Housing for a luminaire

Abstract

An outer cover assembly includes a housing that defines an interior that is configured to at least partially receive one or more electrical components. The housing includes a housing segment that includes an outer plastic portion and an inner metal portion received within the outer plastic portion. Electrical components disposed within the housing segment provide power to at least one other electrical component.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 62 / 979,213 filed on February 20, 2020, and the entire contents of that provisional patent application are hereby incorporated by reference. Technical Field

[0003] The present disclosure relates generally to housings and, more particularly, to light fixture housings. Background Art

[0004] Luminaires are used in a variety of environments. Many of these luminaires utilize advanced technology with multiple components. As a result, these luminaires may have multiple points of failure. In lighting applications such as hazardous environments, the reliability of the lighting system is critical. Unfortunately, the characteristics of many environments (including but not limited to hazardous environments) (e.g., humidity, extreme temperatures, corrosive gases) can cause one or more components of the luminaire to fail more quickly. Additionally, the health and safety of people in such environments may be at risk. When luminaires are placed in certain environments, such as hazardous environments, some of the components of the luminaire may pose safety hazards and violate applicable standards if the components are not properly designed, manufactured, and properly integrated with the rest of the luminaire. Summary of the invention

[0005] In one aspect, a housing assembly generally includes a housing defining an interior configured to at least partially house one or more electrical components. The housing includes a housing segment including an outer plastic portion and an inner metal portion received in the outer plastic portion. The electrical component disposed within the housing segment provides power to at least one other electrical component.

[0006] In another aspect, a housing assembly generally includes a housing defining an interior configured to at least partially house one or more electrical components. The housing includes a first housing segment and a second housing segment, the first housing segment including an exterior plastic portion. A pin connector hingedly attaches the second housing segment to the exterior plastic portion of the first housing segment. The pin connector includes a metal pin attached to the exterior plastic portion of the first housing segment. The electrical component is disposed within the housing to provide power to at least one other electrical component. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 It is a perspective view of a lamp;

[0008] Figure 2 Here is another perspective view of the lamp;

[0009] Figure 3 It is an exploded view of the lamp;

[0010] Figure 4 is a perspective view of a driver compartment assembly of a luminaire;

[0011] Figure 5 is an exploded view of the driver compartment assembly;

[0012] Figure 6 is a top view of the driver compartment assembly with the controller unit and the driver unit removed;

[0013] Figure 7 is in Figure 6 a cross-section taken along line 7-7;

[0014] Figure 8 is a perspective view of the driver housing of the driver compartment assembly;

[0015] Figure 9 is a perspective view of the partition of the driver compartment assembly; and

[0016] Figure 10 is a perspective view of the pin of the driver compartment assembly. DETAILED DESCRIPTION

[0017] Referring to Figure 1 and Figure 2 a luminaire is generally designated by reference numeral 10. The luminaire includes a housing 12 that defines one or more interior spaces for enclosing the interior components of the luminaire. In the illustrated embodiment, the housing 12 includes a plurality of housing components suitably joined together. However, the housing 12 may include a single housing component. In some embodiments, the luminaire 10 may be used in a hazardous environment. In such cases, the exemplary embodiment may be located in any type of hazardous environment, including but not limited to aircraft hangars, rigs (for oil, gas or water), production rigs (for oil or gas), smelters, chemical plants, power plants, mining operations, wastewater treatment facilities, and steel mills. The hazardous environment may include an explosion-proof environment that requires an enclosure with an exemplary humidity control system to meet one or more requirements, including but not limited to flame paths.

[0018] An explosion-proof enclosure is a hazardous location enclosure. In one or more exemplary embodiments, the explosion-proof enclosure (also referred to as a fireproof enclosure) is an enclosure configured to control an explosion that occurs inside the enclosure. Additionally, the explosion-proof enclosure is configured to allow gases from inside the enclosure to escape through joints in the enclosure and cool as the gases leave the explosion-proof enclosure. The joints are also referred to as flame paths and are located at positions where two surfaces intersect and provide a passage from inside the explosion-proof enclosure to the outside of the explosion-proof enclosure, along which one or more gases may travel. The joint may be a mating of any two or more surfaces. Each surface may be any type of surface, including but not limited to flat surfaces, threaded surfaces, and serrated surfaces.

