Light emitting diode luminaire assembly

Abstract

A light-emitting diode (LED) luminaire assembly (10) is provided, comprising: an integrated housing (110) having: a mounting plate (702) horizontally mounted within the integrated housing (110) and dividing the integrated housing (110) into an upper internal cavity (706) and a lower internal cavity (708). A driver (106) is mounted to the mounting plate (702) within the upper internal cavity (706) and configured to supply power to the LED assembly (102). The integrated housing (110) also includes a plurality of fins (112) extending radially outward from the integrated housing (110). Heat from the driver (106) is dissipated through the mounting plate (702) and the fins (112). A driver cover (108) is coupled to the integrated housing (110) to form the upper internal cavity (706). The LED assembly (102) is coupled to the integrated housing (110) to form the lower internal cavity (708).

Description

Technical Field

[0001] This disclosure relates generally to luminaire assemblies, and more particularly to integrated housings for high-lumen light-emitting diode (LED) luminaire assemblies located in harsh and hazardous environments. Background Technology

[0002] Lighting features designed for use in harsh and hazardous environments typically require special attention to thermal management during operation. Such lighting fixtures may include many high-output LEDs operating in combination and may generate excessively high temperatures, for example, in hazardous locations where ambient temperatures are already relatively high. Peak operating temperatures of the lighting components must be managed to prevent system failure or damage. Furthermore, lighting components must be able to withstand dust, moisture, vapor, gases, or other corrosive or non-corrosive substances present in the surrounding environment to provide reliable operation and ensure the lifespan and safety of physical components. To meet these operational requirements, conventional LED luminaires often employ large, heavy, difficult-to-manufacture, and expensive housings to ensure safe and reliable operation in harsh and hazardous environments. Furthermore, large and heavy components can be difficult to carry, install, replace, and maintain. Lighting features are needed that are rated for operation in such environments while being lightweight, durable, inexpensive to manufacture, and aesthetically pleasing. Summary of the Invention

[0003] This disclosure provides a compact and lightweight luminaire lighting assembly for harsh and hazardous environments, as well as other industrial and commercial spaces. A novel integrated housing is designed to house LED elements, circuit boards, drivers, and other electronic and electrical components, and the integrated housing is optimized for higher ambient temperatures to achieve better thermal performance. For example, a single housing can house the LEDs and electronic board on one side, and a mounting plate for the driver and other electronic and electrical components on the other side, separated by a mounting plate. This advantageously reduces the product's packaging size and weight, as less material is required, making the luminaire assembly more cost-effective to manufacture and better suited for constrained installation locations, and providing better heat flow paths and heat dissipation. The assembly according to this disclosure also offers the additional benefits of ease of installation, cleaning, maintenance, and operation through a combination of the features disclosed herein.

[0004] In one embodiment, a light-emitting diode (LED) luminaire assembly is provided, including an integrated housing having a mounting plate horizontally mounted within the housing, dividing the housing into an upper internal cavity and a lower internal cavity. A driver is mounted to the mounting plate within the upper internal cavity and configured to supply power to the LED assembly. The integrated housing also includes a plurality of fins extending radially outward from the housing. Heat from the driver is dissipated through the mounting plate and the fins. A driver cover is coupled to the integrated housing to form the upper internal cavity. The LED assembly is coupled to the integrated housing to form the lower internal cavity.

[0005] In a particular embodiment, the integrated housing also includes a handle. In a particular embodiment, the handle extends from two or more of the plurality of fins. In a particular embodiment, two or more of the plurality of fins are separated from each other by a through-space. In a particular embodiment, two or more of the plurality of fins are separated from each other by a leg spacer to provide an anti-tipping feature. The separation distance of the fins in the leg spacer is greater than the separation distance of the fins in the through-space. In a particular embodiment, the integrated housing includes two anti-tipping features positioned 90 degrees apart from each other. In a particular embodiment, the mounting plate is made of a thermally conductive material. In a particular embodiment, the mounting plate has edges configured with a plurality of slits. In a particular embodiment, the driver cover is coupled to the integrated housing via a hinge. In a particular embodiment, the maximum opening angle of the driver cover relative to the integrated housing is 128 degrees. In a particular embodiment, heat from the LED assembly is dissipated through the plurality of fins. In a particular embodiment, the integrated housing also includes an occupancy sensor. In a particular embodiment, the luminaire assembly also includes one or more Internet of Things (IoT) boards mounted in the lower internal cavity of the integrated housing. In a particular embodiment, the inner surface of the integrated housing includes steps for coupling the mounting plate to the integrated housing.

[0006] In one embodiment, an integrated housing for a light-emitting diode (LED) luminaire assembly is provided, comprising: a mounting plate horizontally mounted within the integrated housing and dividing the integrated housing into an upper internal cavity and a lower internal cavity; a driver configured to supply power to the LED assembly and mounted to the mounting plate within the upper internal cavity; and a plurality of fins extending radially outward from the integrated housing. Heat from the driver is dissipated through the mounting plate and the plurality of fins.

[0007] In a particular embodiment, the integrated housing also includes a handle. In a particular embodiment, the handle extends from two or more of the plurality of fins. In a particular embodiment, two or more of the plurality of fins are separated from each other by a through-space. In a particular embodiment, two or more of the plurality of fins are separated from each other by a leg-space to provide anti-rollover features. The separation distance of the fins in the leg-space is greater than the separation distance of the fins in the through-space.

