted to hold a pair of light bars  1  at a 90° angle relative to one another, 45° relative to the Base features  96 . 
         [0049]    Multi-clip  90  adapts light bar  1  in situations where a direction of light beams are required for best implementation of light bar  1 . Multi-clip  90  has legs  92 ,  93  which can flex slightly in direction of arrow  98 . The flexure of legs  92 ,  93  allows these to open as they slide over metal extrusion  9 . Legs  92 ,  93  are then biased allowing feet  94 ,  95  to engage into grooves  31 ,  32  of extrusion  9  (see  FIG. 5 ) and hold light bar,  1  in place. Grooves  31 ,  32  run the length of extrusion  9  of light bar  1  and allow a pair of mounting multi-clips  90  to be positioned in any practicable position along metal extrusion  9  in the direction of its length  8 . Multi-clip  90  has a planar mounting surface  97  that can be attached to any other planar mounting surface with threaded fasteners, adhesives, or similar fasteners known in the art. Base features  96  could be of other geometric shapes (i.e., curved) to allow for mounting to surfaces other than planar ones. 
         [0050]    Referring now to  FIGS. 11, 12, and 13  is rotational adapter base  80  comprising base adapter  83  and rotating head  88 . Similar to adapter bases  14 ,  15 ,  16 , adapter base  83  has dovetail  21  for mating with base adapter  2 ,  3  and their dovetail  20 . Rotating head  88  has an integral axle  86  that is received by bore  85  in base adapter  83 . Axle  86  and bearing  85  allows a relative rotation of rotating head  83  to base adapter  83  shown by centerline  81  and curved arrow  84 . When a pair of rotational base adapters  80  is mated with LED light bar  1 , the light can be rotated to a position for optimum lighting of an area. A ball detent  82  enables a temporary locking feature between rotating head  88  and rotational adapter base  83  to predetermined angles relative to one another. Rotation head  88  is held to adapter base  83  by hex threaded fastener  87  along with biasing belleville washer  86 . 
         [0051]    Referring to  FIGS. 14 and 15 , they show an existing light fixture  101  with tombstone electrical fitting  102  along with light bar  1 .  FIG. 14  and  FIG. 15  depict how an existing light fixture  101  can be retrofitted with light bar  1 . Tombstone  102  could be used with a pair of adapter bases  14 ,  15  or  16  attached to end base  2 ,  3  of light bar  1 . In  FIGS. 21 and 22 , tombstones  102  are left in place in fixture  101 , but not utilized. Light bar  1  is installed using clips  6 ,  8  and self-tapping hex screws  53 ,  54 . Power supply  103  is positioned and DC wires  104  are electrically interconnected to the circuitry in light bar  1  with quick connectors  105  and  106 . 
         [0052]    Referring now to  FIGS. 16 through 21  what is shown is an embodiment of a Clip  120  adapted for a wide light distribution and an embodiment of a Clip  130  adapted for a narrow light distribution. Turning to  FIG. 16 , Clips  120  are integrated into a fixture  140  and adapted to hold light bars  1  at an angle relative to each other. In this illustrated embodiment the light bars  1  are at a 90° relative to each other, 45° relative to the fixture. Those of ordinary skill in the art will understand that the structure of the Clip  120  may be adapted for other angles as needed. 
         [0053]      FIG. 17  is a side-view of the Clip  120 . The Clip  120  has legs  122 ,  123  which are operable to flex slightly in the direction of arrows  129  and open as the legs  122 ,  123  slide over metal extrusion  9 . The legs  122 ,  123  are then biased allowing feet  124 ,  125  to engage into grooves  31 ,  32  of extrusion  9  (see  FIG. 5 ) and hold light bar  1  in place. In one embodiment the leg  123  is longer than the leg  122 , and includes an extension  123   a  such that the area defined by the legs  122 ,  123  may receive hold the light bar  1 , though the light bar  1  may not fill a substantial portion of the area defined by the legs  122 ,  123 . 
