Note: Descriptions are shown in the official language in which they were submitted.
LUMINAIRE WITH LONG CHAINS OF LOW POWER LEDS AND
MULTIPLE ON-BOARD LED DRIVERS
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part application of U.S.
patent
application 13/828,446, entitled "Luminaires and Luminaire Mounting
Structures," filed
March 13, 2014.
BACKGROUND
TECHNICAL FIELD
[0002] This disclosure relates to luminaires, including outdoor lighting
canopies that
are driven by AC line voltage and include multiple LEDs.
DESCRIPTION OF RELATED ART
[0003] Outdoor canopy lighting may utilize multiple LEDs mounted within a
housing
to provide needed lighting. These LEDs may need a driver to generate the
regulated
current that is needed to drive the LEDs.
[0004] A single large driver is usually mounted outside of the luminaire
housing to
drive the LEDs. This has been done because of concern over the effect of noise
generated by the LEDs within the housing on the operation of the driver,
because of
the absence of strong surge protection inside of the luminaire housing to
protect the
driver from surges in line voltage, and to make it easy to replace components
in the
driver that sometimes fail, such as electrolytic capacitors. However,
positioning the
driver outside of the canopy housing may require a separate housing to house
the
driver. This may add to costs and require added space for the separate housing
[0005] Drivers have also been designed to drive a chain of series-connected
LEDs
in sub-chain steps that correspond to the amplitude of the line voltage.
Typically, the
chain and each of its sub-steps consist of a small number of high power LEDs
to
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Date Regue/Date Received 2022-07-06
minimize costs and maximize durability. However, high power LEDs can be less
efficient and using a small number can result in spotted lighting patterns.
SUMMARY
[0006] A luminaire may include an input connection that receives AC line
voltage,
one or more chains of LEDs, and one or more drivers for driving each chain of
LEDs,
all within a housing. Each chain of LEDs may contain at least 36 LEDs
connected in
series. Each LED may have a power rating of no more than 1 watt and may be
oriented to direct light outside of the housing when illuminated. Each driver
may
receive power that is extracted from AC line voltage connected to the input
connection
and provide one or more outputs that drive at least one of the chains of LEDs.
[0007] Each chain of LEDs may include multiple sub-chains of LEDs connected
in
series, each sub-chain containing multiple LEDs in series. Each of the LED
drivers
may provide a separate output that drives at least one of the chains of LEDs
at each of
the junctions between each of its sub-chains in a stepped sequence that is a
function
of the level of voltage of the power that is received by LED driver.
[0008] At least one sub-chain within each chain may include at least 12
LEDs.
[0009] No sub-chain within each chain may include less than 6 LEDs.
[0010] The outputs of at least two of the LED drivers may be connected in
parallel.
[0011] The outputs of at least one of the LED drivers may be connected to
one of
the chains of LEDs and the outputs of at least one other of the LED drivers
may be
connected to another of the chains of LEDs.
[0012] The input connection, the chains of LEDs, and the LED drivers may
all be on
a single printed circuit board.
[0013] Each chain of LEDs may have at least 48 LEDs.
[0014] The power rating of each LED may be no more than .6 watts.
[0015] The housing may form a canopy light.
[0016] These, as well as other components, steps, features, objects,
benefits, and
advantages, will now become clear from a review of the following detailed
description
of illustrative embodiments, the accompanying drawings, and the claims.
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BRIEF DESCRIPTION OF DRAWINGS
[0017] The drawings are of illustrative embodiments. They do not illustrate
all
embodiments. Other embodiments may be used in addition or instead. Details
that
may be apparent or unnecessary may be omitted to save space or for more
effective
illustration. Some embodiments may be practiced with additional components or
steps
and/or without all of the components or steps that are illustrated. When the
same
numeral appears in different drawings, it refers to the same or like
components or
steps.
[0018] Fig. 1A is a bottom-side perspective view of a luminaire in
accordance with
the present disclosure;
[0019] Fig. 1B is atop-side perspective view of the luminaire depicted in
Fig. 1A
with driver box and stem;
[0020] Fig. 1C is an exploded view of the luminaire depicted in Fig. 1A
with driver
box, stem and gasket;
[0021] Fig. 2A is a bottom-side perspective view of a housing of the
luminaire
depicted in Fig. 1A;
[0022] Fig. 2B is a top-side perspective view of a housing of the luminaire
depicted
in Fig. 1A with the lens frame shown for context;
[0023] Fig. 3A is a top-side perspective view of a lens frame of the
luminaire
depicted in Fig. 1A;
[0024] Fig. 3B is an outtake of a portion of the lens frame of Fig. 3A,
with a gasket
and adhesive sealant not depicted in Fig. 3A;
[0025] Fig. 4A is a cross-section of a portion of the luminaire depicted in
Fig. 1A;
[0026] Fig. 4B is a different cross-section of a portion of the luminaire
depicted in
Fig. 1A;
[0027] Fig. 4C is yet another different cross-section of a portion of the
luminaire
depicted in Fig. 1A;
[0028] Fig. 4D is a cross-section of a portion of the luminaire depicted in
Fig. 1A
showing a greater width of the luminaire than Figs. 4A-C;
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[0029] Fig. 4E is a cross-section of the housing stem of the luminaire
depicted in
Fig. 1A populated with wiring and breathing tube;
[0030] Fig. 5A is a bottom side view of the driver box and driver box stem
depicted
in Fig. 1B;
[0031] Fig. 5B is an exploded view of the luminaire depicted in Fig. 1A and
the
driver box and gasket depicted in Fig. 1C in the context of installation to a
structure;
[0032] Fig. 6 is a bottom side view of the printed circuit board of the
luminaire
depicted in Fig. 1A;
[0033] Fig. 7A is a bottom-side perspective view of the luminaire depicted
in Fig. 1A
mounted in a mounting structure;
[0034] Fig. 7B is a perspective cross-sectional view of the luminaire and
mounting
structure depicted in Fig. 7A;
[0035] Fig. 7C is a top side view of the luminaire and portions of the
mounting
structure depicted in Fig. 7A;
[0036] Fig. 7D is a cross-sectional view of portions of the luminaire and
mounting
structure depicted in Fig. 7A;
[0037] Fig. 7E is a perspective view of a locking wing of the mounting
structure
depicted in Fig. 7A; and
[0038] Figs. 7F and 7G are perspective views of optional mounting structure
extensions of the mounting structure depicted in Fig. 7A.
[0039] FIG. 8 illustrates an example of a circuit that includes a driver
and a long
chain of low power LEDs that may be driven by the driver, all of which may be
on a
single circuit board within an outdoor canopy light.
[0040] FIG. 9 illustrates an example of a circuit that incudes multiple
drivers and a
long chain of low power LEDs that may be driven by the multiple drivers while
their
outputs are connected in parallel, all of which may be on a single circuit
board all
within an outdoor canopy light.
[0041] FIG. 10 illustrates an example of a block diagram of an outdoor
canopy light
that may use a single D.C. power supply to supply power to one or more drivers
that
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each drive one or more long chains of low power LEDs, each LED chain and
associated driver(s) being in a different quadrant of an outdoor canopy light.
[0042] FIG. 11 illustrates an example of one quadrant of a long chain of
low power
LEDs on a single circuit board.
[0043] FIG. 12 illustrates an example of a single circuit board that may be
placed
within an outdoor canopy light that includes four quadrants, each with a long
chain of
low powered LEDs and an associated power supply and drivers.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0044] Illustrative embodiments are now described. Other embodiments may be
used in addition or instead. Details that may be apparent or unnecessary may
be
omitted to save space or for a more effective presentation. Some embodiments
may
be practiced with additional components or steps and/or without all of the
components
or steps that are described.
[0045] While the preferred embodiment uses light emitting diodes ("LEDs")
as light
sources, other light sources may be used in addition to LEDs or instead of
LEDs within
the scope of the present disclosure. By way of example only, other light
sources such
as plasma light sources may be used. Further, the term "LEDs" is intended to
refer to
all types of light emitting diodes including organic light emitting diodes or
"OLEDs".
