Patent Abstract:
An externally adjustable directional canopy luminaire is disclosed that may be easily and quickly adjusted from the outside of its housing to direct light toward a particular target area. The luminaire includes a lamp shroud assembly including a door frame, a shroud and a lamp socket which is connectable to an electrical power source to power a replaceable lamp, an external adjustment member, and an internal mechanism movably connected to the external adjustment member through the shroud and indirectly connected to a portion of the lamp socket, wherein adjustment of the external adjustment member can alter the angle of direction of the lamp socket and thus the direction of light emitted from the replaceable lamp through the opening of the shroud.

Full Description:
CROSS REFERENCE TO RELATED APPLICATION 
   The present application claims the benefit of co-pending U.S. provisional patent application 60/737,304, filed Nov. 16, 2005. 

   FIELD OF THE INVENTION 
   This invention relates generally to luminaires and more particularly to luminaires adapted to direct light in a desired direction. 
   BACKGROUND OF THE INVENTION 
   Luminaires are used in many commercial and consumer venues to illuminate particular areas of a site, such as lighting for a service station, storefront or restaurant, and are typically mounted on or within a support structure such as a ceiling, canopy structure or building exterior. 
   Luminaires of currently existing designs are typically mounted on their support structures either by direct attachment to the structure or by creating an opening and installing the recessed luminaire into the opening. A typical drawback associated with many existing luminaires is that the lamp is mounted in a fixed position on or within the support structure, thereby prohibiting redirection of the light emanating from the lamp toward specific, desired areas below. Although lenses can be used to direct the light toward a particular area and focus the light output downward, a substantial portion of the luminous output of the lamp is nevertheless emitted in other directions. 
   Some existing luminaires permit movement of the luminaire body to direct the light output, most notably track lighting. However, such existing luminaires are not designed to withstand outside environments, such as weather and insects. Further, many have limitations in the rotational range of the lamps and cannot be easily locked into place. U.S. Pat. No. 6,802,627 to Fischer (“the &#39;627 patent”) discloses an adjustable canopy luminaire capable of withstanding outdoor use. However, the luminaire of the &#39;627 patent can only be tilted to a fixed predetermined angle relative to the opening by opening the door of the luminaire and then lifting and placing the lamp edge on tabs that are located within the housing. Thus, the luminaire of the &#39;627 patent provides only a limited number of angles for aiming the lamp, and it is not possible to adjust the lamp from the outside of the housing. 
   Another common problem with canopy luminaires is the amount of electricity consumed by the lamp and the complexity of the lamp&#39;s electrical system. While a variety of types of lighting lamps can be used, including common fluorescent and incandescent lamps, luminaires in commercial applications often use high intensity discharge (HID) lamps to provide the desired level of lighting. The use of HID light sources can have many drawbacks. HID light sources are regulated by control gear, which may include a ballast alone or in combination with other components such as capacitors, igniters, or other such equipment. This control gear may be as large as or larger than the lamp itself. Further, the lamp and control gear are frequently contained within a box-like housing, which must be mounted to the support structure. HID light sources also use more electricity than lighting alternatives. 
   One other drawback associated with existing canopy luminaires, again relating to the difficulty in directing the light output toward the intended area, involves the need for using a larger lamp, such as a HID lamp, to provide the desired level of lighting. As the lens cannot efficiently direct the high intensity light to specific areas, much of the light is scattered toward unintended local and distant destinations. This scattering results in light pollution issues ranging from the disturbance of neighbors to interference of night sky viewing. 
   Thus, there is a substantial need for a luminaire that has increased adjustability over the prior art. It would also be advantageous to provide an externally adjustable luminaire that is easily and quickly adjusted from the outside of the luminaire housing. It would also be advantageous to provide an externally adjustable luminaire that can be aimed through its opening in an infinite number of angles and directions. There also exists a substantial need for a luminaire that may be easily and quickly adjusted to direct light toward a particular target area without scattering light to unintended areas. Further, there is a significant need for a luminaire that is capable of using a smaller lamp and consuming less electricity in its operation while providing the same degree of illumination. 
   SUMMARY OF THE INVENTION 
   The present invention provides a luminaire which overcomes drawbacks associated with the currently existing luminaires. More specifically, one aspect of the present invention is an adjustment mechanism for directing the emitted light from a lamp of a luminaire, the luminaire comprising a luminaire support structure; a door frame attached to the structure; a lamp shroud assembly comprising a shroud rotatably attached to the door frame and having an opening, and a lamp socket sized to receive the base of a replaceable lamp and electrically connectable to an electric power source, the adjustment mechanism comprising a movable external adjustment member and an internal mechanism attached to the external adjustment member through the shroud and indirectly connected to a portion of the lamp socket, the internal mechanism being movable in response to movement of the external adjustment member, wherein movement of the external adjustment member can change the angle of direction of light emitted from the replaceable lamp through the opening of the shroud. 
