Replaceable and reversible light engine with active locking and safety stop

Abstract

A light engine for a floodlight, comprising: a first subassembly for a light emitting diode (LED); and a second subassembly providing a housing for the driver. The first subassembly includes upper and lower mounting hinge arms on one side, and the second subassembly includes upper and lower left hinge pins extending from the upper and lower left arms, respectively, and upper and lower right hinge pins extending from the upper and lower right arms, respectively. The first subassembly may be mounted on either side of the second subassembly by upper and lower mounting hinge arms forming a reversible opening for access to the driver. The upper mounting hinge arm and the lower mounting hinge arm have a shape relative to the hinge pin such that a safe stop can be provided. The lower mounting hinge arm may include a recess that catches on the lower arm to prevent automatic closing when in the open position.

Description

Background Art

[0001] Floodlights and other lighting fixtures can utilize light emitting diodes (LEDs) to improve light efficiency, energy efficiency, and lifespan. LED floodlights can be implemented as light engines, which are integrated assemblies of light emitting diodes (LEDs) and operating components (e.g., integrated drivers, heat sinks, etc.). Summary of the invention

[0002] A replaceable and reversible light engine with positive locking and safety stop for a floodlight is described. By providing safety stop and positive locking features, safety can be improved and ease of maintenance can be achieved while achieving reversibility and replaceability of the light engine of the floodlight.

[0003] A light engine for a floodlight may include: a first subassembly for a light emitting diode (LED); and a second subassembly providing a housing for a driver. The first subassembly includes an upper mounting hinge arm and a lower mounting hinge arm, the upper mounting hinge arm and the lower mounting hinge arm are located on one side of the outer housing, and the second subassembly includes an upper left hinge pin extending from the upper left arm, a lower left hinge pin extending from the lower left arm, an upper right hinge pin extending from the upper right arm, and a lower right hinge pin extending from the lower right arm. The first subassembly may be mounted on either side of the second subassembly by the upper mounting hinge arm and the lower mounting hinge arm on one side, thereby forming a reversible opening for accessing the driver accommodated by the second subassembly.

[0004] To provide a safety stop, the upper and lower mounting hinge arms may have oblong apertures that are offset at an offset angle relative to the major axis of the oblong head of the hinge pin of the second subassembly.

[0005] To provide a positive locking mechanism, the lower mounting hinge arm may include a downwardly facing recess on the downwardly facing surface that snaps onto the lower arm to prevent automatic closing when in the open position.

[0006] This summary is provided to introduce selected concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figures 1A to 1D A view showing a floodlight incorporating a replaceable and reversible light engine is shown. Figure 1A A left perspective view is shown; Figure 1B A right side bottom perspective view is shown; and Figure 1C and Figure 1D A view of the floodlight in an open configuration is shown.

[0008] Figure 2 Shown is a safety stop feature of a floodlight incorporating a replaceable and reversible light engine.

[0009] FIG. 3A to FIG. 3D The operation of the safety stop feature is shown.

[0010] FIG. 4A to FIG. 4C Shown are the closed and open positions of the floodlight with the safety stop feature.

[0011] FIG. 5A to FIG. 5C An active locking mechanism for a floodlight incorporating a replaceable and reversible light engine is shown. DETAILED DESCRIPTION

[0012] A replaceable and reversible light engine with positive locking and safety stop for a floodlight is described. By providing safety stop and positive locking features, safety can be improved and ease of maintenance can be achieved while achieving reversibility and replaceability of the light engine of the floodlight.

[0013] A replaceable and reversible light engine for a floodlight allows for field replacement and repair. As described herein, a light engine for a floodlight includes two subassemblies, a first subassembly for an LED portion and a second subassembly for a driver portion (and other electronics, such as Internet of Things (IoT) components, cables, sensor circuits, etc.). The floodlight includes a front opening that exposes the driver portion (and other electronics) to facilitate installation and repair of the light engine. The light engine has a reversible symmetrical design of hinge pins and corresponding hinges to achieve full reversibility, so that the front opening can be opened from the left or right hand side, depending on how the LED subassembly is attached to the driver housing subassembly.

[0014] In fact, the front opening is reversible so that the hinge can be configured on the left or right side as needed even in the field. The first subassembly (e.g., the housing of the LED part) includes the hinge, and the second subassembly (e.g., the housing of the driver) includes the hinge pin. In this way, the light engine can be hinged at one end and supported by a latch at the other end.

