Note: Descriptions are shown in the official language in which they were submitted.
CA 02893062 2015-05-29
LUMINAIRE
BACKGROUND
[0001] The present application relates generally to lighting fixtures and
particularly to a
luminaire.
[0002] Conventional luminaires include a housing supporting a light
assembly including one
or more light-emitting diodes or LEDs. The light assembly is in electrical
communication with
an electrical power source. Each LED generates heat, which is transferred to a
heat sink in order
to maintain an optimum operating temperature and efficiency of the LEDs. In
some applications,
it can be difficult to generate sufficient air flow to cool the heat sink,
which impacts the
performance of the luminaire.
SUMMARY
[0003] In one aspect, a luminaire includes a housing, a heat sink, and a
light assembly. The
housing includes a pair of elongated, parallel legs and a cross-member
extending between the
legs. The cross-member defines a first surface and a second surface opposite
the first surface,
and the first surface includes an opening. The heat sink is coupled to the
housing proximate the
second surface of the cross-member. The heat sink is positioned between the
legs and the heat
sink includes a plate and a fin array. The plate defines a first surface and a
second surface
opposite the first surface, and the fin array including a plurality of fins
protruding from the first
surface. The light assembly is coupled to the second surface of the heat sink
and includes at least
one light-emitting element.
100041 In another aspect, a luminaire includes a housing, a heat sink, a
circuit board, and a
lens. The housing includes a first surface and a second surface opposite the
first surface. The
first surface includes an opening configured to receive an electrical conduit
coupled to an
electrical source. The heat sink is supported on the housing proximate the
second surface and
the heat sink includes a first side defining a mounting surface and a second
side defining a fin
array. The circuit board includes at least one light-emitting element and is
coupled to the
mounting surface. The lens extends over the circuit board and is coupled to
the mounting
surface independently of the circuit board.
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[0005] In yet another aspect, a luminaire includes a housing, a heat sink,
and a light
assembly. The housing includes a first portion and a second portion. The first
portion has a first
surface and a second surface spaced apart from and opposite the first surface.
The first portion
defines a first axis extending from the first surface to the second surface.
The first surface
includes an opening configured to receive an electrical conduit coupled to an
electrical source.
The first surface defines an uppermost portion of the housing. The heat sink
is supported by the
housing proximate the second surface, and the heat sink includes a plate and a
fin array
protruding from a surface of the plate. The plate has a first end, a second
end, a first edge
extending between the first end and the second end, and a second edge
extending between the
first end and the second end. The fin array defines at least one air flow
channel having an inlet
positioned proximate the first side of the plate. The light assembly includes
at least one light-
emitting element and a lens, and the light assembly is coupled to a surface of
the plate opposite
the fin array.
100061 In still another aspect, a luminaire includes a housing, a heat
sink, a seal, and a light
assembly. The housing includes a main body and a support bracket. The main
body includes an
opening configured to receive an electrical conduit coupled to an electrical
source. The heat sink
is removably coupled to the support bracket, and the heat sink including a
plate and a fin array.
The plate includes a first surface and a second surface, and the fin array
protrudes from the first
surface. The seal is positioned between the heat sink and the main body to
thermally insulate the
main body relative to the heat sink. The light assembly is coupled to the
second surface of the
plate, and includes at least one light-emitting element and a lens.
100071 In yet another aspect, a luminaire includes a housing, a heat sink,
and a light
assembly. The housing includes a main body having an internal compartment. The
main body
includes a first surface and a second surface spaced apart from and opposite
the first surface. A
first axis extends between the first surface and the second surface. The main
body further
includes a first end and a second end, and a second axis extends between the
first end and the
second end and is oriented perpendicular to the first axis. At least one of
the first end and the
second end includes an opening to permit access to the internal compartment.
The heat sink is
coupled to the main body proximate the second surface and is positioned along
the first axis.
The heat sink includes a plate and a fin array. The plate includes a first
surface and a second
2
surface, and the fm array protrudes from the first surface. The light assembly
is coupled to the second
surface of the plate and includes at least one light-emitting element and a
lens.