   Another aspect of the present invention is an externally adjustable directional luminaire comprising a luminaire support structure; a door frame attached to the structure; a lamp shroud assembly comprising a shroud rotatably attached to the door frame and having an opening, and a lamp socket sized to receive the base of a replaceable lamp and electrically connectable to an electric power source; an external adjustment member located on the outside surface of the shroud; and an internal mechanism movably connected to the external adjustment member through the shroud at one end and connected to the lamp socket at another end, the internal mechanism being movable in response to movement of the external adjustment member, wherein movement of the external adjustment member alters the angle of direction of light emitted from the replaceable lamp through the opening of the shroud. 
   In the various embodiments of the present invention, the lamp socket and the lamp are typically directed toward the opening of the shroud, and the opening is typically not perpendicular to the support structure, although it can be perpendicular thereto. Further, the rim edge of the shroud is typically formed with a projection to limit rotation of the shroud within the door frame to a maximum of a single revolution. Still further, the opening of the shroud can be covered by a lens. 
   The internal mechanism typically comprises a non-rotatable adjustment brace to receive the external adjustment member, a lever connected to the non-rotatable adjustment brace by a brace pin, a fulcrum mounted on the inner wall of the shroud and connected to the lever by a fulcrum pin, at least one mounting bracket connected to the lever by a bracket pin, a directional lamp harness mounted to the light supporting means and connected to the at least one mounting bracket by a bracket connector, and an internal support base mounted proximate the opening of the shroud and connected to the directional harness by a harness connector. 
   In one embodiment, the external adjustment member can be a threaded member, such as a bolt, rotatably received by a portion of the internal mechanism, whereby rotation of the threaded member is operable to cause the internal mechanism to move the lamp socket. The movement of the lamp socket by the internal mechanism can be with or without a mechanical advantage. In a particular embodiment, the external adjustment member can comprise a turnbuckle assembly, whereby screwing and unscrewing of the external adjustment member is operable to cause the internal mechanism to move the lamp socket. 
   In yet another embodiment, the external adjustment member can be a handle, wherein the internal mechanism comprises a rod connected to the handle at a first end and pivotally connected to the lamp socket at a second end, whereby pushing and pulling of the handle causes the internal mechanism to move the lamp socket. 
   The nature and advantages of the present invention will be more fully appreciated from the following drawings, detailed description, and appending claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention. 
       FIG. 1  is a partial cross-sectional side view of one embodiment of the lamp shroud assembly and door of the present invention. 
       FIG. 2  is a partial cross-sectional side view of the lamp shroud assembly and door of  FIG. 1  after external adjustment of the lamp. 
       FIG. 3  is a bottom perspective view of one embodiment of the lamp shroud assembly and door of the present invention. 
       FIG. 4  is a perspective view of a lamp as it sits within the lamp shroud assembly and door. 
       FIG. 5  is a top perspective view of the door frame and shroud in an open position away from the luminaire support structure. 
       FIG. 6  is a partial cross-sectional side view of another embodiment of the lamp shroud assembly and door of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The externally adjustable directional luminaire  10 , as depicted in  FIG. 1 , comprises a door frame  12 , a rotatable shroud  14  having an opening  16 , and a lamp socket  18  associated with the shroud and sized to receive the base of a replaceable lamp  20 . The door frame  12  comprises at least one hinge  22  at one end, a clamp bar  24  at the other end, and a retaining lip  26  which defines a hole in the door  12 . The shroud  14  comprises a rim edge  28  that is of substantially similar dimension to the retaining lip  26  of the door frame  12 . The rim edge  28  of the shroud  14  extends over and is received by the retaining lip  26  of the door frame  12 , thereby securing and permitting rotation of the shroud  14  within the door frame  12 . The lamp  20  can be adjusted externally by turning an external adjustment member  30 , which includes an elongated shaft  31  that cooperates with an internal mechanism to move the lamp socket  18  and lamp  20  along line  200  at an angle θ relative to the central axis  100  of the opening  16  of the shroud  14 . The lamp  20  as shown is a reflector type or PAR lamp, but could be any type of lamp, including a HID, fluorescent or incandescent lamp associated with a separate reflector to direct the light along axis  200 . 