[0046] While the luminaire depicted in the Figs. is generally applicable to
any
application that would benefit from indoor or outdoor area lighting, it is
well-suited, in
one example, for application to canopies and the like such as those used at
petroleum
refill stations. In other applications, luminaires and mounting structures
disclosed
herein are applicable to soffits or ceilings.
[0047] Figs. 1A and 1B depict bottom-side and top-side perspective views of
a
luminaire 100, in accordance with the present disclosure, which is a low-
profile
luminaire capable of providing proper light distribution and having a minimum
number
of parts. The luminaire 100 comprises a housing 102, a circuit board 104
populated
with light sources 106 such as LEDs, a plurality of screws 108, a lens 110, a
gasket
112 and a lens frame 114. The circuit board 104 can be any known circuit board
for
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properly arranging the light sources 106 and, in one embodiment, can be a
printed
circuit board ("PCB"). For the sake of simplicity, circuit board 104 will be
referred to
herein as a PCB, but it will be understood that any type of circuit board is
suffice.
[0048] The overall shape of the luminaire 100 is depicted as substantially
square
with rounded corners, but other shapes are contemplated as operating within
the
scope of this disclosure. By way of example only, rectangular, circular and
triangular
are all contemplated. Because the overall shape of the luminaire 100 is
dictated in the
depicted embodiment by the shape of the housing 102 and the lens frame 114,
the
shape of the housing 102 and lens frame 114 are likewise contemplated as have
these
exemplary shapes or others.
[0049] The housing 102 comprises a plate 116, a perimeter 118 and a wall
120
between the face 116 and the perimeter 118. The perimeter 118 extends about
the
perimeter of the housing and thus takes the shape of the housing, which in the
depicted embodiment, is square with rounded corners, as discussed above. The
perimeter 118 defines a front face 118a and a rear face 118b. The front face
118a of
the perimeter 118 extends from an inner edge 118c to an outer edge 118d which
defines the outermost perimeter of the housing 102. The perimeter inner edge
118c
defines the downward most facing portion of the housing 102. The front face
118a of
the perimeter 118 extends from the perimeter inner edge 118c to the perimeter
outer
edge 118d forming a curvilinear front face 118a. In the depicted embodiment,
the
curvilinear front face 118a initially extends outward form the inner edge 118c
in
straight horizontal manner, and then curves upward with an ever-increasing
radius of
curvature to the perimeter outer edge 118d. Other curvilinear shapes are
contemplated as falling within this disclosure. By way of example only, the
front face
could extend horizontally to a 90 edge, which then extends upward to the
outer edge.
[0050] References herein to upward and downward orientation are with
reference
to the depicted embodiments in which the luminaire 100 is mounted to the
underside
of a flat structure (such as a ceiling or a canopy) and are for purposes of
conveying a
description of the elements of the disclosure, but are in no way intended to
be limiting.
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In application, upward can be reoriented downward and downward can be
reoriented
upward.
[0051] The housing perimeter 118 preferably defines one or more locator
grooves
122 extending from the perimeter front face upward into the perimeter with a
locator
groove wall 122a to a locator groove base 122b that is flat in the depicted
embodiments, but can vary, extending horizontally. The locators grooves 122
receive
locator bosses 140 on the lens frame 114 to assist in properly locating the
lens frame
114 on the housing 102 and, separately, to accommodate a boss from the lens
frame
114 which can receive a mounting screw 134 from the groove base 122b, which
will
remain hidden from sight to persons viewing the bottom of the luminaire 100,
in the
depicted embodiment. Fig. 4B depicts a cross-section of a portion of the
luminaire 100
through a locator groove 122, a corresponding locator boss 140 and mounting
screw
134.
[0052] In the depicted embodiment, the luminaire 100 defines two locator
grooves
122 on each of the four sides defining the square shape of the luminaire 100.
Greater
or fewer locator grooves 122 are contemplated. For example, if the locator
grooves
122 are used purely for locating the lens frame 114 on the housing 102, then
one, or
two would suffice. Alternatively, an embodiment of the luminaire 100 is
contemplated
with no locator grooves 122. If, however, the locator grooves 122 are used to
accommodate a boss to facilitate mounting the housing 102 to the lens frame
114 by
screw, or the like, then the number and location of the locator grooves 112
will be
dictated by the size and weight of the lens frame 114 in order to properly
secure the
lens frame 114 to the housing 102 with sufficient sealing there between, if
desired, as
discussed below.
[0053] The housing plate 116 extends across the housing to fill in the area
surrounded by the housing perimeter 118. The housing wall 120 extends downward
from the housing plate 116 just inward of the housing perimeter 118 to a
distal end
120a and about the entire housing plate 116 as depicted in Fig. 2A. The
housing wall
120 does not extend as far down as the inner edge of the perimeter 118.
Rather, the
housing wall 120 extends downward far enough to engage the gasket 112 located
in
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the lens frame 114 as shown in figs. 4A-4D and discussed below. In this
manner, the
wall 120 deforms the gasket 112 forming a vapor and moisture barrier there
between.
Because the wall 120 and gasket 112 extend about the entire luminaire 100 just
inward of the perimeter 118, a vapor and moisture barrier is formed between
areas
inward of the wall 120 (e.g. the PCB) and areas outward of the wall 120. This
construction forms a barrier against vapor and moisture that might otherwise
ingress
between the housing 102 and lens frame 114. The housing wall 120 can take
different
forms as seen in Figs. 4A-4D in order to minimize weight and material while
still
creating sufficient deformation of the gasket 112 to create desired vapor and
moisture
barrier.
[0054] The housing plate 116 has a front face 116a and a rear face 116b.
The
housing plate front face 116a is substantially flat, extending across and
filling in the
perimeter 118, with the exception of a plurality of mounting holes 124 defined
therein
and a spacer boss 126 surrounding and extending each mounting hole 124 out
beyond the housing plate front face 116a. Each spacer boss 126 comprises a
cylindrical wall extending downward from the housing plate front face 116a to
a distal
end 126a and configured so that an inner wall of the spacer boss 126 continues
the
inner wall of the corresponding mounting hole 124 so that the spacer boss 126
effectively extends the depth of the mounting hole 124 to a depth B. In the
depicted
embodiment, the spacer boss distal end 126a sits approximately even with a
front face
104a of the PCB (as depicted in Figs. 4A and 4D), thus acting to space the
head of the
screws 108 a distance approximately equal to the thickness of the PCB, shown
as
distance C in Fig. 4D, to the PCB front face 104a. In one exemplary
embodiment,
distance B can be 0.125 inches, where the distance C can be 0.047 inches. In
another exemplary embodiment, height of the spacer bosses 126 is just short of
the
thickness of the PCB 104 so that the screws 108 not only hold the PCB 104 from
falling off the housing 102, but also hold it steady, preventing rattle of the
PCB 104 and
creating a heat transfer connection between the PCB 104 and the housing 102
causing the housing 102 to act as a heat sink for the PCB 104 and the LEDs 106
mounted thereon. These objectives are enhanced when the screws 108 are
constructed of a pliable material, as discussed below. The height of the
spacer
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bosses 126 could be 0.002 inches shorter than the thickness of the PCB 104 in
one
embodiment. Other dimensions are contemplated to meet these objectives.
[0055] In an alternative embodiment, no spacer bosses 126 are employed.
However, the spacer bosses 126 provide two advantages. First, the spacer
bosses
126 reduce assembly time by allowing screws 108 to be driven into the mounting
holes
124 without regard for when they reach the PCB 104. Without the spacer bosses
126,
advancing the screws 108 would be conducted with concern about advancing them
too far or with too much power, either of which might damage the PCB 104. The
spacer bosses 126 obviate that concern by allowing the screws 108 to be
advanced to
the spacer boss distal end 126a as quickly and efficiently as possible. This
ease of
securing the screws 108 to the housing 102 without damaging the PCB 108 is
further
advanced by using screws 108 of a pliable material such as, by way of example
only,
nylon. Use of such pliable screws 108 will allow the screws 108 to be advanced
without regard for exactly when advancement need stop. That is, over advancing
the
screws 108 will not "strip" the mounting holes 124 or damage the screws 108 to
an
extent such to prevent them from holding the PCB 104 to the housing 102.