[0015] Safety stops and positive locking features provide safety and allow for easy servicing while enabling reversibility and replaceability of the light engine.

[0016] Figures 1A to 1D A view showing a floodlight incorporating a replaceable and reversible light engine is shown. Figure 1A A left perspective view is shown; Figure 1B A right side bottom perspective view is shown; and Figure 1C and Figure 1DThe luminaire 100 includes a first subassembly 110 having a hinge 115 and a latch 120 and a second subassembly 130 having a hinge pin 135. The hinge 115 includes an upper mounting hinge arm 115A and a lower mounting hinge arm 115B, which are located on one side of the first subassembly 110.

[0017] exist Figures 1A to 1C In the configuration shown in FIG. 1 , the first subassembly 110 of the luminaire 100 is positioned so that the hinge 115 is located on the left side (see FIG. 1 ). Figure 1A and Figure 1C ), while the latch 120 is located on the right side (see Figure 1B and Figure 1C ). An aperture 140 is provided in the second subassembly 130 to enable an external sensor (eg, sensor 150) to be coupled to the circuit 155 located within the housing of the second subassembly 130. Figure 1D In the configuration shown in FIG. 1 , the light engine is flipped so that the hinge 115 of the first subassembly 110 is located on the right side of the second subassembly 130 , and the latch 120 is located on the left side of the second subassembly.

[0018] As mentioned above, by providing symmetrical hinge pins 135 on the second subassembly 130, the luminaire 100 has a replaceable and reversible light engine, so that the hinge 115 of the first subassembly 110 can be removed and attached or reattached to the left or right side of the second subassembly 130 as needed. Figure 1C and Figure 1D As can be seen in the figure, the hinge pin 135 of the second subassembly 130 includes an upper left hinge pin 135A extending from the upper left arm 136A, a lower left hinge pin 135B extending from the lower left arm 136B, an upper right hinge pin 135C extending from the upper right arm 136C, and a lower right hinge pin 135D extending from the lower right arm 136D.

[0019] A first feature is provided on the hinge pin, that is, the first feature serves as a stopper / safety stopper to prevent the LED subassembly (e.g., the first subassembly) from being accidentally disassembled during operation or assembly. The stopper is designed so that the LED subassembly can only be disassembled after being opened to a certain specified angle.

[0020] Figure 2 A safety stop feature of a floodlight incorporating a replaceable and reversible light engine is shown. Figure 2To provide a safety stop, the mounting hinge arm 215 of the first subassembly 210 (e.g., LED subassembly) of the light engine 200 has an oblong aperture 220 that is offset by an offset angle θ relative to the major axis 230 of the oblong head 240 of the hinge pin of the second subassembly 250 of the light engine 200. The light engine 200 may be configured as described above. Figures 1A to 1D The term "oblong" refers to an oblong shape including an oval, a rectangle, and a rounded rectangle.

[0021] In some cases, each hinge pin (e.g., the upper left hinge pin, the lower left hinge pin, the upper right hinge pin, and the lower right hinge pin) of the second subassembly 250 has an oblong head 240. In addition, the first diameter of the pin body of the hinge pins of the second subassembly 250 can be smaller than the diameter of the oblong head 240 on the major axis 230.

[0022] FIG. 3A to FIG. 3D The operation of the safety stop feature is shown. Figure 3A , in the closed position (in which the light engine is considered to be open 0°) (also as Figure 2 ), due to the offset angle (e.g., θ), the oblong head 302 of the hinge pin is prevented from falling out through the oblong aperture 304 where the hinge arm is mounted. Figure 3B As the first subassembly is opened from the second subassembly via the hinge, the oblong aperture 304 rotates through an angular range, thereby allowing the oblong head 302 of the hinge pin to fall out or be pulled out (e.g., the angular range is θ±x, where θ is the offset angle and x is the tolerance in degrees, such as having a range of 2 degrees to 10 degrees, in which case the head and the aperture are sufficiently aligned to allow the first subassembly to be removed).

[0023] When the light engine is opened further beyond the angle range that allows the first subassembly to be disassembled in order to expose the components in the second assembly, the oblong head 302 of the hinge pin is prevented from falling out through the oblong aperture 304 of the mounting hinge arm. Figure 3C and Figure 3D As can be seen in the figure, the open position of the first subassembly for enabling components in the second subassembly to be repaired (such as, 90° and greater than 90°) allows continued misalignment between the oblong hole 304 for mounting the hinge arm and the oblong head 302 of the hinge pin, thereby preventing accidental disassembly of the first subassembly.