[0007A] In a broad aspect, the present invention pertains to a luminaire
comprising a housing including
a pair of elongated, parallel legs and a cross-member extending between the
legs. The cross-member
defines a first surface and a second surface spaced apart from the first
surface, the first surface including
an opening. Each leg includes an inner surface and a lower extend and at least
one groove extending
between the inner surface and the lower extent. A heat sink is coupled to the
housing and is positioned
proximate the second surface of the cross-member. The heat sink is positioned
between the inner surface
of the legs, and includes a plate and a fin array. The plate defines a first
surface and a second surface
opposite the first surface, and the fin array includes a plurality of fins
protruding from the first surface, the
fin array defining at least one air flow channel having an inlet and an
outlet. A light assembly is coupled
to the second surface of the heat sing, the light assembly including at least
one light-emitting element.
The groove directs air flow from below the housing toward the at least one air
flow channel, and each leg
includes an outer surface facing away from the other leg, at least one of the
outer surfaces including an
opening to permit access to an internal compartment of the housing.
[0007B] In a further aspect, the present invention provides a luminaire
comprising a housing, including
a pair of elongated, parallel legs and a cross-member extending between the
legs. The cross-member
defines a first surface and a second surface spaced apart from the first
surface, the first surface including
an opening. Each leg includes an inner surface and a lower extent and at least
one groove extends
between the inner surface and the lower extent. There is a heat sink coupled
to the housing and
positioned proximate the second surface of the cross-member, the heat sink
being positioned between the
inner surface of the legs and including a plate and a fin array. The plate
defines a first surface and a
second surface opposite the first surface, the fin array including a plurality
of fins protruding from the
first surface, and defining at least one air flow channel having an inlet and
an outlet. A light assembly is
coupled to the second surface of the heat sink and includes at least one light-
emitting element. The
groove directs air flow from below the housing toward the at least one air
flow channel, and the fin array
defines at least one air flow channel extending from a first edge of the heat
sink to a first end of the heat
sink, the air flow being directed from the first edge of the heat sink and
toward the first end of the heat
sink.
2a
Date Recue/Date Received 2021-10-14
[0007C] In a still further aspect, the present invention provides a luminaire
comprising a housing,
including a first portion and a second portion, the first portion having a
first surface and a second surface
spaced apart from the first surface. The first portion defines a first axis
extending between the first
surface and the second surface, the first surface including an opening
configured to receive an electrical
conduit in electrical communication with a power source, the first surface
defining an uppermost portion
of the housing. There is a heat sink supported by the housing and positioned
proximate the second
surface, the heat sink including a plate and a fm array protruding from a
surface of the plate. The plate
has a first end, a second end, a first edge extending between the first end
and the second end, and a second
edge extending between the first end and the second end. The fin array defines
at least one air flow
channel having an inlet positioned proximate the first edge of the plate and
an outlet positioned proximate
one of the first end and the second end of the plate. A light assembly
includes at least one light-emitting
element and a lens, the light assembly coupled to a surface of the plate
opposite the fin array. The first
portion of the housing includes a first side wall and a second side wall. The
first side wall and the second
side wall extend between the first surface and the second surface. The heat
sink defines a heat sink axis
extending between the first end of the plate and the second end of the plate,
the first end of the heat sink
extending beyond the first side wall of the housing and the second end of the
heat sink plate extending
beyond the second side wall of the housing.
2b
Date Recue/Date Received 2021-10-14
[0008] Other aspects will become apparent by consideration of the detailed
description and
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a luminaire.
[0010] FIG. 2 is a lower perspective view of the luminaire of FIG. 1.
[0011] FIG. 3 is a side view of the luminaire of FIG. 1.
[0012] FIG. 4 is atop view of the luminaire of FIG. L
[0013] FIG. 5 is a bottom view of the luminaire of FIG. 1.
[0014] FIG. 6 is a section view of the luminaire of FIG. 4 viewed along
section 6--6.
[0015] FIG. 7 is an exploded perspective view of the luminaire of FIG. 1.
[0016] FIG. 8 is a lower perspective view of a housing.
[0017] FIG. 9 is a perspective view of a heat sink.
[0018] FIG. 10 is a lower perspective view of the heat sink of FIG. 9.
[0019] FIG. 11 is a top view of the heat sink of FIG. 9.
[0020] FIG. 12 is a top view of the heat sink of FIG. 9 and a support
bracket.
DETAILED DESCRIPTION
[0021] Before any embodiments are explained in detail, it is to be
understood that the
invention is not limited in its application to the details of construction and
the arrangement of
components set forth in the following description or illustrated in the
following drawings. The
invention is capable of other embodiments and of being practiced or of being
carried out in
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Date Recue/Date Received 2021-10-14
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various ways. Also, it is to be understood that the phraseology and
terminology used herein is
for the purpose of description and should not be regarded as limiting. Use of
"including" and
"comprising" and variations thereof as used herein is meant to encompass the
items listed
thereafter and equivalents thereof as well as additional items. Use of
"consisting of' and
variations thereof as used herein is meant to encompass only the items listed
thereafter and
equivalents thereof. Unless specified or limited otherwise, the terms
"mounted," "connected,"
"supported," and "coupled" and variations thereof are used broadly and
encompass both direct
and indirect mountings, connections, supports, and couplings.
