Patent Document

CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation in part of application Ser. No. 12/197,436 filed on Aug. 25, 2008 which claims the benefit of Provisional 60/993,559 filed Sep. 13, 2007 which claims priority to U.S. application Ser. No. 11/282,274 filed Nov. 18, 2005, now U.S. Pat. No. 7,524,083 the entire contents of which is hereby expressly incorporated by reference herein. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable 
       INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    1. Field of the Invention 
         [0006]    This invention relates to improvements in replaceable high by lighting. More particularly the present screw-in inductive replacement light is an adapter for high bay lighting to accept a threaded base inductive lamp. 
         [0007]    2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98 
         [0008]    Lighting is used to provide light when it is dark or to provide supplemental lighting for a dark area. Often in large buildings, overhead lighting is provided from lights placed near the ceiling of the building and the light is directed downward. Most light bulbs used in these lighting installations are inefficient, and a portion of the energy used in these lights is expended in heat. In the summer, the heat must be cooled with the building air conditioning system. The maintenance cost of these bulbs is also high due to the cost of government imposed lamp disposal fee, the short lifespan and the rapid degradation of 30 to 40% after a year. What is needed is a new lighting fixture that includes a retrofit kit that converts a high bay lighting fixture to a threaded base and further includes an inductive lighting element that can be secured within the retro fit kit. The retrofit kit and or the inductive lighting fixture may further include the dome that can easily be replaced with existing fixtures simply by having a new energy efficient fixture. The invention proposed provides a solution to all the listed requirements. 
         [0009]    U.S. Pat. No. 5,497,048 issued to Burd is for a fluorescent bulb that has multiple fluorescent elements located within the light bulb. This invention provides the equivalent energy efficiency and an equivalent amount of light, but the bulb is a custom light bulb, and the light bulb is not manufactured in high volume. The invention does not provide multiple efficient light bulbs that are cost effective and readily available. 
         [0010]    U.S. Pat. No. 5,541,477 issued to Maya et al. is for a single fluorescent bulb that also has multiple fluorescent bulb elements that are connected into a single screw-in base. This invention provides the equivalent energy efficiency and the equivalent amount of light, but the bulb is a custom light bulb, and the light bulb is not manufactured in high volume. The invention does not provide multiple efficient light bulbs that are cost effective and readily available. 
         [0011]    U.S. Pat. No. 4,664,465 issued to Johnson et al. is for a bulb with a clip attached that allows the bulb to be attached to a metal strip. The patent covers the clip connected to a hollow tube that can extend from a vertical or horizontal surface. This invention uses a single bulb connected to an elongated metal tube or neck. The invention is intended for wiring to an electrical power source. The invention does not include multiple light sockets that connect into a base that can be screwed into a lamp base. 
         [0012]    U.S. Pat. No. 6,964,502 issued to Neal R. Verfuerth on Nov. 15, 2005 discloses a retrofit fluorescent light tube fixture apparatus. While this retrofit apparatus that fits into older fluorescent fixtures it simply replaces one fluorescent lighting fixture with another fluorescent lighting fixture that is prone to the same efficiencies and life expectancy of that it replaces. 
         [0013]    U.S. Pat. No. 7,070,303 issued to Charles E. Kassey et al. on Jul. 4, 2006 discloses a fluorescent lighting fixture with improved up lighting the bulb receiving portion of the fixture is curved so the outer bulbs have a reflector that is not parallel with the ground. While this configuration provide for more up lighting the illumination elements are still fluorescent bulbs. 
         [0014]    The ideal product would allow for modification of a high bay lighting fixture to accept screw-in lighting elements. The ideal product would further include a fixture that accepts inductive lighting elements and creates a threaded base that is securable into the converted lighting fixture. 
       BRIEF SUMMARY OF THE INVENTION 
       [0015]    It is an objective of the screw-in inductive replacement light to provide an energy efficient lighting system that replaces custom high bay lighting fixtures with a retro fit base that converts the hardwired high bay lighting fixture into a socketed fixture where lighting elements can be quickly installed, replaced or upgraded without requiring the services of an electrician. 