[0024] Thus, the offset angle of the oblong aperture 220 / 304 is configured such that when the first subassembly is at an angle within a first angular range of less than 90 degrees relative to the second subassembly in the first open position, the major axis 230 of the oblong aperture is aligned with the oblong head 240 / 302 of the corresponding hinge pin. In some cases, the first angular range is between 20 and 30 degrees.

[0025] FIG. 4A to FIG. 4C Shown are the closed and open positions of the floodlight with the safety stop feature. Figure 4A Shown as Figures 1A to 1C 1. A rear left perspective view of a floodlight 400 constructed as described with reference to the floodlight 100 in FIG. 1 and also showing an enlarged view of an upper left hinge 410 formed by an upper mounting hinge arm 440 and an upper left hinge pin 420 extending from an upper left arm 430. Figure 4B A top view (with some perspective) showing an enlarged view of the upper left hinge 410 when the first subassembly 405 is in the open position; and Figure 4C Shows Figure 4B Another perspective view of the top view in which the lower left hinge 450 formed by the lower mounting hinge arm 480 and the lower left hinge pin 460 extending from the lower left arm 470 can be seen.

[0026] refer to Figure 4B and Figure 4C , it can be seen that the oblong heads 492A, 492B of the hinge pins 420, 460 are misaligned with the oblong apertures 494A, 494B of the mounting hinge arms 440, 480, which prevents accidental removal of the first subassembly 405 when the luminaire 400 is in an open position (such as for servicing) (see also Figure 3C and Figure 3D ).

[0027] A second feature is provided on the hinge that acts as an active locking mechanism. The active locking mechanism helps to lock the LED subassembly in place during repair or maintenance. When the LED subassembly is opened for repair / maintenance, after the front opening is opened to more than 90 degrees, the active locking feature comes into play and prevents the LED subassembly from closing past the locked position until / unless the LED subassembly is lifted and the active locking mechanism can be bypassed. This makes repair / maintenance easier because the front opening is prevented from closing and does not need to be manually propped open.

[0028] FIG. 5A to FIG. 5C An active locking mechanism of a floodlight incorporating a replaceable and reversible light engine is shown. To provide an active locking mechanism, the lower mounting hinge arm includes a recess on the downward facing surface that snaps onto the lower arm to prevent automatic closing when in the open position. Figure 5AA left front perspective view of the luminaire 500 in an open position and an enlarged view of the lower hinge 510 are shown. Figure 5A , when the floodlight 500 is in the open position, that is, the first subassembly 530 is at least 90 degrees relative to the second subassembly 540, the active locking mechanism 520 operates. Figures 1A to 1C Construct as described.

[0029] refer to Figure 5A and Figure 5B The active locking mechanism 520 is provided by a lower recess 550 located on a downwardly facing surface 562 of a lower mounting hinge arm 560, which is captured on a lower arm (e.g., a left lower arm 570). The lower recess 550 has a starting boundary 552 along a first axis and an ending boundary 554 along a second axis, wherein the first axis extends from the lower hinge origin (O) and passes through an aperture 580 of the lower mounting hinge arm 560, and the second axis extends from the lower hinge origin (O) and is spaced a radial distance (θ) from the first axis. P ). The radial distance can be, for example, 90 degrees, but can vary depending on the desired positive locking position of the first subassembly 530 relative to the second subassembly 540, the desired opening range of the first subassembly 530 relative to the second subassembly 540, and the ability of the recess to be clamped on the lower arm for opening and / or closing. In some cases, the starting boundary 552 and the ending boundary 554 are positioned so that when one of the left lower arm or the right lower arm of the second subassembly 540 is located in the lower recess 550, the first subassembly 530 is opened to at least 180 degrees.

[0030] Figure 5C The active locking mechanism is shown in a disengaged state, for example, when the first subassembly is hingedly opened outwardly from a closed position before opening wide enough to fall onto the lower arm due to the lower recess 550, or when the first subassembly is hingedly closed inwardly from an open position after being lifted by a user to disengage the active locking mechanism. Figure 5C , a downwardly facing surface 562 of the lower mounting hinge arm 560 that is outside the starting boundary 552 of the lower recess 550 contacts the lower arm 570 .

[0031] Since the light engine is reversible (eg, the first subassembly can be connected to be opened from the right or left side), both the lower mounting hinge arm and the upper mounting hinge arm include a recess. Figure 2 and FIG. 4A to FIG. 4C The recess in the upper mounting hinge arm can be seen in FIG, but the recess faces upward unless the first subassembly is rotated so that the upper mounting hinge arm is viewed as the lower mounting hinge arm.