[0022] FIGS. 1-5 illustrate a luminaire 10 for an industrial application,
such as illuminating a
parking garage. The luminaire 10 includes a housing 100, a heat sink 200, and
a light assembly
300 (FIGS. 2 and 5). In the illustrated embodiment, the housing 100 includes a
main body 104
generally forming an H-shape having a pair of legs 108 and a cross-member 112.
The cross-
member 112 forms a first portion of the main body 104. The cross-member 112
includes a first
or upper surface 116 and a second or lower surface 120 (FIGS. 1 and 3)
opposite the upper
surface 116. The upper surface 116 includes an opening 122 (FIGS. 1 and 4),
and an electrical
connector 20 passes through the opening 122. The connector 20 is coupled to an
electrical
source (e.g., a junction box, a pendant, a rigid electrical conduit, etc. ¨
not shown) and provides
electrical communication between the source and the luminaire 10.
[0023] Referring to FIGS. 1-3, the legs 108 form second portions, and each
leg 108 defines
an upper extent 124 and a lower extent 128. A light sensor 132 (FIGS. 2 and 3)
is positioned on
the lower extent 128 of one leg 108. A first axis 136 extends through the
upper surface 116 and
the lower surface 120 of the cross-member 112, and the cross-member 112
extends in a direction
that is perpendicular to the first axis 136. Unless otherwise specified, as
used herein the term
-axial" and its variants refer to a direction that is parallel to the first
axis 136.
[0024] The lower surface 120 of the cross-member 112 is spaced apart from
the upper
surface 116 of the cross-member 112. The lower surface 120 of the cross-member
112 is axially
offset from the upper extents 124 and the lower extents 128 of the legs 108.
The upper surface
116 of the cross-member 112 defines a first plane, the lower extents 128 of
the legs 108 define a
second plane, and the lower surface 120 of the cross-member 112 is positioned
between the first
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plane and the second plane. In the illustrated embodiment, the upper surface
116 of the cross-
member 112 is also positioned above the upper extents 124 of the legs 108. In
addition, the
cross-member 112 includes side walls 140 extending between the upper surface
116 and the
lower surface 120.
[0025] The legs 108 of the housing 100 are positioned on opposite sides of
the cross-member
112, and each leg 108 extends along a leg axis 144 (FIGS. I and 2)
perpendicular to the cross-
member 112 axis. Each leg 108 extends beyond the side walls 140 of the cross-
member 112,
such that each end of the leg 108 is laterally spaced apart from a
corresponding side wall 140.
[0026] As shown in FIG. 6, each leg 108 defines an internal compartment or
chamber 148.
In one embodiment, the internal chamber 148 of one leg 108 includes one or
more controllers or
drivers, and the internal chamber 148 of the other leg 108 includes various
sensors and
accessories. Each leg 108 also includes an outer surface or outer side wall
152 and an inner
surface or inner side wall 156. The outer side wall 152 may define an opening
to permit access
to the internal chamber 148, and the housing 100 further includes a removable
cover 164 to
selectively close the opening. The removable covers 164 provide manual access
to the drivers
and sensors even while the luminaire 10 is secured to an electrical source;
that is, the internal
chambers 148 are accessible from a side of the luminaire 10 without requiring
the luminaire 10
to be dismounted.
100271 Referring to FIG. 7, in the illustrated embodiment, the housing 100
further includes
an elongated support bracket 168 removably coupled to the main body 104 and
defining the
lower surface 120 of the cross-member 112. The support bracket 168 extends
between the legs
108 and is removably coupled (e.g., by threaded fasteners) to the cross-member
112. In the
illustrated embodiment, the support bracket 168 includes holes 170 for
receiving a second set of
fasteners 280 (see below). A seal 174 is positioned between the support
bracket 168 and the
main body 104 to thermally insulate the main body 104 from the support bracket
168. The
support bracket 168 also includes an opening 176 for receiving an electrical
supply conduit 180.