[0019] In one or more exemplary embodiments, the explosion-proof enclosure needs to meet certain standards and / or requirements. For example, NEMA has established standards that an enclosure must follow to qualify as an explosion-proof enclosure. Specifically, NEMA Types 7, 8, 9, and 10 enclosures specify the standards that explosion-proof enclosures in certain hazardous locations must follow. For example, the NEMA 7 standard applies to enclosures that are constructed for indoor use in certain hazardous locations. The hazardous locations can be defined by one or more of a number of regulatory bodies, including but not limited to the National Electrical Code of the United States (e.g., Class I, Division 1) and UL (e.g., UL 1203). For example, a Class I hazardous area as defined by the "National Electrical Code" is an area where there may be a sufficient quantity of combustible gas or vapor in the air to cause an explosion. The standards created and maintained by NEMA can be found at www.nema.org.

[0020] In one or more example embodiments, the present enclosure is a CID2 hazardous location enclosure and meets the UL844 Class I, Division 2 requirements.

[0021] As defined herein, an electrical enclosure is any type of cabinet or enclosure that houses electrical, mechanical, electromechanical, and / or electronic devices inside it. Such devices can include but are not limited to controllers (also known as control modules), hardware processors, power supplies (e.g., batteries, drivers, ballasts), sensor modules, safety barriers, sensors, sensor circuits, light sources, cables, and electrical conductors. Examples of electrical enclosures can include but are not limited to the housings for light fixtures, the housings for sensor devices, electrical connectors, junction boxes, motor control centers, breaker boxes, electrical enclosures, conduits, control panels, indicator panels, and control cabinets.

[0022] See Figures 1 to 3 , the housing 12 includes a first housing segment 14 and a second housing segment 16. The first housing segment 14 is disposed on top of the second housing segment 16 and includes a bottom housing portion 18 and a top housing portion 20 attached to the bottom housing portion. The separate first housing segment 14 can be considered as an enclosure or a part of an enclosure, whereby the bottom housing portion 18 and the top housing portion 20 respectively include the first housing segment and the second housing segment. In one embodiment, the top housing portion 20 is hingedly attached to the bottom housing portion 18. For example, a pin connector 22( Figure 2)The top housing portion 20 can be hingedly attached to the bottom housing portion 18. The top housing portion 20 can be constructed of any suitable material. In one embodiment, the top housing portion 20 is formed of metal such that the top housing portion can be characterized as a metal top cap. The first housing segment 14 defines an interior space 23 that is configured to receive one or more components of the luminaire 10. For example, a controller unit 24 for controlling the operation of the luminaire 10 and a driver unit 26 for providing power to a light source (not shown) of the luminaire can be received within the first housing segment 14.

[0023] Reference Figure 3 and Figure 4 , the bottom housing portion 18 of the first housing segment 14 includes an outer shroud 30 and an inner shroud 32 received within the outer shroud. The controller unit 24 and the driver unit 26 are received within the bottom housing portion 18. In the illustrated embodiment, the outer shroud 30 includes a polymeric housing that defines the outermost housing structure of the bottom housing portion 18, and the inner shroud 32 includes a metal housing mounted within the outer polymeric housing. In one embodiment, the inner shroud 32 defines the innermost housing structure of the bottom housing portion 18. The polymeric housing 30 includes a bottom wall 34 and a circumferentially extending sidewall 36 that projects upwardly from the bottom wall. In one embodiment, the inner shroud 32 includes an aluminum partition that has a flat bottom wall 38 and a circumferentially extending sidewall 40 that projects upwardly from the bottom wall. Without departing from the scope of the present disclosure, the inner shroud 32 can have other configurations. For example, the sidewall 40 can project from the bottom wall 38 to a greater or lesser extent. Additionally, the inner shroud can include a single plate having a bottom wall that does not have projecting sidewalls. The thickness of the bottom wall can also vary. Without limitation, the thickness of the bottom wall 38 can be between approximately 0.05 inches (0.13 cm) and approximately 0.125 inches (0.32 cm).

[0024] Reference Figure 5 , Figure 6 and Figure 9 , a plurality of holes 42 can be formed in the inner shroud 32 such that the plastic outer shroud 30 can be overmolded onto the inner shroud. The holes 42 can be formed in the sidewall 40 of the inner shroud 32. In this way, the plastic material of the outer shroud 30 can flow into the holes 42 in the inner shroud 32, thereby bonding the outer shroud to the inner shroud. However, without departing from the scope of the present disclosure, the outer shroud 30 and the inner shroud 32 can be secured together in other ways.