   Looking now at  FIG. 2 , the external adjustment member  30  including the elongated threaded shaft  31  is rotatably secured to the shroud  14  at a first end by a first securing means  32 A. Threaded shaft  31  is threadably attached to a non-rotatable securing means  33  and a non-rotatable adjustment brace  34 , and is prevented from being threadably separated from the non-rotatable adjustment brace  34  at a second end by a second securing means  32 B. A lever  36  is pivotally connected near its mid-point to the non-rotatable adjustment brace  34  by brace pin  37 . Fulcrum  38 , mounted on the inner wall of the shroud  14 , is pivotally connected to one end of the lever  36  by fulcrum pin  39 , and a mounting bracket  40  is pivotally connected to the other end of the lever  36  by bracket pin  41 . A directional lamp harness  42  is mounted over the lamp socket  18  and lamp  20  and is pivotally connected at a position along its length to the mounting bracket  40  by bracket connector  43 . An internal support base  44  is mounted proximate the opening  16  of the shroud  14  and is pivotally connected to the proximal end of the directional harness  42  by harness connector  45 . A spring  46  extends from the fulcrum  38  to the distal end of the lamp harness  42 , and serves to stabilize the lamp  20  as it assumes its various positions within the shroud  14 . 
   It can be appreciated from  FIG. 2  that the lamp  20 , which was aimed to direct light out of the opening  16  of the shroud  14  along line  200  and at an angle θ from the axis  100  of the shroud  14  in  FIG. 1 , is now aimed to direct light out of opening  16  along line  200  and at a different angle θ from the axis  100  of the shroud  14  in  FIG. 2 . This change in the angle θ is accomplished by external manipulation of the adjustment member  30  by a user. In practice, the shaft  31  of adjustment member  30  acts directly upon the non-rotatable adjustment brace  34 , which is part of an internal mechanism, whereby rotation of the external adjustment member  30  causes the shaft  31  to be screwed into or out of (depending upon which direction one turns) the non-rotatable adjustment brace  34 , starting a chain of events which ultimately moves the replaceable lamp  20  through angle θ with a mechanical advantage. More specifically, as the shaft  31  is screwed out of the securing means  33  of the non-rotatable brace  34 , lever  36  is pushed in an inward direction away from the shroud  14 . Lever  36  then causes mounting bracket  40  to pivot about bracket pin  41 . Mounting bracket  40 , connected to the directional lamp harness  42  via bracket connector  43 , pivots about the harness connector  45 , which is stationary and connected to the stationary internal support base  44 . 
   Thus, internal support base  44  acts as a fulcrum for the harness  42 , and since the harness  42  is rigidly secured to the lamp socket  18 , then the lamp socket  18  (and also the lamp  20 ) will move with the harness  42  as it pivots about the support base  44 . A mechanical distance advantage is gained because a relatively short distance of movement of the non-rotatable securing means  33  and adjustment brace  34  along the shaft  31  results in a larger distance of movement of the mounting bracket  40 , and in turn, the distance of movement of the bracket connector  43  results in an even larger distance of movement of the socket  18 . Therefore, the lamp socket  18  and lamp  20  are caused to move a relatively large distance (through angle θ) upon movement of the external adjustment member  30  a short distance, resulting in a mechanical advantage. Thus, the lamp  20  can be aimed along an infinite amount of lines  200  at an angle θ from the axis  100  of the shroud  14 , and a user can easily adjust the vertical direction of the light coming from the luminaire from outside the housing of the luminaire. Typically the angle θ can be altered by a user from between about −35° to about +35°, more typically from between about −20° to about +20°, relative to the axis  100  of the shroud. 
     FIG. 3  illustrates a bottom perspective view of one embodiment of the luminaire  10  of the present invention, showing the door  12 , the shroud  14  with its opening  16 , hinges  22 A and  22 B at one end, the clamp bar  24  at the other end, external adjustment member  30  housing the elongated shaft  31  on the outside of shroud  14 , and a securement  50  on the outside of the door  12 . The securement, shown as screw  50 , whose function will be explained in more detail below, is tightened or loosened as desired in order to restrict or allow rotation of the shroud  14  within the door  12 . It can be appreciated from viewing  FIG. 3  that the external adjustment member  30  and screw  50  are both accessible to a user from the outside of the shroud  14 . Thus, the door  12  docs not need to be opened in order to adjust the vertical direction of light coming from the opening  16 , or to adjust the horizontal direction in which the opening  16  of the shroud  14  is aimed, in relation to the door  12 . 
