Patent Description:
Light Emitting Diode (LED) can provide instant illumination with no warm-up required. LED luminaires are engineered to provided maintenance-free operation while delivering long life and high lumen performance. Luminaries feature custom optics designed to maximize light distribution and intensity while providing flexibility for retrofits or new installations throughout a site.

Light emitted from LED luminaires can be distributed in predetermined orientations and patterns for an illuminated area. Luminaries may have three optical options designed to maximize light distribution and intensity. The pattern of the illuminated area by LED luminaries is established by the Illumination Engineering Society of North American (IESNA). IESNA Type I provides an optic pattern that is a long and rectangular light distribution that can be ideal for hallways, walkways, loading docks, catwalks, etc. IESNA Type-III provides an optic pattern that has a three-way light distribution and is ideal for narrow crosswalks, passages with wall mounted fixture, tunnels with wall mount, etc. IESNA Type-V provides an optic pattern that is a regular circular distribution pattern ideal for high/low bay indoor and outdoor ceilings, pendants, large buildings, warehouses, etc..

Light distribution from luminaries may be offset or incorrectly positioned with respect to a road, sidewalk, etc. As such, IESNA Type-I and IESNA Type-III optic patterns can be adjusted in the field as desired.

<CIT> discloses a light fixture including a LED and a pivotable optic.

There is a need for improved flexibility when adjusting light beam outputs of luminaries.

The present disclosure relates generally to a "clocking" mechanism that give customers the flexibility to adjust light output distribution for luminaires to a desired level or orientation so that a given light distribution pattern effectively illuminates a
desired location. The "clocking" mechanism gives the flexibility to adjust a position of a retainer ring of a LED system with respect to a mounting module that includes a heat sink adapter housing.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad concepts upon which the embodiments disclosed herein are based.

The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:.

Reference will now be made in detail to the exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like structure.

<FIG> illustrate an example light system <NUM>. The light system <NUM> includes a driver compartment <NUM>, a heat sink adapter housing <NUM> (e.g., housing), and a LED system <NUM> (e.g., light engine). The driver compartment <NUM> is configured to house a driver assembly (not shown) that can include a power supply and enable operation thereof. In certain examples, the light system <NUM> can be mounted to a ceiling, a wall, or other structure via a mounting bracket (not shown) secured to the driver compartment <NUM>. It will be appreciated that the light system <NUM> includes a front side configured to face away from a wall or ceiling to which the light system <NUM> mounts, and a back side configured to face toward the wall or ceiling to which the light system <NUM> mounts.

The heat sink adapter housing <NUM> can be coupled to the driver compartment <NUM> to be fixed thereto. The heat sink adapter housing <NUM> includes a plurality of parallel-oriented fins <NUM> that are integrally formed with a base <NUM> to ensure good thermal conductivity. Any heat generated by the LED system <NUM> can be drawn into the heat sink adapter housing <NUM> to dissipate the heat. That is, the heat sink adapter housing <NUM> acts as a heat spreader (thermally conductive) to distribute heat and to provide a relatively large surface area for allowing heat to be transferred to the surrounding air. The heat sink adapter housing <NUM> may be made of aluminum, brass, copper, polymer steel, or any other material that is thermally conductive. The base <NUM> of the heat sink adapter housing <NUM> has a front surface <NUM> that provides a mounting platform <NUM> for the LED system <NUM>. The LED system <NUM> can be removably mounted to the front surface <NUM> of the heat sink adapter housing <NUM> by one or more fasteners <NUM> (see <FIG>).

Turning to <FIG>, an exploded view of the LED system <NUM> is shown. The LED system <NUM> can include a baseplate <NUM>, a retainer ring <NUM>, and a LED sub-assembly <NUM>. The LED sub-assembly <NUM> can include a printed circuit board assembly (PCBA) <NUM> and optics <NUM>. The optics <NUM> can include one or more light emitting diodes (LEDs) <NUM> coupled to a substrate <NUM>. The PCBA <NUM> can provide the necessary electrical connections to the optics <NUM> and other electrical components of the light system <NUM>.

The baseplate <NUM> includes an outer surface <NUM> that may be covered by a thermal pad <NUM>. Adhesive on the thermal pad <NUM> glues the thermal pad <NUM> to the outside surface <NUM> of the baseplate <NUM>. The optics <NUM> and the PCBA <NUM> can be fastened together to the baseplate <NUM> with a plurality of screws <NUM> to fix the optics <NUM> relative within the LED system <NUM>.