[0025] The configuration of the polymeric outer shroud 30 and the metallic inner shroud 32 has been found to have thermal properties similar to those of a lighting shroud incorporating a conventional single aluminum driver housing. Any suitable polymeric material can be used for the outer shroud 30. Examples include glass-reinforced polyester (GRP) and thermoplastics. For example, SMC150 produced by Menzolit and SMC405 produced by Mahindra are suitable materials for the outer shroud 30. Other polymeric materials and compounds are also contemplated without departing from the scope of the present disclosure.

[0026] Referring Figures 4 - 7 , the lip 44 projects radially outward from the sidewall 36 of the outer shroud 30 and extends circumferentially around the sidewall. The lip 44 and the sidewall 36 define a groove 46 in the outer shroud 30. The groove 46 faces upward and is configured to receive a gasket 48 that engages the bottom surface of the top housing portion 20 to provide a sealed engagement between the top housing portion 20 and the bottom housing portion 18 to maintain the requirements of the luminaire 10 to comply with applicable standards for hazardous environments.

[0027] Referring Figure 2 、 Figure 4 、 Figure 6 、 Figure 8 and Figure 10 , the pin connection 22 between the top housing portion 20 and the bottom housing portion 18 is provided by a first pin engagement structure 50 of the top housing portion, a second pin engagement structure 52 of the bottom housing portion, and a cylindrical pin 54 that engages the first and second pin engagement structures to pivotally attach the top housing portion to the bottom housing portion. The first pin engagement structure 50 includes a hook 56 that extends from one side of the top housing portion 20 near the bottom of the top housing portion. The second pin engagement structure 52 includes a pair of tabs 58 that project from the sidewall 36 of the outer shroud 30. Each tab 58 has an opening 60 ( Figure 8 ) that receives a portion of the pin 54 such that the pin is retained to the tab. The pin 54 has a pair of reduced-diameter segments 62 ( Figure 10) The pair of diameter-reduced segments 62 is received in the opening 60 in the tab 58. The segment of the pin 54 adjacent to the diameter-reduced segment 62 has a diameter larger than the diameter of the opening 60 in the tab 58, thereby retaining the pin in the opening. The hook 56 of the first pin engagement structure 50 on the top housing portion 20 is received around the intermediate segment of the pin 54 between the diameter-reduced segments 62, enabling the top housing portion to pivot relative to the bottom housing portion 18. Without departing from the scope of the present disclosure, the pin engagement structures 50, 52 can have other configurations. For example, the tab 58 of the second pin engagement structure 52 can have a different shape, or each tab can be replaced with a pair of tabs to enhance the engagement between the tab and the pin 54. In one embodiment, the pin 54 includes a metal pin, and the second pin engagement structure 52 is overmolded on the metal pin. In the illustrated embodiment, the pin 54 extends laterally beyond the tab 58. However, the longitudinal ends of the pin 54 can be configured such that the ends do not extend beyond the tab 58. For example, the ends of the pin 54 can be flush with the outer surface of the tab 58. When the top housing portion 20 pivots to engage the bottom housing portion 18, the gasket 48 on the bottom housing portion 18 seals between the housing portions. The mating locking structures 64 on the top housing portion 20 and the bottom housing portion 18 facilitate locking the housing portions together. In the illustrated embodiment, the locking structure 64 includes a flange 66 having a fastener hole 68 formed therein for receiving a fastener 70 to secure the top housing portion 20 and the bottom housing portion 18 together. Without departing from the scope of the present disclosure, the top housing portion 20 and the bottom housing portion 18 can be secured together by other means.

[0028] The second housing segment 16 is also configured to accommodate one or more components of the luminaire 10. For example, one or more light sources (not shown) can be disposed at least partially over or within the second housing segment 16 of the housing 12. A cover or lens (not shown) can be disposed on the second housing segment 16 to cover the light source 29. The housing 12 can have one or more communication links (not shown) disposed between the housing segments 14, 16 for operably connecting components within the separate housing segments. Additionally, the housing segments 14, 16 can be designed to be coupled to each other such that the entire housing 12 complies with applicable standards (e.g., hazardous location requirements).

[0029] The heat sink assembly 74 (broadly, a heat sink) can be disposed on and / or integrally formed with a portion of the housing 12. In the illustrated embodiment, the heat sink 74 is integrally formed with a portion of the second housing segment 16 of the housing 12. The heat sink assembly 74 includes one or more heat sink fins that increase the surface area of the heat sink assembly 74, thereby enhancing its heat transfer efficiency. The heat sink fins 76 can be any number and / or have any one of a variety of configurations. In the illustrated embodiment, the heat sink fins 76 are vertically oriented protrusions that extend outwardly from the second housing segment 16 of the housing 12 and are spaced apart from each other substantially equidistantly around the outer perimeter of the second housing segment. However, the heat sink fins 76 can have other configurations without departing from the scope of the present disclosure.