         [0016]    It is an objective of the screw-in inductive replacement light to provide an energy efficient lighting system that replaces custom high bay lighting fixtures with an adapter for inductive lamps. The adapter allows for quick changing of inductive lamps to replace, change the output rating and upgrade the lamp as technology improves inductive lighting elements. 
         [0017]    The fixture may also include a dome or other reflector or fixture design to focus the light downward. A standard 100-watt incandescent bulb uses 100 watts of energy, a fluorescent light (or inductive light) bulb that provides the same amount of light only requires about 20 to 25 watts of energy. Fluorescent light consume 45 to 50% less energy than a standard incandescent light bulb. The light from fluorescent light is similar or superior to the light from an incandescent light, and can be tinted to provide different shades to simulate other lighting sources. The fixture requires the installation onto the rafters or ceiling of the building where it is installed to produce light that is emitted above and below the lighting fixture as well as out the sides of the lighting fixture. A reflector dome or cover located in the lighting fixture helps to focus the lighting down to where the light is needed. An inductive light source provides an improved lighting source 20 to 30% brighter than standard fluorescent bulbs with increased efficiency and 50% longer bulb life. 
         [0018]    A warehouse typically uses 450-465 watt incandescent, halogen or similar light bulb and ballast system. The proposed invention replaces the single 400-watt light bulb with five fluorescent or inductive self ballasting fluorescent lights providing the same or more illumination. The standard warehouse light uses 450-465 watts to produce the light. The five self ballasting fluorescent lights only require 240 to 250 watts of energy. An inductive light source only requires 200 to 220 watts of energy to produce the same amount of illumination, saving 170 to 255 watts of energy that would be spent in heat. A 400 watt metal halide light operates at 1750 degrees of heat, where a fluorescent or inductive lamp operates at 190 to 210 degrees. Inside an air conditioned building the 170 to 255 watts of heat would need to be cooled with the air conditioning system within the building. The savings come from three places, first the more efficient lights, second from air conditioning costs and third, from less maintenance costs. In addition, there can be safety benefits from less ultraviolet rays, and for less chance that the fluorescent bulbs will explode. Inductive lighting provides improved efficiency and savings where a standard warehouse light uses 450-465 watts to produce the light. One to three inductive lights may require as little as 200 watts of energy to produce more light than a standard warehouse light and will provide saving of 250 to 265 watts of energy and 1500 degrees of heat would be spent in heat. Inside an air conditioned building the 1750 degrees of heat would need to be cooled with the air conditioning system within the building. The savings come from three places, first the more efficient lights, and second from air conditioning costs, induction lamps further reduce re-lamping costs by 500%, or mounted separately to 600% reduce, and third the maintenance and government imposed hazardous waste disposal costs. 
         [0019]    One problem with placing a torus lighting element within the dome is the shadow that exists from the light of the lighting element blocking the light emitted from the back side of the lighting element. Different light diameters and different dimensions will yield varying reflective angles that will reflect the light from behind the lighting element to the front of the lighting fixture to eliminate the shadow that can be appear under the lighting dome. The internal geometry to minimize or eliminate the shadow. The proposed lighting apparatus minimizes the blocked light by reflecting light around the torus, inductive lighting element. 
         [0020]    Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         [0021]      FIG. 1  is a sectional view of a high bay lighting fixture using inductive lighting elements. 
           [0022]      FIG. 2  is a detailed cross sectional view of the lighting fixture from  FIG. 7  showing the retaining tab. 
           [0023]      FIG. 3  is a perspective view of the lighting fixture showing the arrangement of the components. 
           [0024]      FIG. 4  is a view showing the light transmission and reflection rays of the dome and deflector 
           [0025]      FIG. 5  is a sectional view of a 2 foot×2 foot lighting fixture using an inductive lighting element. 
           [0026]      FIG. 6  is a perspective view looking up into the 2 foot×2 foot inductive lighting fixture. 