A first gasket <NUM> may be disposed in a groove <NUM> in the outer surface <NUM> of the baseplate <NUM>. The first gasket <NUM> may be pressed into the groove <NUM> to create an environmental seal with a back side of an outer flange <NUM> of a protective lens <NUM> when the retainer ring <NUM> is attached to the baseplate <NUM>. The retainer ring <NUM> can be attached to the baseplate <NUM> via one or more screws <NUM> with a second gasket <NUM> located between the retainer ring <NUM> and a front side of the outer flange <NUM> of the lens <NUM>. The first and second gaskets <NUM>, <NUM> can provide a seal as shown in <FIG> that provides suitable ingress protection against solids and liquids (i.e., intrusion of dust, dirt, accidental contact, and water) into a compartment defined by the protective lens <NUM>.

As indicated above, the LED system <NUM> may also include the lens <NUM> having an outer flange disposed (e.g., clamped) between the baseplate <NUM> and the retainer ring <NUM>. The lens <NUM> may at least partially surround the optics <NUM> and the PCBA <NUM> and enclose them on the baseplate <NUM>. The lens <NUM> may be made of any at least partially transparent or translucent material, including glass and hard plastics, so as to enable light to be emitted from the light system <NUM>. The lens <NUM> may also provide a protective barrier for the optics <NUM> and shield the optics <NUM> from moisture or inclement weather. The retainer ring <NUM> is configured to secure together all the components of the LED system <NUM>. The one or more screws <NUM> mount the retainer ring <NUM> to the baseplate <NUM> to form the LED system <NUM> as a fixed unit.

In operation, the optics <NUM> can emit light so that the light system <NUM> can illuminate a required or desired area. The light emitted from the optics <NUM> can be distributed in predetermined orientations and patterns for the desired illuminated area. That is, the light system <NUM> may be configured for a specific light distribution profile to project a predetermined pattern of light onto a surface (e.g., a walkway, roadway).

Referring to <FIG>, one classification system that is used to describe the pattern of the illuminated area by the light system <NUM> is established by the Illumination Engineering Society of North American (IESNA). IESNA Type I beam pattern has a long and rectangular pattern that is used when the light system <NUM> is placed near the center of a pathway and provides lighting for narrower paths or roadways. IESNA Type III beam pattern has a bent pattern that is used when the light system <NUM> is placed towards one side of a pathway and provides lighting that projects more outward. IESNA Type V beam pattern has a regular circular pattern that is used for large buildings, warehouses, processing mills, and industrial plants. <FIG> show the example IESNA Type I, III, V optics 126a-c that can be used in the light system <NUM>.

Referring to <FIG>, illustrates multiple views of the retainer ring <NUM>. The retainer ring <NUM> includes four equally spaced mounting regions <NUM> around an outer periphery <NUM> of the retainer ring <NUM>. The retainer ring <NUM> can rotate about a central axis X of the light system <NUM>. The mounting regions <NUM> can allow adjustable rotation of the retainer ring <NUM> by at least <NUM> degrees to change the light distribution illumination direction of the light system <NUM>. In certain examples, the retainer ring <NUM> can be rotated between <NUM> degrees and <NUM> degrees to change the light distribution of the light system <NUM>.

The mounting regions <NUM> of the retainer ring <NUM> can be used to attach the LED system <NUM> to the front surface <NUM> of the heat sink adapter housing <NUM> via the one or more screws <NUM>. The screws <NUM> may be fitted into screw holes <NUM> (e.g., internally threaded holes, openings, see <FIG>) on the front surface <NUM> of the heat sink adapter housing <NUM>. In certain examples, the retainer ring <NUM> may be shaped and sized to engage a cavity <NUM> (see <FIG>) defined in the heat sink adapter housing <NUM> when the LED system <NUM> is attached thereto.

The mounting regions <NUM> can each include a plurality of discrete openings <NUM>, although alternatives are possible. The plurality of discrete openings <NUM> are spaced apart equally in an arcuate array and are located near the outer periphery <NUM> of the retainer ring <NUM>. In certain examples, the mounting regions <NUM> can each include a slot opening <NUM> (see <FIG>). The mounting regions <NUM> are diametrically positioned about the retainer ring <NUM> and are identical to each other. Thus, only one mounting region <NUM> will be described in detail or referred to. Each of the mounting regions <NUM> can correspond to a circumferential flange segment <NUM>. The circumferential flange segments <NUM> can be separated by projections <NUM>. In one example, the plurality of discrete openings <NUM> are not internally threaded and are slightly oversized with respect to the shanks of the fasteners <NUM>.