Instead, by
using screws 108 of a pliable material, over advancing the screws will
slightly deform
the threads of the screws 108, but not so much as to prevent the pliable
threads of the
screws 108 from grasping the inside of the mounting holes 124.
[0056] Moreover, in the depicted embodiment, the inner wall of the mounting
holes
124 is straight (i.e. is not threaded). This further limits production costs
by removing
the need to tap the mounting holes 124 or create a complicated mold having
reliable
threads in the mounting hole 124. Additionally, using straight mounting holes
124
actually allows shallower mounting holes 124 because the use of a typically
tap to
create the threads in a mounting hole requires a certain depth in order to
facilitate the
tapping. Using straight holes eliminates the need to be able to tap the
mounting holes
124, thus allowing shorter mounting holes 124 than could otherwise be used. In
one
exemplary embodiment, the depth B of the mounting holes 124 is 0.125 inches.
Furthermore, by using the spacer bosses 126 to extend the wall of the mounting
hole
124 out to the face of the PCB 104, the depth of the mounting hole 124 is
moved into
the luminaire 100, reducing the distance that the mounting hole 124 need
extend
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toward the housing plate rear face 116b, thus allowing a thinner overall
luminaire 100.
Moreover, using pliable screws 108 in straight mounting holes 124 further
reduces, or
eliminates, the likelihood of damaging the screws 108 by over advancement.
[0057] The second advantage provided by the spacer bosses 126 is their
inherent
ability to reduce tolerances in the stack of elements (housing 102, PCB 104,
screws
108, lens 110 and lens frame 114) contributing to the over all height of the
luminaire
100, and thus its low-profile. As discussed in greater detail below, tight
stack of these
element contributes to the low-profile. The ability to advance the screws 108
against
the spacer bosses 126 without exception so as to limit the tolerances
necessary and
contribute to an overall low profile. The additional cost of these spacer
bosses is
negligible in an embodiment where the housing is cast from a material (e.g.
aluminum).
[0058] The housing plate rear face 116b is also substantially flat, with
the exception
of a matrix of interconnecting walls 128 extending from the rear face 116b a
short
distance off that face. This matrix 128 increases the overall rigidity of the
plate 116
and thus the housing 102. The matrix 128 also provides additional surface area
on the
rear of the housing 102 to increase the ability of the housing to dissipate
heat when
any of the matrix 128 is exposed to ambient air. The matrix 128 also assists
in
providing surface contact with structure to which the housing is mounted when
that
structure has surface irregularities (i.e. is not flat). This surface contact
can also be
helpful in directing heat away from the luminaire 100 in installations such as
a
petroleum refill station canopy which is constructed of sheet metal and much
of the
sheet metal, except where contacted by the housing, is exposed to ambient air
to
facilitate transferring to the surrounding air, some of the heat generated by
the light
sources or utilities for powering the light sources.
[0059] The matrix 128 may optionally include bosses 130 at the bottom of
the
mounting holes 124. These bosses 130 provide additional thickness to account
for
molding irregularities.
[0060] In the depicted embodiment, the housing perimeter rear face 118b
follows
the curvature of the housing perimeter front face 118a for the most part. A
cross-
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section of one embodiment is depicted in Fig. 4C. This embodiment keeps the
perimeter thin and reduces material usage while the curvature provides
structural
rigidity. Other shapes and thicknesses are contemplated. The housing perimeter
rear
face 118b also includes the backside of the locator groove wall 122a and
locator
groove base 122b protruding therefrom.
[0061] As discussed above, one or more of the locator groove bases 122b define
a
screw aperture 132 to accommodate a screw 134 to extend through the housing
102
and into the lens frame 114 to secure the lens frame 114 to the housing 102.
In the
depicted embodiment, the screw 134 enters from the housing and extends into
the
lens frame 114 so as to not be visible from the front side of the luminaire
100. A
cross-section of this embodiment is depicted in Fig. 4B. Other embodiments are
contemplated.
[0062] In order to minimize the number of screws 134 necessary for assembly
and
minimize the corresponding assembly steps, one or more fins 136 may extend
across
the housing perimeter rear face 118b to fill in the back side of the housing
perimeter
118 curvature and provide the housing perimeter 188 with added structural
rigidity. In
the depicted embodiment, each side of the square housing comprises a single
such fin
136 between the two screws 134 and one such fin 136 at each rounded corner of
the
housing perimeter 118. A cross-section of this embodiment is depicted in Fig.
4A.
Other embodiments are contemplated.
[0063] The lens frame 114 defines a front face 114a and a rear face 114b
and
comprises a lens frame perimeter 136 at the outermost perimeter of the lens
frame
136 and a trough 138 defined by an inner trough wall 138a and outer trough
wall 138b.
The contour of rear face 114b of the lens frame perimeter 136 follows the
contour of
the housing perimeter front face 118a, extending to a distal end 136a that
lies in
approximately the same horizontal plane as the housing perimeter outer edge
118d.
References herein to a "horizontal" plane are by way of describing
relationships
between elements and portions of elements in the disclosed luminaire 100 and
the
term "horizontal" is used because the luminaire 100 is described as being
mounted to
a ceiling or the like. Use of the term "horizontal" is not limiting on the
luminaire 100 as
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it could be rotated to be mounted in any orientation. By extending the lens
frame
perimeter distal edge 136a to the housing perimeter outer edge 118d, the lens
frame
can cover the housing perimeter 118 from view to provide the luminaire 100 a
simple
and elegant aesthetic look as seen in Fig. 1A. One of more locator boss 140
extends
rearward from the lens frame rear face 114b into the curvature defined by the
lens
frame perimeter 136. As described above, the locators grooves 122 of the
housing
102 receive the locator bosses 140 to assist in properly locating the lens
frame 114 on
the housing 102 and, separately, to receive the mounting screw 134, which will
remain
hidden from sight to persons viewing the bottom of the luminaire 100, in the
depicted
embodiment. Fig. 4B depicts a cross-section of a portion of the luminaire 100
through
a locator groove 122, a corresponding locator boss 140 and mounting screw 134.
The
lens frame 114 is oriented vertically at the distal edge 136 and then curves
downward
and inward with an ever increasing radius of curvature the farther it is from
the distal
edge 136 until it is oriented approximately horizontal where it is adjacent to
the
housing perimeter inner edge 118c.
[0064] A base 138c of the lens frame trough 138 continues to extend inward
from
the lens frame perimeter 136 horizontally and seamlessly from the lens frame
perimeter 136. Other embodiments are contemplated. The lens frame trough inner
trough wall 138a then extends vertically to define the lens frame innermost
perimeter
which defines a lens frame aperture 142 through which light emitted by the
light
sources 106 passes to leave the luminaire 100.
[0065] Gasket 112 is located about the perimeter of the trough outer wall
138b
(depicted in Fig. 3B and Figs. 4A-4D, but not Fig. 3A), which holds the gasket
112 in
place during assembly. When the housing 102 and lens frame 114 are brought
into
alignment with, and secured one to the other, the housing wall 120 contacts
and
deforms the gasket 112. In the deformed state, the gasket 112 forms a seal
against
ingress of vapor, moisture, water or dirt between the housing 102 and the lens
frame
114. The gasket 112 extends around the entire perimeter of the outer trough
wall
138b and the housing wall 120 extends around the entire housing 102 such that
the
seal formed between the housing wall 120 and the gasket 112 extends about the
entire perimeter of the PCB 104 preventing ingress of vapor, moisture, water
or dirt
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between the housing 102 and the lens frame 114 that could reach the PCB 104 or
other portions of the luminaire 100 within that perimeter seal. In an
alternative
embodiment, a urethane sealant could be substituted for the gasket 112. For
the sake
of efficiency, this urethane adhesive could be the same urethane adhesive as
used in
the trough 138, as discussed below.