         [0054]    Clip  120  has a Base Feature  126  and fasteners  127 ,  128  that are adapted to fasten the Clip  120  to a fixture. In one embodiment the fasteners  127 ,  128  are leaf springs. The Clip  120  may be inserted to a through-hole in the fixture  140  such that the back surface of the fixture  140  firmly abuts the top surface of the Base feature  126 , and fasteners  127 ,  128 , which flex slightly, bias against the front surface of the fixture  140 , pinching the fixture  140  between the fasteners  127 ,  128  and the Base feature  126 . Other fastening techniques known in the art may be used instead of or in addition to those described herein, by way of non-limiting example, adhesives, bolts, screws, and the like. 
         [0055]      FIG. 18  is a perspective-view of the Clip  120  illustrated in  FIG. 17 . 
         [0056]    Referring now to  FIG. 19 , what is shown is an embodiment of a Clip  130  adapted for a narrow light distribution. Clips  130  are integrated into a fixture  140  and adapted to hold light bars  1  vertically, parallel to each other. 
         [0057]      FIG. 20  is a side-view of the Clip  130 . The Clip  130  has legs  132 ,  133  which are operable to flex slightly in the direction of arrows  139  and open as the legs  132 ,  133  slide over metal extrusion  9 . The legs  132 ,  133  are then biased allowing feet  134 ,  135  to engage into grooves  31 ,  32  of extrusion  9  (see  FIG. 5 ) and hold light bar  1  in place. In one embodiment the legs  132 ,  133  are substantially the same length. 
         [0058]    Clip  130  has a Base Feature  136  and fasteners  137 ,  138  that are adapted to fasten the Clip  130  to a fixture. In one embodiment the fasteners  137 ,  138  are leaf springs. The Clip  130  may be inserted to a through-hole in the fixture  140  such that the back surface of the fixture  140  firmly abuts the top surface of the Base feature  136 , and fasteners  137 ,  138 , which flex slightly, bias against the front surface of the fixture  140 , pinching the fixture  140  between the fasteners  137 ,  138  and the Base feature  136 . Other fastening techniques known in the art may be used instead of or in addition to those described herein, by way of non-limiting example, adhesives, bolts, screws, and the like. 
         [0059]      FIG. 21  is a perspective-view of the Clip  130  illustrated in  FIG. 15 . 
         [0060]    Referring now to  FIGS. 22A and 22B , which show the Clip  120  inserting into the through-holes  141  of the Fixture  140 .  FIG. 22A  is a perspective view of the Clip  120  being inserted into a through-hole  141  along a trajectory  142 .  FIG. 22B  illustrates the Clip  120  inserted into the through-hole  141  and fastened to the fixture  140 . 
         [0061]      FIG. 23  illustrates a new fixture with an angled clip and a vertical clip installed and retaining LED light bars, according to an embodiment of the disclosure. 
         [0062]    Once being apprised of this disclosure, one of ordinary skill in the art would be readily able to make and use the various embodiments of the disclosure. By way of non-limiting example, various embodiments of the disclosure facilitate ability to install light bars in fixtures to change light output, offer different kelvin options from stock that could be used as an LED light, quickly offer many different fixture types, facilitate procuring fixtures from many different sources, and change the beam pattern to meet utility requirements by utilizing clips without needing to change a fixture. 
         [0063]    Various embodiments of the disclosure include both a method for the practice of replacing fluorescent tubular lamps with LED light bars while also describing the devices that provide the means of adapting the LED light bars into existing lamp fixtures. 
         [0064]    Although operation illustrated by or in connection with  FIGS. 1 through 23  and accompanying text recites acts performed in a particular order, embodiments of the present disclosure do not necessarily need to operate in that recited order. One of ordinary skill in the art would recognize many variations, including performing acts in parallel, or in a different order. 
         [0065]    While certain illustrative embodiments have been described in connection with the figures, those of ordinary skill in the art will recognize and appreciate that the scope of this disclosure is not limited to those embodiments explicitly shown and described in this disclosure. Rather, many additions, deletions, rearrangements and other modifications to the embodiments described in this disclosure may be made to produce embodiments within the scope of this disclosure, such as those specifically claimed, including legal equivalents. In addition, features from one disclosed embodiment may be combined with features of another disclosed embodiment while still being within the scope of this disclosure, as contemplated by the inventors. As such, the invention is not to be defined only by the preceding illustrative description, but only by the claims which follow, and legal equivalents thereof.

Technology Classification (CPC): 5