A grommet or seal 184 is positioned in the opening 176 to thermally insulate
the conduit 180
from the support bracket 168 and heat sink 200. The heat sink 200 is coupled
to the lower
surface 120 of the cross-member 112 and the heat sink 200 is positioned
between the legs 108.
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[0028] As shown in FIG. 8, the inner side walls 156 of the legs 108 face
toward one another.
Each inner side wall 156 includes slots or grooves 194 adjacent the lower
extent 128 of the leg
108. Each groove 194 is defined between a pair of tabs 196 and has a surface
extending from the
inner side wall 156 to the lower extent 128 of the leg 108.
[0029] Referring now to FIGS. 9 and 10, the heat sink 200 has a first end
204 and a second
end 208 and defines a heat sink axis 212 therebetween. The first end 204 and
the second end 208
are laterally spaced apart from a corresponding side wall 140 of the cross-
member 112. In other
words, each end 204, 208 of the heat sink 200 extends beyond a plane defined
by a
corresponding side wall 140. The heat sink 200 includes a first side or first
edge 216 extending
between the first end 204 and the second end 208, and a second side or second
edge 220
extending between the first end 204 and the second end 208. In the illustrated
embodiment, the
heat sink axis 212 extends parallel to and between the legs 108 (FIG. 8).
[0030] The heat sink 200 includes a plate 224 having a first surface 228
and a second surface
or mounting surface 232. A fin array 236 is positioned on the first surface
228, while the
mounting surface 232 supports the light assembly 300 (FIG. 7). The heat sink
200 further
includes an opening or passageway 240 extending through the fin array 236 and
the plate 224 to
the mounting surface 232. The electrical conduit 180 (FIG. 7) passes through
the passageway
240 to provide electrical communication between the drivers, controllers, etc.
in the internal
chambers 148 and the light assembly 300. In addition, the heat sink 200
includes multiple posts
244 aligned with holes 170 in the support bracket 168 (FIG. 3) to couple the
heat sink 200 to the
housing 100 (e.g., by a threaded fastener 280).
[0031] As best shown in FIG. 11, the fin array 236 includes a longitudinal
fin 252 extending
between the first end 204 and the second end 208 of the heat sink 200 (i.e.,
parallel to the heat
sink axis 212), and a transverse fin 256 extending laterally across the heat
sink 200. The
transverse fin 256 and the longitudinal fin 252 intersect one another at a
center point and define
four quadrants of the heat sink 200. In the illustrated embodiment, the
passageway 240 extends
through a portion of the transverse fin 256.
[0032] Referring again to FIG. 9, the fin array 236 further includes elbow
fins 260 positioned
in each quadrant. Each elbow fin 260 includes a first planar portion 264
parallel to the
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longitudinal fin 252, a second planar portion 268 parallel to the transverse
pin, and a connecting
portion 272 extending between the first planar portion 264 and the second
planar portion 268.
Stated another way, the first portion 264 and the second portion 268 of each
elbow fin 260 are
oriented 90 degrees apart from one another and are connected by an arcuate
portion. Air flow
channels are defined between adjacent fins 252, 256, 260.
[0033] In one embodiment, the fin array 236 includes four elbow fins 260
positioned in each
quadrant. The first elbow fin 260a is positioned nearest to the longitudinal
fin 252 and
transverse fin 256; the second elbow fin 260b is spaced apart from the first
elbow fin 260a and
positioned farther away from the longitudinal fin 252 and the transverse fin
256. The third
elbow fin 260c is spaced apart from the second elbow fin 260b and positioned
farther away from
the longitudinal fin 252 and the transverse fin 256. The fourth elbow fin
260c1 is spaced apart
from the third elbow fin 260c and is the elbow fin 260 that is the furthest
distance from both the
longitudinal fin 252 and the transverse fin 256. In other embodiments, the fin
array 236 may
include fewer or more elbow fins 260, and the spacing between the elbow fins
260 and the
longitudinal fin 252 and/or the transverse fin 256 may be increased or
decreased. In the
illustrated embodiment, the third elbow fin 260c in each quadrant extends
upwardly beyond the
other fins 252, 256, 260; in other embodiments, the elbow fins 260 may have
the same height, or
a different elbow fin 260 may extend above the other fins 252, 256, 260. One
or more of the
elbow fins 260 may also have a height that is less than the other fins 252,
256, 260.