[0066] The trough inner wall 138a extends upward a distance A (Fig. 4D)
from the
trough base 138c to a distal end on which the lens 110 rests. The lens 110 is
sized so
as to rest on the trough inner wall 138a distal end and extend almost all of
the way to
the trough outer wall 138b, leaving at least sufficient space there between to
ease
assembly. The trough outer wall 138b extends upward from adjacent the lens
frame
perimeter 136 and upward beyond the lens 110. The trough inner wall 138a is
therefore shorter than the trough outer wall 138b. An adhesive sealant 144 is
deposited into the trough 138 during assembly in a bead having a height
sufficient so
that when the lens 110 is placed on top of the bead, the lens 110 will deform
the bead
of adhesive sealant 144 until the lens 110 contacts and rests on the tough
inner wall
138a distal end. The height of the trough inner wall 138a is a height A, and
is
designed to prevent the lens 110 from squeezing all of the adhesive sealant
144 out
from between the lens frame 114 and lens 110 by limiting the distance between
the
lens 110 and the trough base 138c to height A. In this manner, the deformed
bead of
adhesive sealant 144 will have sufficient height to provide adhesion between
the lens
110 to the lens frame 114. In one exemplary embodiment, the height A is 0.094
inches when using a 0.225 inch diameter bead of a urethane adhesive (SikaTack -
Ultrafast, sold by Sika Corporation, in one embodiment). In this embodiment,
it has
been found that the bead compresses to approximately the height A and
approximately 0.425 inches, providing sufficient surface area to adhere to the
lens
110. Other heights A, bead diameters and adhesive sealants are contemplated.
[0067] As depicted in Figs. 4A-4D, the lens 110 in the assembled luminaire
100, is
held by inner trough wall 138a and forced into contact with the head of the
screws 108.
In this depicted embodiment of the luminaire 100, the head of one or more of
the
screws 108 is sized (height of D) to facilitate this contact between the heads
of the
screws 108 and the lens 110. This contact holds the screws 108 in the mounting
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holes 124 and eliminates the need for any holding force between the screws 108
and
the mounting holes 124 once the luminaire 100 is assembled. The need for only
short
term holding force between the screws 108 and mounting holes 124 can further
reduce the requirements of the mounting hole 124 and the screws 108 allowing
them
to be even shorter and allowing an even thinner overall luminaire. The short
term
requirement for this holding force can also reduce the requirements of screws
108,
reducing the overall cost of the luminaire 100. In one exemplary embodiment,
the
height of the screws is just sufficient to prevent the screws 108 from backing
off the
force with which they press on the PCB 104. In an alternative exemplary
embodiment,
the lens 110 increases the force with which the screws 108 press on the PCB
104. In
one exemplary embodiment, the height D of the head of such screws 108 is 0.190
inches. Alternative embodiments are also contemplated in which the screw 108
is not
held by the lens 110 or are rivets through the PCB 104 and through a hole (not
depicted) in the housing 102. Other attachment hardware is also contemplated.
[0068] The PCB 104 comprises a PCB front face 104a populated with LEDs 106
and a PCB rear face 104b. The PCB rear face 104b is pressed into contact with
the
housing 102 by the screw 108 to create sufficient contact between the PCB 104
and
the housing 102 to allow the housing 102 to act as a heat sink, taking away
heat
generated by the LEDs 106 and associated circuitry.
[0069]
With the exception of the LEDs 106, the PCB front face 104a is covered with
a reflective coating or covering. In one exemplary embodiment, the PCB front
face
104a is covered with a white adhesive paper adhered to the PCB front face
104a. In
another embodiment, the PCB front face 104a is covered with a sheet of
reflective
aluminum (not depicted). The reflective coating or covering covers the PCB
from view
while, at the same time, redirecting light off of the PCB front face 104a
rather than
absorbing it. Many luminaires, especially those using LEDs, place reflectors
or optics
near the light sources to redirect light emitted from the light sources to
travel out of the
luminaire. When using this reflective coating or covering discussed above, the
luminaire of the present disclosure does not use any such reflectors or
optics. The
absence of reflectors and optics allows the distance between the PCB 104 and
the
lens 110 to be set as low as desired, bounded only by the need to secure the
PCB 104
- 14 -
Date Recue/Date Received 2022-07-06
to the housing 102. In this manner, the absence of any reflectors or optics
further
contributes to a thin (i.e. low-profile) luminaire 100.
[0070] In order to further reduce the overall height of the luminaire 100,
the light
sources are LEDs 106 comprised of 0.25 Watt LEDs rather than larger, more
powerful
LEDs. Historically, one challenge of using LEDs for area lighting has been
that LEDs
have traditionally emitted insufficient light to replace more conventional
light sources
such as incandescent or fluorescent. This deficiency has traditionally been
overcome
by the use of a matrix of LEDs. However, as the acceptance of LEDs for area
lighting
has become more accepted, technologies have been driven to increase the lumen
output LEDs. As the technologies have advanced in this manner, conventional
thinking in the LED lighting industry has been to use the biggest and
brightest LEDs
available for area lighting. The luminaire 100 of the present disclosure takes
advantage of the advances in technology, but bucks traditional thinking by
using a
larger number of smaller, low output LEDs 106 as opposed to a larger number of
larger, higher lumen output LEDs. The use of these smaller, low- output LEDs
106
provides the luminaire 100 two advantages.
[0071] First, many manufacturers currently manufacture and sell 1 Watt
LEDs. For
example, Nichia sells the NS9W383 1 Watt LED. This 1 Watt LED has a height of
approximately 0.108 inches. Instead of using these, or other, 1 Watt LEDs, the
LEDs
106 used by the luminaire 100 are 0.25 Watt LEDs. In one exemplary embodiment
the
LEDs 106 are Nichia NS2VV757A LEDs. More LEDs 106 are required to provide the
luminaire 100 the same lumen output than would be necessary if the 1 Watt LEDs
were used. However, the 0.25 Watt LEDs 106 reduce the height of the LEDs by
0.086
inches, allowing further reduction in the overall height of the luminaire 100.
[0072] In one embodiment of the disclosed luminaire depicted in Fig. 6, the
PCB
104 is populated with 460 Nichia 0.25 Watt NS2VV757A LEDs arranged in a matrix
spacing them at a pitch of 0.625 inches. When driven at 530 mA, these 460 LEDs
emit approximately 37 lumens each for a total of approximately 17,000 lumens.
When
driven at 650 mA, these 460 LEDs emit approximately 44 lumens each for a total
of
approximately 20,240 lumens.
- 15 -
Date Regue/Date Received 2022-07-06
[0073] Second, it has been found that the larger number of lower Watt and
lumen
LEDs 106 provide a more even light distribution that is more pleasant to the
eye. This
more even glow can be expressed as a ratio of the lumens (L) per LED 106 to
the
pitch (P) of the LEDs 106. In the embodiments disclosed in the preceding
paragraph,
each of the 460 LEDs are spaced at a pitch P of 0.625 inches. When these LEDs
are
driven at 530 mA they produce approximately 37 lumens each for a ratio of 59.2
lumens/inch. When these same LEDs are driven at 650 mA they produce
approximately 44 lumens each for a ratio of 70.4 lumens/inch. Other lumen
outputs
per chip and pitches are acceptable. It has been found that a P/L ratio of
between
approximately 59.2 lumens/inch and approximately 70.4 lumens/inch provide a
combined even glow when the 0.25 Watt LEDs are illuminated. This ratio is
contemplated as applicable to LEDs of other small wattage.