The front surface <NUM> of the heat sink adapter housing <NUM> defines at least four screw holes <NUM> that are equally spaced about the heat sink adapter housing <NUM>. The screw holes <NUM> can each be aligned with a corresponding one of the plurality of parallel-oriented fins <NUM> of the heat sink adapter housing <NUM>. For example, the four screw holes <NUM> can be defined in a respective one of the plurality of parallel-oriented fins <NUM>. In certain examples, each screw hole <NUM> corresponds to one of the mounting regions <NUM>.

In certain examples, there are at least six openings <NUM> per mounting location <NUM> for each of the screw holes <NUM> of the heat sink adapter housing <NUM>. In certain examples, there are at least seven openings <NUM> per mounting location <NUM> for each of the screw holes <NUM> of the heat sink adapter housing <NUM>. In certain examples, there are at least eight openings <NUM> at each mounting location <NUM> for each of the screw holes <NUM> of the heat sink adapter housing <NUM>. In certain examples, there are at least nine openings <NUM> at each mounting location <NUM> for each of the screw holes <NUM> of the heat sink adapter housing <NUM>. In certain examples, there are at least ten openings <NUM> at each mounting location <NUM> for each of the screw holes <NUM> of the heat sink adapter housing <NUM>.

Although the mounting regions <NUM> are shown on the retainer ring <NUM> and the screw holes <NUM> are defined by the heat sink adapter housing <NUM>, the reverse could be provided. That is, the mounting regions <NUM> can be defined by the heat sink adapter housing <NUM> and the screw holes <NUM> can be defined by the retainer ring <NUM>.

Referring to <FIG>, when the LED system <NUM> is mounted to the heat sink adapter housing <NUM>, one of the plurality of discrete openings <NUM> of the retainer ring <NUM> can be respectively aligned with one of the screw holes <NUM> of the heat sink adapter housing <NUM>. To secure the LED system <NUM> to the heat sink adapter housing <NUM>, one of the fasteners <NUM> can be inserted axially through one of the plurality of discrete openings <NUM> and threaded into the screw holes <NUM> of the heat sink adapter housing <NUM>. This engagement prevents any movement of the LED system <NUM> relative to the heat sink adapter housing <NUM>.

Because luminaires are generally placed alongside walkways or conveyer locations where light distribution may not be fully utilized with respect to a road, "clocking" mechanisms can be provided to give a customer flexibility to adjust the light distribution to provide illumination in a desired direction, orientation, or level.

The retainer ring <NUM> may be configured to alter or otherwise modify the light emitted by the optics <NUM>. When a customer desires to "clock" a luminaire or adjust the lighting path or pattern of the optics <NUM> of the light system <NUM>, the LED system <NUM> may be rotated relative to the heat sink adapter housing <NUM>. The amount of rotation needed to achieve a desired light distribution can be determined by using the retainer ring <NUM>. Rotating the retainer ring <NUM> also rotates the baseplate <NUM>, the PCBA <NUM>, and the optics <NUM> of the LED system <NUM>. Because the optics <NUM> can rotate with the retainer ring <NUM>, the illumination direction of the light emitting pattern of the light system <NUM> can be adjusted.

To adjust the illumination direction of the light system <NUM>, the fasteners <NUM> are first completely removed from a respective one of the plurality of discrete openings <NUM> of the retainer ring <NUM> and the screw hole <NUM> of the heat sink adapter housing <NUM>. This allows the LED system <NUM> to be removed from the heat sink adapter housing <NUM> to allow the LED system <NUM> to be rotated relative to the heat sink adapter housing <NUM> to adjust the clock face position and thus the direction of illumination of the light system <NUM>. The plurality of discrete openings <NUM> of the retainer ring <NUM> allow the LED system <NUM> to be moved in discrete increments to achieve a desired light distribution in the field that can yield optimal performance. For example, the plurality of discrete openings <NUM> of the retainer ring <NUM> can be rotated in a clockwise or counterclockwise direction relative to the screw hole <NUM> of the heat sink adapter housing <NUM> to change the light distribution illumination direction by increments of the plurality of discrete openings <NUM>. That is, the direction in which light distribution of the light system <NUM> shines can be adjusted as the retainer ring <NUM> of the LED system <NUM> is rotated such that a different one of the plurality of discrete openings <NUM> of the retainer ring <NUM> can be aligned to the screw hole <NUM> of the heat sink adapter housing <NUM>.