     FIG. 4  is a perspective view of the lamp socket  18  and lamp  20  as they associate with the shroud  14 . The non-rotatable adjustment brace  34  can be seen as it receives the external adjustment member  30 . The directional lamp harness  42  is mounted over the lamp socket  18  and lamp  20 , and connected to the mounting bracket  40  by bracket connector  43  and to the internal support base  44  by harness connector  45 . Electrical wiring  56  exits the top of the lamp socket  18  and passes through the lamp harness  42  on its way to a connection (not shown) with second electrical wiring  57 . Second electrical wiring  57  is received by a second socket  59 , which is connected to a power source. Spring  46  extends from the fulcrum  38  to the distal end of the lamp harness  42 , and serves to stabilize the lamp  20  as it assumes its various positions within the shroud  14 . A top clamp  52  contacts the rim edge  28  of the shroud. Securement or screw  50  extends from beneath the door frame  12  and is threaded through an opening in the top clamp  52 . Upon tightening of the screw  50 , the top clamp  52  presses the shroud  14  and the door frame  12  together and frictionally restricts rotational movement of the coupled shroud  14  and door frame  12 . A plurality of guides  54  are secured with a screw into the door frame  12 , and flexibly contact the rim edge  28  to stabilize the movement of the shroud  14  as it rotates about the retaining lip  26  of the door frame  12 . 
   As illustrated in  FIG. 5 , the directional luminaire assembly is shown coupled with a luminaire housing structure  58 . Electrical wiring  56  exits the lamp socket  18  and passes through a housing opening  60  and is connected to the electrical power source, accessible through the housing opening  60 . The luminaire is connected to the housing structure  58  via hinges  22 A,  22 B on one end and a flexible clamp mechanism on the other end, including a receiving flexible clamp  62  and the clamp bar  24  that fits into and is held by the clamp  62 . 
     FIG. 6  illustrates another embodiment of the luminaire of the present invention, in which the external adjustment member  130  with its elongated shaft  131  is part of a turnbuckle assembly associated with another embodiment of the internal mechanism which includes a non-movable nut  132  rigidly connected to turnbuckle bar  134 . The shaft  131  of the external adjustment member  130  is rotatably secured to the shroud  14  by securing means  133 . Turnbuckle pin  136  pivotally connects the turnbuckle bar  134  to the lamp socket  18 . In use, screwing and unscrewing of the shaft  131  via member  130  causes the internal mechanism to laterally move the lamp socket  18  and lamp  20 . Typically, the lens end of the lamp  20  is fixed in position proximate the opening  16  of the shroud  14 . More specifically, as member  130  is turned, the elongated shaft  131  is screwed into or out of the non-movable nut  132  (depending on which direction the member  130  is turned), causing the turnbuckle bar  134  to laterally push or pull the lamp socket  18 . Thus, as the lamp  20  is moved by the turning of the external adjustment member  130  from a first position in which light is aimed along line AA to a second position (shown in phantom) in which light is aimed along line BB, it can be positioned at any position along angle CC, so that the desired vertical direction of the light coming from the shroud is achieved. In the embodiment shown in  FIG. 6 , retaining clips  138  and  142  are located on either side of the lamp  20  in order to stabilize and fix the position of the lens end of the lamp. Support  140  anchors the retaining clips  138 ,  142  within the shroud  14 . 
   In an alternative embodiment (not shown), the external adjustment member can be a simple handle and the internal mechanism can be a rod pivotally connected to the lamp socket at one end and linearly connected to the handle at another end, whereby pushing and pulling of the handle causes the internal mechanism to laterally pivot or move the lamp socket. With this embodiment, like the embodiment of  FIG. 6 , the linear movement of the internal mechanism caused by movement of the external adjustment member is equivalent to the angular movement of the lamp socket, providing no mechanical advantage. 
   In the various embodiments of the present invention, the lamp socket  18  and the lamp  20  are typically directed toward the opening  16  of the shroud  14 , and the opening  16  is typically not perpendicular to the support structure. However, embodiments of the luminaire are envisioned in which the opening is perpendicular to the support structure. Assuming that the support structure is typically parallel with the ground so that a vertical line passing from support to the ground is an angle of 0°, then the angle of the line  100 , which corresponds to the axis of the shroud  14 , is typically at an angle from about 10° to about 80° from vertical, more typically about 30° to 60°. The external adjustment means of the present invention further allows the line  200  of light emitted from lamp  20  to be altered at an angle θ from line  100 . Typically the angle θ can be altered by a user from between about −35° to about +35°, more typically from between about −20° to about +20°, relative to the axis  100  of the shroud. Further, the shroud  14  can be rotated up to 360° within the door frame  12 . The rim edge  28  of the shroud  14  is typically formed with a projection to limit rotation of the shroud  14  within the door frame  12  to a single revolution. Still further, the opening of the shroud  14  can be covered by a lens. 
   While the present invention has been illustrated by description of several embodiments which have been described in detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages will readily appear to those skilled in the art. Thus, the invention in its broadest aspects is not limited to the specific details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from the details without departing from the spirit or scope of applicant&#39;s general inventive concept.

Technology Classification (CPC): 5