[0074] The accumulation of the above discussed advantages of the disclosed
luminaire 100 result in an overall thin (i.e. low profile) luminaire 100. With
the height E
between the rear of the housing 102 and the housing plate front face 116a
(0.193
inches in one exemplary embodiment) minimized to the thickness of a plate
necessary
for molding the mounting holes 124 in the housing plate front face 116a and
the matrix
128 on the housing place rear face 116b, the height E can be less than 0.2
inches and
it has been found that a height of 0.193 inches is optimal. Furthermore, use
of pliable
screws 108, with straight mounting holes 124, spacer bosses 126, thin LEDs 106
and
a lens frame trough 138 having an inner trough wall 138a working in
conjunction with
the screws 108 to precisely control the height of the lens 110 with respect to
the PCB
104 and the lowermost extremity of the lens frame aperture 142 creates a high
precision, low tolerance stack of parts that facilitate a precisely thin
luminaire 100 that
eliminates the need for reflectors or optics thus further reducing the
thickness of the
luminaire 100. The height F between the housing plate front face 116a and the
lowermost extremity of the lens frame aperture 142 (0.510 inches in one
embodiment)
is thus minimized and in conjunction with the minimized height E, provides an
overall
low profile, highly efficient luminaire 100. In the exemplary embodiment of
height E
being 0.193 inches and height F being 0.510 inches, the total height of the
luminaire is
- 16 -
Date Regue/Date Received 2022-07-06
only approximately 0.703 inches and is facilitated by one or more of the above
discussed features.
[0075] The low height F, minus the low height C of the PCB 104 provides a
very
low height between the base of the LEDs 106 and the lowermost extremity of the
lens
frame aperture 142 through which light rays emitted from the LEDs 106 escape
the
luminaire 100. This resulting low height allows most of the lumens emitted
from the
LEDs 106 to escape the luminaire 100 without need for reflectors or optics. In
the
example identified above using 460 Nichia 0.25 Watt NS2VV757A LEDs driven at
650
mA to emit a total of 20,240 lumens, it has been found that of the 20,240
emitted
lumens, 20,195 escaped the luminaire 100 in this configuration.
[0076] In one embodiment of the disclosed luminaire, a driver column 146
extends
upward from the rear of the housing plate 116. The driver column 146 may be
integral
with the housing plate 146 or not integral. In the depicted embodiment, the
driver
column 146 is integrally cast as part of housing 102. The driver column 146
comprises
four wings 148 extending radially from a central axis of the driver column
146. The
driver column 148 could comprise greater or fewer wings 148; three in one
exemplary
embodiment. Each wing 148 extends upward from the housing plate 116, having
opposing lateral walls 148a and a circumferential wall 148b at the
circumferential
perimeter of the driver column 146. In the exemplary depicted embodiment, the
circumferential wall 148b extends approximately tangential to the
circumference of the
driver column 146 and the opposing lateral walls 148a extend approximately
perpendicular to the circumferential wall 148b inward generally toward the
central axis
of the driver column 146. The entire driver column 146, including the wings
148, are
depicted as hollow, which is a result of the cost savings available by
producing the
housing 102, including the driver column 146 as an integral, unitary casting.
Other
embodiments are contemplated, however. For example, the wings could be solid
and/or secured to the housing in an alternative embodiment.
[0077] Each wing 148 defines a mounting boss 150 at its top 152 for
receiving
fixing hardware for mounting a driver box 200 to be associated with the
luminaire 100
during installation. In the depicted embodiment, the mounting boss defines a
screw
- 17 -
Date Regue/Date Received 2022-07-06
hole 154 for receiving a screw, but other fixing hardware is contemplated in
the
alternative. The mounting boss 152 is limited to the outer portion of each
wing 148,
leaving a recessed land 156 defined by the four mounting bosses 152.
[0078] An aperture 158 is defined at the center of the driver column 146
through
the land 156 to allow utilities to pass from the luminaire 100 to the driver
box 200. For
example, wiring 160 to provide power to the light sources passes through the
aperture
158 to deliver power from a driver located in the driver box 200 to the light
sources.
[0079] In an exemplary embodiment, the aperture 158 is designed to allow
air to
pass thereth rough, even when the wires 160 are present. Air expands and
contracts
as it is heated and cooled, respectively. As discussed above, the seal created
by
gasket 112 seals the air in the portions of the luminaire 100 inward of the
gasket from
the ambient environment. Thus sealed, the expansion and contraction of this
sealed
air would create air pressure above or below the ambient air pressure unless
that
sealed air was somehow vented. If the air pressure of this sealed air were to
fall
below the ambient air pressure, then the luminaire 100 would tend to try to
draw air
outside the luminaire, along with any dirt, moisture, etc. into the luminaire.
Over time,
this could tend to break down the seal created by the gasket 112. Allowing air
to pass
through the driver column aperture 158 allows the luminaire 100 to breath and
prevents the luminaire 100 from trying to draw moisture across the seal
created by the
gasket 112.
[0080] In one particular exemplary embodiment of the luminaire 100, a
breathing
tube 162 is run through the aperture 158 along with the wiring 160 and a
sealant 164
fills the remainder of the aperture 158 so that no moisture, air, dirt, etc.
can pass
through the aperture unless through the breathing tube 162. In one embodiment,
the
sealant 164 is the same urethane adhesive discussed above. In another
embodiment,
the sealant 164 is an elastomer. Other sealants 164 are contemplated. In yet
another
exemplary embodiment, a cylindrical gland 166 having a sealant 164 therein is
screwed into threads formed in the aperture 158 and the breathing tube 162 and
wiring
160 are run through the sealant 164, which forms a tight seal around the
breathing
tube 162 and wiring 160 to prevent ingress of any dirt, moisture, air, etc.
into the
- 18 -
Date Recue/Date Received 2022-07-06
luminaire 100. The gland 166 could be a commercially available liquid tight
fitting for
individual conductors such as a Conta-Clip brand model PG9, in one example.
Other
embodiments are contemplated. Regardless of how the sealant 164 is provided,
the
breathing tube 162 is run into the driver box 200 to prevent rain water, dirt,
etc. from
entering the breathing tube 162 and running down into the luminaire 100.
[0081] The driver box 200 comprises a box having a bottom wall 200a and
perimeter walls 200b creating an upwardly open box. The driver box 200 is
closed by
a cover plate 202 having a central plate 202a and downwardly depending edges
202b
along each side of the central plate 202a to direct water, snow, etc. downward
past the
opening to the driver box 200. In one exemplary embodiment, the central plate
202a
extends outward beyond each wall 200b of the driver box to further prevent
water,
snow, etc. from entering the driver box. The driver box comprises mounting
hardware
to facilitate securing the cover plate 202 to the driver box 200. In one
embodiment, the
driver box 200 comprises driver box ears 200c extending from one or more
driver box
walls 200a and defining a hole therein to receive a screw for securing the
cover plate
202 to the driver box 200. In the depicted embodiment, driver box ears 200c
extend
from two opposing ones of the driver box walls 200a. By extending the driver
box ears
200c, and thus the hole in the cover plate 202 to accommodate the screws,
outward
beyond the driver box walls 200a, any rain, snow, etc. falling through the
hole in the
driver box cover plate 202 will fall outside of the driver box 200 rather than
into the
driver box 200. In one possible embodiment, the driver box ears 200c do not
extend
as high as the driver box walls 200a, but fall just short thereof. This
prevents any
water that may fall through the screw holes in cover plate 202 from traveling
across
the driver box ears 200c and into the driver box. Alternatively, the driver
box ears
200c may extend as high as the driver box walls 200a, but have a groove
extending
across the driver box ears 200c between the screw holes and the driver box
wall 200a.
[0082] A stem 204 extends downward from the driver box bottom wall 202a. In
the
exemplary depicted embodiment, the stem 204 is integrally cast with the driver
box
200, but other options are contemplated. The stem 204 is configured to slide
over the
driver column 146 of the luminaire and accommodate the driver column 146
within the
stem 204. In one embodiment, the stem comprises a wall 204a having an inner
- 19 -
Date Recue/Date Received 2022-07-06
surface defining an opening 204b to receive the driver column 146. A top 204c
of the
opening 204b may be defined by the driver box bottom wall 202a (as in the
depicted
embodiment) or by a separate top 204c. The opening top 204c can be shaped to
complement all or portions of the top of the driver column 146 so that the
driver box
200 will sit securely on the driver column 146. The stem opening top 204c
defines a
utilities aperture 204d to accommodate the wiring 160 and the breathing tube
162 and
gland 166, where present, allowing them to enter the driver box 200. The
breathing
tube 162 need only enter the driver box 200 and be protected from the elements
by
the driver box 200 and cover plate 202. The wiring 160 enters the driver box
200
through the utilities aperture 204d and is connected to a driver (not
depicted) for
providing power to the light sources. One or more hardware apertures 204e are
defined in the top 204c and configured to allow screws or the like to pass
through and
secure into a corresponding one of the screw holes 154 on the driver column
146 to
secure the driver box 200 to the driver column 146 and, thus, the luminaire
100.