Turning again to <FIG>, the plurality of discrete openings <NUM> may be spaced no more than <NUM> degrees apart with respect to the central axis X of the light system <NUM>. In certain examples, the plurality of discrete openings <NUM> may be spaced no more than <NUM> degrees apart with respect to the central axis X of the light system <NUM>. In certain examples, the plurality of discrete openings <NUM> may be spaced no more than <NUM> degrees apart with respect to the central axis X of the light system <NUM>. As such, the light distribution illumination direction can be change by relatively small increments (e.g., increments less than or equal to about <NUM>, <NUM>, or <NUM> degrees).

After the desired adjustment is made, the fasteners <NUM> can be reinserted through the selected one of the plurality of openings <NUM> of the retainer ring <NUM> and threaded into the screw hole <NUM> of the heat sink adapter housing <NUM>. This process of "clocking" allows for easy adjustment of luminaires in the field without having to remove the one or more screws <NUM> that seal the LED system <NUM>. The screws <NUM> keep the LED system <NUM> fastened and sealed such that the LED system <NUM> is not loosened or broken open to give risk to any ingress protection.

Referring to <FIG>, an alternative LED system 106a is depicted. To the extent that the embodiments are similar, the description will not be repeated and will instead be directed to the primary differences. Specifically, the LED system 106a differs in how the retainer ring 120a mounts to the baseplate 118a. For example, adhesive tape <NUM> can be used to secure the retainer ring 120a and the baseplate 118a together. As such, there is a reduction in parts as the screws <NUM> are replaced by the adhesive tape <NUM>. The adhesive tape <NUM> can be a double-sided adhesive film. In certain examples, the adhesive tape <NUM> can have a tensile load capacity of <NUM> to <NUM> Newtons (N). In certain examples, the adhesive tape <NUM> preferably has a tensile strength of about 300N to about 350N.

According to an aspect which does not form part of the claimed invention, the LED system 106a differs from the LED system <NUM> shown in <FIG> in that the mounting regions 148a of the retainer ring 120a include the slot openings <NUM> versus discrete openings, although it will be appreciated that the discrete openings described above can be used. The fastener 116a can be inserted through the slot opening <NUM> of the retainer ring 120a and into the screw hole <NUM> of the heat sink adapter housing 104a to attach the LED system 106a to the heat sink adapter housing 104a.

The slot openings <NUM> defined in the retainer ring 120a allow the LED system 106a to be "clocked" in a desired direction relative to the heat sink adapter housing 104a by loosening, but not removing, the fastener 116a positioned within the slot openings <NUM> of the retainer ring 120a. The fastener 116a can be backed out of the slot opening <NUM> so that ¼ inch to ½ inch of thread is showing to allow the LED system 106a to be rotated relative to the heat sink adapter housing 104a up to about <NUM> degrees to change the light distribution. In certain examples, the "clocking" direction can include at least about <NUM> degrees of adjustability.

Claim 1:
A light system (<NUM>) comprising:
a driver compartment assembly (<NUM>);
a heat sink adapter housing (<NUM>) fixed to the driver compartment assembly (<NUM>), the heat sink adapter housing (<NUM>) defining a plurality of openings that are each internally threaded;
a light engine (<NUM>) adapted to be removably attached to the heat sink adapter housing (<NUM>), the light engine (<NUM>) including:
a baseplate (<NUM>);
optics (<NUM>) coupled to the baseplate (<NUM>);
a retainer ring (<NUM>) removably mounted to the baseplate (<NUM>), the retainer ring (<NUM>) including a plurality of mounting regions (<NUM>) circumferentially positioned thereabout, wherein the plurality of mounting regions (<NUM>) each include a plurality of discrete openings (<NUM>) spaced apart equally in an arcuate array, each of the plurality of mounting regions (<NUM>) corresponding to a circumferential flange segment (<NUM>) of the retainer ring (<NUM>), the circumferential flange segments (<NUM>) of the retainer ring (<NUM>) being separated by projections (<NUM>), the plurality of discrete openings (<NUM>) being defined through the circumferential flange segments (<NUM>), respectively; and
a lens (<NUM>) having an outer flange (<NUM>) disposed between the baseplate (<NUM>) and the retainer ring (<NUM>), the lens (<NUM>) at least partially surrounding the optics (<NUM>) to enclose the optics (<NUM>) on the baseplate (<NUM>);
wherein the retainer ring (<NUM>) is rotatable relative to the heat sink adapter housing (<NUM>) in discrete increments via the plurality of discrete openings (<NUM>), the plurality of discrete openings (<NUM>) of the plurality of mounting regions (<NUM>) each respectively corresponding to one of the plurality of openings (<NUM>) of the heat sink adapter housing (<NUM>), wherein the optics (<NUM>) rotate with the retainer ring (<NUM>) to change the light distribution illumination direction emitted by the optics (<NUM>).