           [0027]      FIG. 7  shows an exploded perspective view of the components for the screw-in inductive lamp and fixture. 
           [0028]      FIG. 8  shows an assembled perspective view of the components for the screw-in inductive lamp and fixture. 
           [0029]      FIG. 9  shows a back perspective view of the cap. 
           [0030]      FIG. 10  shows a front perspective view of the cap. 
           [0031]      FIG. 11  shows a perspective view of the mid base adapter. 
           [0032]      FIG. 12  shows a perspective view of the lamp holder. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0033]      FIG. 1  shows a sectional view of a bay lighting fixture using inductive lighting elements  200 . The reflective or focusing dome  10  directs light from the lighting elements  202  and  204  downward so more of the light shines where desired. This figure show two lighting elements of different size, but the size, shape and output illumination of the lighting elements can be the same or different depending upon the desired amount of light that is required. The reflective or focusing dome  10  is attached to the housing with clips or fasteners  230 . The dome rests on the dome retainer  220 , where gravity and the retaining tab  230  lock the dome in place. The shape and configuration of these clips is shown and described in more detail with  FIG. 2  below. The dome retainer is connected or integrated with a connecting tube  250  that supports the lighting and dome in addition to providing a conduit for wiring. The connecting tube  250  is attached to the ballast enclosure. In some configurations contemplated, the ballast box may be empty, when the ballast is included with the lighting elements. The ballast  240  is shown housed in the ballast box  210 . One configuration of electrical connection to the ballast is with screw terminals  245 , but the wiring connection(s) could be made with wire nuts or spring clips where the wires are pushed into the terminals and retained by spring force that both retain the wires and provide electrical connection between the ballast and the external wiring. An electrical connection from the ballast extends through connecting tube  250 , into the dome retainer  220  for connection with the lighting elements  202 ,  204  or lighting socket for the lighting elements. Locking bars  270  and  275  hold the inductive lighting elements in place within the dome and on the lower cover  260  that is capped with an extender  262 , and an extender cap  264 . The extender allows the placement and retention of the additional lighting element  204  that holds locking bar  275 . 
         [0034]    A lower cover  260  encloses the lower portion of the housing to protect the electrical wiring. The ballast box  210 , dome retainer  220 , and the lower cover  260  can be fabricated using a number of different methods including but not limited to casting, machining, drawing, forming or molding. In the preferred embodiment the part are made from an injection molded process. The materials for these components can also be variety of types including but not limited to plastics, resins, ceramic, ferrous and non-ferrous materials, with the qualities of strength, heat resistance. A safety locking mechanism  285  is installed on the end of retaining cable  280  to hold the light fixture in position. While in this figure the retaining mechanism  285  is shown extended from the cable  280 , upon installation the safety device is secured against the bottom of the lighting fixture. 
         [0035]      FIG. 2  is a detailed cross-sectional view of the lighting fixture from  FIG. 1  showing the retaining tab  230 . The reflective or focusing dome  10  is shown resting upon a portion of the dome retainer  220 . For installation, the dome is brought over the dome retainer  220 , the retaining tabs  230  will flex inward from the hinge area  234  allowing the dome  10  to pass by the clip, and then spring back into position locking the dome  10  under the tab at point  232 . Once the dome is in position, gravity, in addition to the clips  230  will keep the dome resting on the dome retainer at location  236  and all around the dome retainer. The lower housing  260  is shown in position under the dome retainer protecting the wiring connections. Vent  29  is shown in this view as it passes through the dome retainer. The vents are a critical part of the design because they allow heat from the room and from the lights to vent out of the fixture. 