[0083] In one embodiment, the stem wall 204a defines a lower edge 204f and
a
groove 206 about the entirety of the lower edge 204f. The groove 206
accommodates
a gasket 208. In the depicted embodiment, the stem wall 204a is cylindrical
and the
groove 208 and corresponding gasket 208 are circular. Other embodiments are
contemplated.
[0084] During installation to a structure 210, the housing 102 is elevated
to the
structure and the driver column 146 passed through an aperture 210a in the
structure.
The structure 210 could be, by way of example only, a ceiling or a canopy for
a
petroleum refill station. The structure aperture 210a could be a pre-existing
aperture
left over from a previously installed luminaire or it could be a newly
constructed
aperture. The gasket 208 rests in the groove 206 defined by the stem wall
lower edge
204f and becomes compressed when brought into contact with the structure and
the
stem 204 tightly secured to the driver column 146. When in this compressed
state, the
gasket 208 forms a seal around the structure aperture 210a to prevent material
above
the structure (e.g. dirt, water, etc.) from getting to the structure aperture
210a. The
ability of the gasket 208 to prevent material from getting to the structure
aperture 210a
in this manner is predicated on the gasket 208 and the groove 206, in which is
resides,
- 20 -
Date Recue/Date Received 2022-07-06
being larger than the structure aperture 210a. In one exemplary embodiment,
the
stem wall 204a is sized to allow the gasket 208 to circumscribe at least a 4
inch
diameter structure aperture 210a, which is commonly left behind by pre-
existing
luminaires. Other dimensions are also contemplated. While this size stem is
larger
than necessary for some applications, it has also been found that the large
size of the
stem also assists in providing stability of the structure 210 when the
structure is
somewhat flexible, such as in a sheet metal canopy as is often found at a
petroleum
refill station.
[0085] The stem 204 is preferably of a height to elevate the driver box
200, or
portions thereof, above the height where water, snow, etc. may be allowed to
accumulate. For example, a sheet metal canopy a petroleum refill station will
often
accumulate some water and/or snow during precipitation before that water is
directed
off the canopy. The height of the stem is preferably designed so that the
driver box
200 is above the height to which water and/or snow are likely to accumulate.
In this
embodiment, the driver within the driver box 200 is more likely to be kept dry
than if
the stem places the driver box 200 below that height.
[0086] A mounting apparatus 300 is depicted in Figs. 7A-7G which can be used
with the luminaire 100 described above, or with a different luminaire. For
continuity,
the mounting apparatus 300 of the present disclosure will be described in
conjunction
with the luminaire 100 previously described herein. The mounting apparatus 300
is
beneficial in mounting a luminaire, such as luminaire 100, to a mounting
structure 302,
which may depend from another structure such as a ceiling or the canopy of a
petroleum refill station.
[0087] The mounting structure 302 comprises four walls 302a forming a
rectangular
box, square in the depicted embodiment. The mounting structure 302 further
comprises a face plate 304 extending between the four walls 302a slightly
above their
lower distal ends 302b. The face plate 304 lies generally horizontal and
defines a face
plate aperture 306. The face plate 304 can be separate from the walls 302a or
extend
integrally from the walls 302 as depicted in Fig. 7B. The mounting structure
302 can
be a pre-existing mounting structure in which a different luminaire had been
installed
- 21 -
Date Regue/Date Received 2022-07-06
or can be newly constructed for installation of a luminaire such as the
luminaire 100.
However, the mounting assembly 300 finds particular use for installing modern
LED-
based luminaires (such as luminaire 100) in mounting structures such as
mounting
structure 302 which is typical for housing older model luminaires such as HID
or
incandescent luminaires.
[0088] The mounting apparatus 300 comprises a mounting plate 308 mounted to
the back of a luminaire, such as luminaire 100. The mounting plate 308
optionally
defines a mounting plate aperture 308a to allow portions of the luminaire to
project
through. In the depicted example, the driver column 146 of the previously
described
luminaire 100 is allowed to project through the mounting plate 308 due to the
aperture
308a. Flanges 308b extend upward from each edge of the mounting plate 308 a
short
distance to contact, or come close to contacting, the mounting structure 302
when
installed. A hinge flange 308c extends from a first of the flanges 308b and
comprises
an extending portion 308c' and wings 308c" extending from opposing sides of
the
extending portion 308". The extending portion 308c' does not extend to the
ends of
the first of the flanges 308b, but instead leaves clearance on both ends. The
wings
308c" extend beyond the ends of the first of the flanges 308b and beyond the
edges of
the corresponding aperture 306 of the mounting structure face plate 304. In
this
configuration, the luminaire (such as luminaire 100) may hang from the
mounting
structure 302 by the wings 308c" and may rotate about those wings 308c". The
clearance left on both ends of the extending portion 308c' provides clearance
between
the extending portion and the edges of the corresponding aperture 306 during
rotation.
During installation, this structure allows an installer to connect the wiring
of the
luminaire to the power source in the mounting structure 302. The mounting
plate 308
can be mounted to the luminaire by screws or other hardware.
[0089] A catch 310 optionally extends from the mounting plate 308 adjacent
to a
second of the flanges 308b extending from the mounting plate 308 on a side
opposite
to the first of the flanges 308b from which the hinge flange 308c extends. The
catch
310 comprises a stem 310a and a hook 310b extending from the flange. In the
depicted embodiment, stem 310a is mounted to the mounting plate 308 and extend
upward to a stem distal end 310c, while the hook 310b extends downward from
the
- 22 -
Date Recue/Date Received 2022-07-06
stem distal end 310c angled toward the face plate 302 and extending to a hook
distal
end 310d that lies outside of the face plate aperture 306 such that when the
luminaire
100 is rotated downward from the mounting structure 302, the hook catches the
face
plate 304 and prevents the luminaire 100 from rotating further. A person
seeking to
rotate the luminaire 100 further may bend the stem 310a inward a distance
sufficient to
allow the hook distal end 301d to pass the face plate 304. When rotating the
luminaire
100 into the mounting structure, the angle of the hook 310b causes the stem
310a to
deflect inward as the hook 310b slides past the face plate 304, allowing the
hook 310b
to pass the face plate 304 and spring back to an unbiased position after
passing the
face plate 304. While the mounting apparatus 300 is beneficial without the
optional
catch 310, the catch 310 is preferable for the above discussed benefits. Other
embodiments of a catch are also contemplated.
[0090] One or more lock wings 312 are optionally mounted to one lock screw 314
each, which extends vertically through the luminaire 100 and the mounting
plate 308 at
a location adjacent to the second of the flanges 308b extending from the
mounting
plate 308 on a side opposite to the first of the flanges 308b from which the
hinge
flange 308c extends. In the depicted embodiment, the mounting apparatus 300
comprises two lock wings 312, each mounted to one lock screw 314. Each lock
screw
314 comprises a head 314a located at the face of the luminaire 100, making the
head
314a accessible when the mounting apparatus 300 is in the closed position
depicted in
Figs. 7A, 7B and 7D (i.e. fully mounted to the mounting structure 302). The
lock screw
314 also comprises a threaded shaft 314b extending through the luminaire 100,
through the mounting plate 308 and far enough above the mounting plate 308
such
that it extends above the mounting structure face plate 304 when the mounting
apparatus 300 is in the closed position.