[0034] Referring to FIG. 12, the heat sink 200 is coupled to the support
bracket 168. In the
illustrated embodiment, one post 244 is positioned in each quadrant and each
post is formed
integrally with the first elbow fin 260a (i.e., the elbow fin 260 positioned
nearest the longitudinal
fin 252 and the transverse fin 256). Each post 244 is positioned proximate the
connecting
portion 272a (FIG. 9) of the first elbow fin 260a and includes an opening 276
for receiving a
fastener (e.g., a threaded fastener 280) extending through the support bracket
168 in order to
couple the heat sink 200 to the lower surface 120 of the cross-member 112. In
some
embodiments, the posts 244 may extend above some or all of the fins 252, 256,
260.
[0035] The support bracket 168 has tabs 172 on each end, and each tab 172
includes a hole
for receiving a fastener (FIG. 7) to couple the bracket 168 to the housing
100. The support
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bracket 168 is positioned between the extended third elbow fins 260 of the
heat sink 200 and
abuts the upper edges of the fins positioned between the extended third elbow
fins 260. The ends
of the support bracket 168 are coupled to the housing 100 (e.g., by
fasteners), thereby supporting
the heat sink 200 relative to the housing 100. The seal 174 between the
support bracket 168 and
the housing 100 thermally insulates the heat sink 200 from the housing 100 to
reduce heat
conduction to the housing 100. In addition, individual seals 284 (FIG. 6) may
be placed adjacent
the posts 244 and between the fin array 236 and the support bracket 168 to
resist heat conduction
from the heat sink 200 to the support bracket 168.
[0036] As best shown in FIG. 10, the mounting surface 232 of the plate 224
includes a first
recess 288 and a second recess 292. The first recess 288 may be formed as a
rectangular
depression, and the second recess 292 may extend around the perimeter of the
first recess 288.
[0037] Referring again to FIG. 7, the light assembly 300 is secured to the
mounting surface
232 of the heat sink 200. The light assembly 300 includes a circuit board 304
supporting light-
emitting elements such as light-emitting diodes (LEDs) 308 and a lens 312
positioned over the
circuit board 304 and the light-emitting elements 308. The circuit board 304
is secured within
the first recess 288 of the mounting surface 232 of the heat sink 200 and the
lens 312 includes a
peripheral portion coupled in the second recess 292. The lens 312 is directly
to the mounting
surface 232 independently of the circuit board 304. As a result, the lens 312
does not exert a
compressive stress on the circuit board 304 and additional heat can be removed
from the circuit
board 304. In the illustrated embodiment, the circuit board 304 is coupled to
the mounting
surface 232 by a first set of fasteners 316 and the lens 312 is coupled to the
mounting surface
232 by a second set of fasteners 320. A seal 322 is positioned between the
circuit board 304 and
the lens 312. A cover 324 is also coupled to the heat sink 200 and extends
over the lens 312.
[0038] Air flow across the heat sink 200 could be restricted due to the
fact that the heat sink
200 is positioned directly below the legs 108 and the support bracket 168 is
positioned adjacent
the upper edges of the fins 252, 256, 260. However, the grooves 194 on the
inner side walls 156
of the housing 100 are aligned with the air flow channels between the elbow
fins 260. As a
result, the grooves 194 facilitate air flow from below the heat sink 200 and
direct the flow toward
the channels between the elbow fins 260 along the edges of the heat sink 200.
The air flowing
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through the fin array 236 cools the fins 252, 256, 260, and the air is heated.
The air flow is
exhausted from the air flow channels adjacent the first end 204 or the second
end 208 of the heat
sink 200.
[0039] The heated air flow rises from the fin array 236 in the area
proximate the side walls
140 of the cross-member 112. The air flow therefore exits the fin array 236
above the heat sink
200 but below the upper surface 116 of the cross-member 112. Because the
exhaust point for the
air flow is not at an uppermost point of the housing 100, the heated air
continues to rise and can
be cooled by ambient air. This avoids the possibility that the heated air will
become trapped
against a ceiling surface in the vicinity of the heat sink 200. By creating
better air flow and
allowing the exhausted air to continue to rise away from the heat sink 200,
the operating
temperature of the heat sink 200 is decreased and the efficiency is improved.
As a result, the
luminaire 10 has a longer working life.
[0040] In addition, the independent mounting of the heat sink 200 to the
support bracket 168,
as well as the seals between the heat sink 200, the support bracket 168, and
the housing 100
significantly reduce conductive heat transfer from the heat sink 200 to the
housing 100 or the
housing's electrical components.
[0041] Although certain embodiments have been described in detail,
variations and
modifications exist within the scope and spirit of one or more independent
aspects as described.
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