         [0036]      FIG. 3  is a perspective view of the lighting fixture showing the arrangement of the components. A retaining cable  280  passes through the entire lighting fixture and is secured with a safety line  285  located at the end of the cable. The top portion of the cable  280  is attached to a hook  290  that can be secured to the ceiling or joists of a building. The bottom portion  297  of the hanging hook  290  is secured to the ballast box with a nut  292  that is threaded onto the end of the hook at  297  from inside the ballast box. In an alternate mounting embodiment the hook  294  is connected to the top of the dome retainer  220 . The dome  10  is shown below the dome retainer  220 . A seams  221 ,  223 ,  227  are shown in this figure. The seam allows the dome retainer to be fabricated in multiple sections that can be connected. In the embodiment shown, the dome retainer is made from four pieces. In another contemplated embodiment, the dome retainer and at least a portion of the ballast box is made from a single component. The enclosure for ballast is shown located above the lighting fixture with a top housing  212 , of the ballast box  210  and an access cover  217 . In this embodiment the top and bottom housings are connected with a hinged arrangement with a closure. In yet another contemplated embodiment, the ballast box dome retainer and connecting pipe are made in two halves. This view shows the dome retainer essentially as a dish shape but other similar shapes can be used. The lower cover  260  is shown under the dome and it is attached to the dome retainer. The design of the lower cover is critical to the transmission of light around the lighting element(s). A description of the design requirement to reflect light around the lighting elements is shown and described with  FIG. 4 . The extender  262  is shown below the lower cover and attaches to the lower cover. The extender cap  264  is shown below the extender and closes the opening in the bottom of the extender  262 . 
         [0037]    The disk shape is ideal because it allows for any heat to be channeled up through the lighting fixture. Vents  29  are shown around the dome retainer. In the embodiment shown the vents are essentially rectangular in shape, but other shapes are contemplated to include but not be limited to rectangular, circular, elliptical vents or combination thereof. 
         [0038]      FIG. 4  is an isometric view of a one piece light dome  10  with a separate ballast box  210 . In this embodiment the dome is cast from a clear, multi-colored, translucent, or opaque material and is then internally coated or painted with an aluminum or chrome to provide a reflective surface. The dome is made from a polycarbonate abs or other similar material as opposed to being cast or spun out of aluminum or other metal. The ballast box  210  is shown mounted separately from the lighting dome, and prototypes have been made with a separation of 15 feet between the ballast and the lighting elements. The wiring from the buildings electrical system  6  enters into the ballast box  210  and, after the voltage is converted, a separate set of wiring  5  connects to the lighting fixture  10 . This entire lighting system is attached to the ceiling or joist  28  of the building from hooks  35 , chain  40  and or hooks integrated into the lighting or ballast enclosure  290 . 
         [0039]      FIG. 5  is a sectional view of a 2 foot×2 foot lighting fixture  200  using an inductive lighting element. While the majority of fluorescent fixtures are configured in a 2 foot by four foot configuration a number of fluorescent fixtures are 2 foot by 2 foot in size. In this embodiment the reflector is a bent reflector  100  is formed from sheet metal. The inside surface of this reflector is preferably painted white or other similar reflective color or a silver color to reflect the light. The inductive lighting element  202  is attached to the bent reflector with clips or fasteners. It is also contemplated that the lighting fixture is clamped through the bent reflector  100  using the cover and the ballast box. 
         [0040]    The connecting tube  250  is attached to the ballast enclosure. In some configurations contemplated, the ballast box may be empty, when the ballast is included with the lighting elements. The ballast  240  is shown housed in the ballast box  210 . One configuration of electrical connection to the ballast is with screw terminals  245 , but the wiring connection(s) could be made with wire nuts or spring clips where the wires are pushed into the terminals and retained by spring force that both retain the wires and provide electrical connection between the ballast and the external wiring. An electrical connection from the ballast extends through connecting tube  250 , into the dome retainer  220  for connection with the lighting elements  202  or lighting socket for the lighting elements. In the preferred embodiment the lighting element is torus shaped. Locking bars  270  hold the inductive lighting elements in place within the dome and on the lower cover  260  that is capped with an extender  262 . 