[0091] Each lock wing 312 comprises a lock arm 312a and a stop arm 312b
connected by a bridge member 312c. In the depicted embodiment, the lock wing
312
is constructed of sheet metal bent into a U-shaped configuration in which the
lock arm
312a constitutes one leg of the U, the stop arm 312b constitutes the other leg
of the U
and the bridge member 312c constitutes the base of the U. In the depicted
embodiment, an optional strengthening flange 312d extends along and
perpendicular
- 23 -
Date Recue/Date Received 2022-07-06
to the lock arm 312a to provide structural rigidity to the lock arm 312. Each
of the lock
arm 312a and the stop arm 312b define a screw aperture 312e for allowing the
screw
shaft 314b to pass through. Optionally, one or both of the screw apertures
312e is
threaded so that the lock wing 312 can be threaded onto the screw shaft 314b.
Alternatively, or in addition, the lock wing 312 can be mounted to the screw
shaft 314b
by other means, such as, by way of example only, adhesive.
[0092] Each lock wing 312 is mounted on the screw shaft 314b at a distance
from
the screw head 314a that will locate the lock arm 312a slightly above the
mounting
structure face plate 304. In this configuration, each lock wing 312 can be
rotated
about the central axis of its corresponding screw 314 by rotating the screw
head 314a
of the corresponding screw 314. Rotating the lock wing 312 can bring the lock
arm
312a over the mounting structure face plate 304 or over the aperture 306
defined in
the mounting structure face plate 304. When the lock arm 312a is over the
mounting
structure face plate 304, the lock arm 312a prevents the luminaire 100 from
rotating
about the wings 308c" of the hinge flange 308c, thus keeping the luminaire 100
secure
to the mounting structure 302. However, when the lock arm 312a is over the
aperture
306 defined in the mounting structure face plate 304, the luminaire 100 may
freely
rotate about the wings 308c" of the hinge flange 308c, thus allowing access to
the
luminaire 100 or removal of the luminaire 100 from the mounting structure 100
(with
the above described manipulation of the optional catch 310, if present). In
this
configuration, locking and unlocking the luminaire 100 to the mounting
structure 302
requires only a ninety degree (90 ) rotation of the screw head 314a. The stop
arm
312b assists a person seeking to lock the luminaire 100 to the mounting
structure 302
by contacting the adjacent mounting plate flange 308b before the lock arm 312a
has
rotated too far. In this manner, the stop arm 312b stops rotation of the lock
wing 312
at the appropriate location so that it does not continue rotation and end up
over the
face plate aperture 306. In the embodiment in which one or more of the screw
apertures 312e of the lock wing 312 are threaded to the screw shaft 314b, the
stop
arm 312b prevents rotation of the lock wing 312 and continued advancement of
the
screw 314 would draw the lock wing 312 closer to the screw head 314a drawing
the
luminaire 100 closer to the mounting structure face plate 304, allowing a
person to
-24 -
Date Recue/Date Received 2022-07-06
tighten the luminaire 100 up against the mounting structure face plate 304, or
leave an
gap there between at the option of the person. Fig. 7B depicts one lock wing
312 in
the locked position and one lock wing 312 in the unlocked position. Other
configurations and operations of the lock wings 312 are contemplated.
[0093] Optionally, the driver and/or other utilities can be mounted to the
mounting
plate 308. In the depicted exemplary embodiment, the mounting plate 308
comprises
a driver flange 308d extending upward from the mounting plate and the
utilities are
attached thereto. By extending the driver flange 308d upward of the mounting
plate,
the driver is separated from the luminaire housing to remove the heat of the
utilities
from the housing. The driver flange 308d may also act as a heat dissipation
fin to
dispel heat from the luminaire housing into the mounting apparatus 300.
[0094] Figs. 7F and 7G depict optional mounting structure extensions 316a,
316b
that may be mounted to the inner edge of the mounting structure face plate
aperture
306 to extend the edges of that aperture 306 inward if slightly larger than
desired for
an appropriate fit with the mounting apparatus 300. In operation, the mounting
structure extensions 316a, 316b are slide over the inner edge of the aperture
360 onto
the face plate to provide a new aperture appropriately sized.
[0095] The LEDs of this exemplary embodiment can be of any kind, color
(e.g.,
emitting any color or white light or mixture of colors and white light as the
intended
lighting arrangement requires) and luminance capacity or intensity, preferably
in the
visible spectrum. Color selection can be made as the intended lighting
arrangement
requires. In accordance with the present disclosure, LEDs can comprise any
semiconductor configuration and material or combination (alloy) that produce
the
intended array of color or colors. The LEDs can have a refractive optic built-
in with the
LED or placed over the LED, or no refractive optic; and can alternatively, or
also, have
a surrounding reflector, e.g., that re-directs low-angle and mid-angle LED
light
outwardly. In one suitable embodiment, the LEDs are white LEDs each comprising
a
gallium nitride (GaN)-based light emitting semiconductor device coupled to a
coating
containing one or more phosphors. The GaN-based semiconductor device can emit
light in the blue and/or ultraviolet range, and excites the phosphor coating
to produce
- 25 -
Date Regue/Date Received 2022-07-06
longer wavelength light. The combined light output can approximate a white
light
output. For example, a GaN-based semiconductor device generating blue light
can be
combined with a yellow phosphor to produce white light. Alternatively, a GaN-
based
semiconductor device generating ultraviolet light can be combined with red,
green, and
blue phosphors in a ratio and arrangement that produces white light (or
another
desired color). In yet another suitable embodiment, colored LEDs are used,
such are
phosphide-based semiconductor devices emitting red or green light, in which
case the
LED assembly produces light of the corresponding color. In still yet another
suitable
embodiment, the LED light board may include red, green, and blue LEDs
distributed
on the printed circuit board in a selected pattern to produce light of a
selected color
using a red-green-blue (RGB) color composition arrangement. In this latter
exemplary
embodiment, the LED light board can be configured to emit a selectable color
by
selective operation of the red, green, and blue LEDs at selected optical
intensities.
Clusters of different kinds and colors of LED is also contemplated to obtain
the
benefits of blending their output.
[0096] The various luminaires that have been discussed may be used as outdoor
lighting canopies. Each may have within it a single circuit board that
contains one or
more power supplies, drivers, and long chains of low power LEDs. Examples of
these
are described in the following figures and text that describes them.
[0097] FIG. 8 illustrates an example of a circuit that includes a driver
801 and a
long chain of low power LEDs 803 that may be driven by the driver 801, all of
which
may be on a single circuit board within an outdoor canopy light.
[0098] The driver 801 may be an integrated circuit, such as a DT3001TB
(made by
Seoul Semiconductor). The driver 801 may receive a full wave rectified sign
wave as
input power by connecting the positive side of this to input pin 4 and the
ground side to
input pin 2. This may be supplied, for example, by an AC line voltage that is
delivered
to an input connection 804. A fuse 805 may protect the circuit from an
overload. A full
wave bridge rectifier 807 may rectify the AC line voltage. The current that is
delivered
by the full wave bridge rectifier 807 may be limited, such as by resistor
pairs 809 and
resistor pairs 811 in each leg of the rectified voltage which may have a low
resistance,
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Date Regue/Date Received 2022-07-06
such as about 20 ohms each. The rectified and current-limited output from the
full
wave bridge rectifier 807 may be protected against surges in the AC line
voltage by a
transient voltage suppression diode (TVS) 813 and/or a metal oxide varistor
(MOV)
815. Operating points of the driver 801 may be set by various components, such
as by
a R_set resistor 815 and a R_bld resistor 817.
[0099]
The driver 801 may deliver a voltage-stepped, current-regulated output at its
output, such as at its output pins 11, 10, 9, and 8, with an output pin 2
serving as a
ground reference. The driver 801 may deliver current in a voltage-stepped
sequence.
The first step may provide a ground connection at pin 11, the next step at pin
10, the
next step at pin 9, and then the final step at pin 8. The voltage may increase
at each
step in synchronism with increases in the full wave bridge rectified voltage
input on pin
4. The voltage may then step back down, first back to pin 9, then back to pin
10, and
then finally back to pin 11, again in synchronism with decreases in the full
wave bridge
rectified input voltage on pin 4. The driver 801 may repeat this stepped up
and then
stepped down cycle during each rising and falling portion of each 180 degree
segment
of the full wave bridge rectified AC line input voltage.