[0030] Additionally, the external plastic shroud 30 of the bottom housing portion 18 of the first housing segment 14 thermally isolates the interior of the first housing segment from the interior of the second housing segment 16. Specifically, the polymeric material of the shroud 30 provides thermal isolation from the hot air generated by the electrical components in the interior of the second housing segment 16. Further, the metal inner shroud 32 draws heat from the interior of the first housing segment 14 to the exterior of the first housing segment to transfer the heat to the perimeter of the housing 12. Accordingly, the bottom housing portion 18 improves the overall thermal efficiency of the luminaire 10 as compared to conventional luminaires.

[0031] The overall construction of the luminaire 10 is also configured to withstand the environmental conditions and physical demands of a hazardous environment. Specifically, the heat resistance of the luminaire 10 is in the range of approximately -35°C to approximately 140°C. When the luminaire 10 is maintained in an environment of 55°C, the luminaire is capable of maintaining the driver unit 26 at a temperature below 85°C. The luminaire 10 is also configured to withstand a 7 J impact at -35°C and room temperature. Additionally, load testing performed on the luminaire 10 indicates that the hinge connection between the top housing portion 20 and the bottom housing portion 18 of the first housing segment 14 is configured to support a load of more than 300 pounds. The housing 12 generally also passes a load test in which the housing is demonstrated to be able to support more than 170 pounds for one hour in both the open (the top housing portion 20 and the bottom housing portion 18 are in the open position) and closed (the top housing portion and the bottom housing portion are in the closed position) configurations. Accordingly, the luminaire 10 meets the physical requirements for operation in hazardous conditions.

[0032] When introducing elements of the present disclosure or its preferred embodiments, the articles “a,” “an,” “the,” and “said” are intended to mean that there is one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be other elements in addition to the listed elements.

[0033] In view of the above, it can be seen that several objects of the present disclosure have been achieved and other advantageous results have been obtained.

[0034] Various changes can be made to the components without departing from the scope of the present disclosure, and all the content included in the above specification should be understood as illustrative rather than restrictive.

Claims

1. An outer cover assembly, the outer cover assembly comprising: A housing that defines an interior configured to at least partially receive one or more electrical components, the housing including: A first housing segment having: A bottom housing portion including an outer plastic portion and an inner metal portion received within the outer plastic portion, the inner metal portion having a bottom wall; A top housing portion formed of metal and attached to the top of the bottom housing portion such that the bottom housing portion includes a metal top cap; and A second housing segment attached to the bottom housing portion and enclosing a light source operatively connected to a controller, the second housing segment including a heat sink in thermal communication with the light source; and An electrical component disposed within the bottom housing portion and mounted directly on the bottom wall of the inner space of the inner metal portion for providing power to the light source.

2. The outer cover assembly according to claim 1, wherein the top housing portion is hingedly attached to the bottom housing portion.

3. The outer cover assembly according to claim 2, further comprising a pin connection member that attaches the top housing portion to the external plastic portion of the bottom housing portion.

4. The outer cover assembly according to claim 3, wherein the pin connection member comprises a metal pin.

5. The outer cover assembly according to claim 4, wherein the pin comprises at least one reduced-diameter segment for retaining the pin to the external plastic portion of the bottom housing portion.

6. The outer cover assembly according to claim 1, wherein the external plastic portion defines a groove in which a gasket is received for sealing between the bottom housing portion and the top housing portion.

7. The outer cover assembly according to claim 1, wherein the external plastic portion is overmolded on the internal metal portion.

8. The outer cover assembly according to claim 7, wherein the internal metal portion has a plurality of holes formed therein, and the external plastic portion is molded into the holes to bond the external plastic portion to the internal metal portion.

9. The outer cover assembly according to claim 1, wherein the radiator comprises a plurality of fins formed on the housing.

10. The outer cover assembly according to claim 1, wherein the external plastic portion of the bottom housing portion thermally isolates the interior of the bottom housing portion from the interior of the top housing portion.

11. The outer cover assembly according to claim 1, wherein the assembly is a CID2 hazardous location outer cover.

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