         [0041]    A lower cover  260  encloses the lower portion of the housing to protect the electrical wiring. The materials for these components can also be variety of types including but not limited to plastics, resins, ceramic, ferrous and non-ferrous materials, with the qualities of strength, heat resistance. A safety locking mechanism  285  is installed on the end of retaining cable  280  to hold the light fixture in position. While in this figure the retaining mechanism  285  is shown extended from the cable  280 , upon installation the safety device is secured against the bottom of the lighting fixture. 
         [0042]      FIG. 6  is a perspective view looking up into the 2 foot×2 foot inductive lighting fixture. The fixture is constructed with a bent metal reflector  100 . While a bent metal reflector is shown and described, because it is the most common and cost effective, other materials are contemplated including but not limited to glass, paper and plastics. The sides of the reflector  100  are bent to ensure more of the light shines downward. Inside the reflector the top of the fixture has an inside bend  110  to spread the light from the top of the inductive lighting element  202 . This figure shows the electromagnet(s)  160  that encircle a portion of the illumination torus. The end of the extender  262  can be seen extending through the inductive lighting element  202 . Locking bar(s)  270  hold the inductive lightning element  202  in the fixture and provide some protection from vibration and shock. 
         [0043]      FIG. 7  shows an exploded perspective view of the components for the screw-in inductive lamp and fixture.  FIG. 8  shows an assembled perspective view of the components for the screw-in inductive lamp and fixture. In this preferred embodiment the fixture is actually two assemblies that convert the wiring  6  of a structure to accept a first threaded base  130 . A mating second threaded base  142  allows for an inductive lighting element to be secured into the first threaded base. From these  FIGS. 7 and 8  wiring  6  from the building or structures&#39; electrical system is brought in the lower cover  260 . This lower cover is the same component that is shown and described in  FIGS. 1 and 5 . The lower cover  260  has a plurality of mounting holes  261  that allows the lower cover to be secured to an electrical junction box on a ceiling, wall or other structural support. An extender cap  264  is secured into the lower cover  260 . 
         [0044]    The extender cap  264  is used in two placed in  FIGS. 7 and 8 . The extender cap is shown and described in more detail in  FIGS. 9 and 10  where  FIG. 9  shows a back perspective view of the cap while  FIG. 10  shows a front perspective view of the cap. The extender cap  264  has hook tabs  120  that engage into openings  121  in the extender  262 . The extender cap  264  further has an annular lip  126  that limits how far the extender cap  264  can be inserted into the extender  262 . The extender cap  264  has a central hole  125  for electrical wires to pass through the extender cap  264 . The extender cap  264  further has two pairs of holes  123  and  124  that are sized to accept #6 screws  124  and #8 screws  123 . When screws are placed through the appropriate holes a lamp holder with bushings  130  is secured to the extender cap  264 . 
         [0045]      FIG. 12  shows a perspective view of the lamp holder  130 . The lamp holder  130  has an internal threaded socket that accepts a typical household threaded lamp. The lamp holder is secured to the extender cap  264  using screws that secure the lamp holder  130  in the #6-32 retaining holes with screws  134 . The electrical wiring connects to conductor  131  and the internal thread area. An adapter mid base adapter  140  is threaded into the lamp holder  130  to provide electrical connection to a lighting element  202 . 
         [0046]      FIG. 11  shows a perspective view of the mid base adapter  140 . The mid base adapter  140  has an end conductor  143  that connects to the conductor  131  in the lamp holder  130 . The threaded base  142  of the mid base adapter  140  makes contact with the mating threads of the lamp holder  130 . A plurality of side openings  141  in the mid base adapter provide openings for the hook tabs  265  of the extender  262  to engage into. 
         [0047]    The extender  262  extends and connects the mid base adapter  140  to a second extender cap  264 . A locking bar  270  is captured between the mid base adapter  140  and the extender cap  264  in a saddle area  266  in the extender and with a complimentary saddle in the extender cap  264 . Locating holes  271  in the locking bar  270  are located onto tabs  127  (shown in  FIGS. 9 and 10 ) to locate, position and secure the locking bar from movement. 
         [0048]    Thus, specific embodiments of a screw-in inductive replacement light have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.

Technology Category: 2