[00100] The long chain of low power LEDs 803 may consist of a minimum of 36 or
a
minimum of 48 low power LEDs connected in series. Each LED may have a power
rating that is no more than 1 watt or .6 watts. The LEDs may be of any type,
such as a
Nichia NFSVV757D-v1 or NFSL757D-v1. They may emit white light or light of any
desired color or color combination.
[00101] As can be seen in FIG. 8, the long chain of low powered LEDs 803 may
be
divided into sub-chains, with each sub chain being driven by one of the
stepped
outputs from the driver 801. At least one sub-chain may have a minimum of 12
or 16
LEDs connected in series. No sub-chain may have less than 6 or 8 LEDs
connected in
series. Although only one chain of LEDs is shown in FIG. 8, multiple chains of
LEDs
may instead be connected in parallel to the various outputs of the driver 801,
or each
additional chain of LEDs may be connected to a separate driver with separate
or
(partially or fully) shared support circuitry.
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[00102] The design illustrated in Fig. 8 and discussed above may not require
any
electrolytic capacitors and thus may not be susceptible to failures caused by
defective
electrolytic capacitors when they age.
[00103] FIG. 9 illustrates an example of a circuit that incudes multiple
drivers 801
and 901 and a long chain of low power LEDs 803 that may be driven by multiple
drivers 801 and 901 with their outputs connected in parallel, all of which may
be on a
single circuit board, all within an outdoor canopy light. The circuit in FIG.
9 may be
identical to the one shown in FIG. 8, except that the multiple drivers 801 and
901 are
being used to drive the same chain of LEDs (or chains of LEDs if more than one
chain
of LEDs is connected in parallel). The driver 901 may be the same type as the
driver
801 or different.
[00104] As also shown in FIG. 9, the additional driver 901 may have its own
operating point setting resistors 915 and 917, but otherwise may share the
power
supply and surge suppression components that are also used with the driver 801
and
described above. Additional drivers and their associated operating point
setting
resistors may be added in parallel in the same way to provide added current-
driving
capability, which may be useful when multiple chains of LEDs are connected in
parallel
or to match the current needs of a single chain of LEDs.
[00105] FIG. 10 illustrates an example of a block diagram of an outdoor canopy
light
1001 that may use a single full wave bridge rectifier circuitry 1013 to supply
power to
multiple sets of driver circuitry / LED chain(s) 1015, 1017, 1019, 1021. The
full wave
bridge rectifier circuitry 1013 may generate a full wave bridge rectified AC
signal, such
as the one generated by the power supply illustrated in FIGS. 8 and 9. The
full wave
bridge rectifier circuitry 1013 may include the line voltage inputs 804, the
fuse 805, and
the full wave rectifier bridge rectifier 807). Each of the driver circuitry /
LED chain(s)
1015, 1017, 1019, 1021 may include one or more drivers, such as the drivers
801
and/or 901, the current limiting resistor pairs 809 and 811, the voltage
suppression
diode (TVS) 813, the metal oxide varistor (MOV) 815, associated operating set
point
circuitry, such as the R_sets 815 and 915, the R_blds 817 and 917, and one or
more
long chains of low power LEDs, such as the long chain of low power LEDs 803.
All of
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Date Regue/Date Received 2022-07-06
the components may again be on a single circuit board, with the full wave
bridge
rectifier circuitry 1013 being in a central areas and each of the multiple
sets of driver
circuitry / LED chain(s) 1015, 1017, 1019, 1021 being in one of the four
quadrants One
or more of these components may instead be placed in other locations. Separate
full
wave bridge rectifier circuitry may also instead be provided for each of the
driver
circuitry! LED chain(s) or for sub-groups of them. Similarly, a common set of
the
current limiting resistor pairs 809 and 811, the voltage suppression diode
(TVS) 813,
and the metal oxide varistor (MOV) 815 may also instead be used.
[00106] FIG. 11 illustrates an example of one quadrant of a long chain of low
power
LEDs on a single circuit board 1101. An example of one of these LEDs is LED
1103.
The light grey area on the circuit board is a foil pattern that may
advantageously be
used to connect the LEDs in series and that provides electrical connections
1105,
1107, 1109, and 1113 to sub-chains within the chain.
[00107] FIG. 12 illustrates an example of a single circuit board 1201 that may
be
placed within an outdoor canopy light that includes a centralized area 1203
which may
contain an input connection for the AC line voltage and four quadrants. Each
quadrant
may include a long chain of low power LEDs, such as the long chain of low
power
LEDs 1205, 1207, 1209, or 1211. Each quadrant may also include its own power
supply, driver(s) and operational set point components, such as in the areas
1213,
1215, 1217, and 1219 of each quadrant.
[00108] Optics may be used to direct the light generated by the LEDs. Separate
optics may be used for each LED or section of LEDs. Or all of the LEDs may
share the
same optics. The canopy lights that have been described may be used for any
purpose, such as for outdoor lighting, such as in parking lots and gas
stations.
[00109] The components, steps, features, objects, benefits, and advantages
that
have been discussed are merely illustrative. None of them, nor the discussions
relating
to them, are intended to limit the scope of protection in any way. Numerous
other
embodiments are also contemplated. These include embodiments that have fewer,
additional, and/or different components, steps, features, objects, benefits,
and/or
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Date Regue/Date Received 2022-07-06
advantages. These also include embodiments in which the components and/or
steps
are arranged and/or ordered differently.
[00110] For example, the component values that have been described may be
ideal
when the input line voltage is 120 VAC. However, other input line voltages may
be
used instead, such as 240VAC. In this situation, the typical number of
components
and/or their values may be adjusted to compensate for this voltage change, as
should
readily be apparent to those skilled in the art. For example, the number or
wattage of
the LEDs per chain and sub-chain may be doubled.
[00111] Unless otherwise stated, all measurements, values, ratings, positions,
magnitudes, sizes, and other specifications that are set forth in this
specification,
including in the claims that follow, are approximate, not exact. They are
intended to
have a reasonable range that is consistent with the functions to which they
relate and
with what is customary in the art to which they pertain.
[00112] The phrase "means for" when used in a claim is intended to and should
be
interpreted to embrace the corresponding structures and materials that have
been
described and their equivalents. Similarly, the phrase "step for" when used in
a claim is
intended to and should be interpreted to embrace the corresponding acts that
have
been described and their equivalents. The absence of these phrases from a
claim
means that the claim is not intended to and should not be interpreted to be
limited to
these corresponding structures, materials, or acts, or to their equivalents.
[00113] The scope of protection is limited solely by the claims that now
follow. That
scope is intended and should be interpreted to be as broad as is consistent
with the
ordinary meaning of the language that is used in the claims when interpreted
in light of
this specification and the prosecution history that follows, except where
specific
meanings have been set forth, and to encompass all structural and functional
equivalents.
[00114] Relational terms such as "first" and "second" and the like may be used
solely
to distinguish one entity or action from another, without necessarily
requiring or
implying any actual relationship or order between them. The terms "comprises,"
"comprising," and any other variation thereof when used in connection with a
list of
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Date Regue/Date Received 2022-07-06
elements in the specification or claims are intended to indicate that the list
is not
exclusive and that other elements may be included. Similarly, an element
preceded by
an "a" or an "an" does not, without further constraints, preclude the
existence of
additional elements of the identical type.
[00115] Nothing that has been stated or illustrated in this disclosure is
intended or
should be interpreted to cause a dedication of any component, step, feature,
object,
benefit, advantage, or equivalent to the public, regardless of whether it is
or is not
recited in the claims.
[00116] The abstract is provided to help the reader quickly ascertain the
nature of
the technical disclosure. It is submitted with the understanding that it will
not be used
to interpret or limit the scope or meaning of the claims. In addition, various
features in
the foregoing detailed description are grouped together in various embodiments
to
streamline the disclosure. This method of disclosure should not be interpreted
as
requiring claimed embodiments to require more features than are expressly
recited in
each claim. Rather, inventive subject matter lies in less than all features of
a single
disclosed embodiment.
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