[0032] It should be understood that when a value (such as an angle in degrees) is provided, the exact number (e.g., significant digits / number of digits) has flexibility to allow for acceptable manufacturing tolerances and values ​​sufficient to achieve the same desired result. For example, 90 degrees may encompass 90 degrees plus or minus an acceptable tolerance (e.g., 1% to 5%).

[0033] Although the subject matter has been described in language specific to structural features and / or acts, it should be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Instead, the specific features and acts described above are disclosed as examples of implementing the claims, and other equivalent features and acts are intended to fall within the scope of the claims.

Claims

1. A light engine for a floodlight, comprising: a first subassembly including a light emitting diode (LED) of the light engine, wherein the first subassembly includes an upper mounting hinge arm and a lower mounting hinge arm, the upper mounting hinge arm and the lower mounting hinge arm being located on one side of the first subassembly; and a second subassembly comprising a housing for a driver of the light engine, wherein the second subassembly comprises an upper left hinge pin extending from an upper left arm, a lower left hinge pin extending from a lower left arm, an upper right hinge pin extending from an upper right arm, and a lower right hinge pin extending from a lower right arm, Wherein, the first subassembly is configured to be attached to the second subassembly through the connection between the upper hinge arm and the upper left hinge pin and the connection between the lower hinge arm and the lower left hinge pin so as to be opened to the left through the hinge, and the first subassembly is configured to be flipably attached to the second subassembly through the connection between the upper hinge arm and the upper right hinge pin and the connection between the lower hinge arm and the lower right hinge pin so as to be opened to the right through the hinge.

2. The light engine according to claim 1, wherein: The upper mounting hinge arm and the lower mounting hinge arm each include an oblong aperture that is offset at an offset angle relative to a major axis of an oblong head of a corresponding hinge pin of the second subassembly.

3. The light engine according to claim 2, wherein: The offset angle of the oblong aperture is configured such that a major axis of the oblong aperture is aligned with the oblong head of the corresponding hinge pin when the first subassembly is angled within a first angular range of less than 90 degrees relative to the second subassembly in a first open position.

4. The light engine according to claim 3, wherein: The first angle range smaller than 90 degrees is between 20 degrees and 30 degrees.

5. The light engine of any preceding claim, further comprising an active locking mechanism formed by a recess on a downwardly facing surface of the lower mounting hinge arm and snapping onto one of the left or right lower arms.

6. The light engine according to claim 5, wherein: The active locking mechanism prevents the first subassembly from closing beyond the second open position until the first subassembly is lifted to allow the left lower arm to exit the lower recess.

7. The light engine according to claim 6, wherein: The first subassembly is at an angle greater than or equal to 90 degrees relative to the second subassembly when in the second open position.

8. The light engine according to claim 5, wherein: The lower recess has a starting boundary along a first axis and an ending boundary along a second axis, wherein the first axis extends from a lower hinge origin and passes through the oblong aperture of the lower mounting hinge arm, and the second axis extends from the lower hinge origin and is at a radial distance from the first axis.

9. The light engine according to claim 8, wherein: The radial distance between the second axis and the first axis is 90 degrees.

10. The light engine according to claim 8, wherein: The starting boundary and the ending boundary are positioned so that when one of the left lower arm or the right lower arm of the second subassembly is located within the lower recess, the first subassembly is opened to at least 180 degrees.

11. The light engine according to claim 8, wherein: The upper mounting hinge arm has an upper recess on an upwardly facing surface, the upper recess having a corresponding starting boundary along a corresponding first axis and a corresponding ending boundary along a corresponding second axis, wherein the corresponding first axis extends from an upper hinge origin and passes through the oblong aperture of the upper mounting hinge arm, the corresponding second axis extends from the upper hinge origin, and the corresponding second axis is at the radial distance from the corresponding first axis.

12. A light engine according to any preceding claim, wherein: The first subassembly also includes an upper latch and a lower latch located on an opposite side of the first subassembly from the upper mounting hinge arm and the lower mounting hinge arm.

13. A light engine according to any preceding claim, wherein: The upper left hinge pin, the lower left hinge pin, the upper right hinge pin and the lower right hinge pin each include an oblong head and a pin body, wherein a first diameter of the pin body is smaller than a diameter of the oblong head on a major axis.

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