[0008] In one embodiment, a method of manufacturing a light-emitting diode (LED) luminaire assembly is provided, comprising: providing an integrated housing including a plurality of fins extending radially outward from the integrated housing; horizontally coupling a mounting plate within the integrated housing such that the mounting plate divides the integrated housing into an upper internal cavity and a lower internal cavity; mounting a driver to the mounting plate within the upper internal cavity, the driver being configured to provide power to the LED assembly, wherein heat from the driver during operation is dissipated through the mounting plate and the plurality of fins; coupling a driver cover to the integrated housing to form the upper internal cavity; and coupling the LED assembly to the integrated housing to form the lower internal cavity. Attached Figure Description

[0009] Embodiments according to this disclosure will now be described with reference to the accompanying drawings, in which:

[0010] Figure 1-5 Views from multiple perspectives are shown of embodiments of the luminaire assembly according to the present disclosure;

[0011] Figure 6 It shows Figure 1-5 An independent view of an embodiment of the integrated housing of the lighting assembly;

[0012] Figure 7-9 It shows Figure 1-5 Multiple cross-sectional views of the lighting assembly, specifically showing the interior of the integrated housing with the various components in place;

[0013] Figure 10A-10D Views from multiple perspectives are shown of another embodiment of a luminaire assembly according to the present disclosure;

[0014] Figure 11A-11D Views from multiple perspectives are shown of yet another embodiment of the luminaire assembly according to the present disclosure;

[0015] Figure 12A-12D Views from multiple perspectives are shown of another embodiment of a luminaire assembly according to the present disclosure;

[0016] Figure 13-14 The illustration schematically shows a luminaire assembly with an integrated housing that opens at different angles;

[0017] Figure 15-19 Various design alternatives for the mounting plate of the luminaire assembly according to this disclosure are shown; and

[0018] Figure 20 A method for manufacturing a light-emitting diode (LED) lamp assembly according to the present disclosure is shown. Detailed Implementation

[0019] The examples shown in the accompanying drawings will now be described in detail. Throughout the drawings, the same reference numerals are used as much as possible to refer to the same or similar parts. Directional designations such as "upper," "lower," "right," and "left" are for ease of reference to the drawings and are not intended to limit the scope of this disclosure.

[0020] Various types of lighting fixtures utilizing LEDs have been developed for a wide range of commercial and industrial environments. More specifically, LED lighting fixtures have been developed for lighting tasks in harsh and hazardous environments, such as those designed to be explosion-proof. In harsh and hazardous environments, such lighting fixtures are typically constructed to be, for example, but not limited to, shock and vibration resistant without causing filament or glass breakage, capable of providing immediate full illumination upon start-up, without lifespan reduction due to switching cycles, and with reduced handling costs. Addressing heat dissipation requirements, or thermal management, is a problem area for LED lighting fixtures. Part of the difficulty in heat dissipation stems from the fact that high-brightness LED lighting fixtures typically have a large number of LEDs operating simultaneously with relatively small spacing between them. Furthermore, the lighting fixture's electronics (e.g., drivers, boards, etc.) are also included in the lighting fixture and also dissipate heat. Therefore, in many instances, complex structures for LED module mounting and heat dissipation are considered necessary, which in turn increases the complexity and cost of the fixture.

[0021] In addition, some known LED devices use heat sinks coupled to the device, which are designed to provide a path for heat transfer and remove heat from the device to ensure longer lifespan, better lumen output, and accurate color temperature. Many of these typical LED lighting devices used in hazardous environments are high-brightness devices and generate a significant amount of heat during use. Heat dissipation in LED lighting devices is typically achieved through the manufacture of expensive heat sinks, which, due to their stacking on the device, increase the system's footprint.

[0022] Lighting fixtures operating in hazardous environments also pose a risk of explosion due to the ignition of surrounding gases or vapors, dust, fibers, etc. Such hazardous environments may occur in places such as oil refineries, petrochemical plants, grain silos, wastewater treatment facilities, or other industrial facilities, where unstable conditions exist in the surrounding environment and there is a high risk of fire or explosion. The accidental or persistent presence of airborne flammable gases, vapors, dust, or other flammable substances raises significant concerns about the overall safety and reliable operation of such facilities, including, but not limited to, the safe operation of lighting equipment within predetermined temperature limits, which, if exceeded, may create ignition sources that could cause fire or explosion. Therefore, any lighting equipment installed in these hazardous locations must operate reliably at a safe temperature relative to the surrounding atmosphere. Traditional LED lighting equipment includes numerous heat sink features for heat dissipation, which can make the lighting equipment components quite complex and lead to undesirably high manufacturing costs. Therefore, it is necessary to design lighting equipment to integrate with heat sinks to optimize heat dissipation within the components, enabling the lighting equipment to operate at a safe temperature at all times.

[0023] In addition to the hazardous sites discussed above, so-called harsh sites also require special attention in the design of lighting equipment used with them. Harsh sites may contain corrosive elements in the atmosphere, which are not necessarily explosive, and / or are subjected to temperature cycling, pressure cycling, shock, and / or mechanical vibration—elements typically absent in non-harsh operating environments. Of course, some sites where LED lighting equipment is intended are inherently both harsh and dangerous; therefore, heavy-duty equipment is designed to withstand various operating conditions that typical lighting characteristics for other purposes cannot.

[0024] Therefore, there is a demand for simpler, more reliable, and more cost-effective LED lighting components for harsh and hazardous environments. Further requirements include reducing the weight and / or size of components and increasing the durability of lighting fixtures to lower manufacturing costs, while also making the fixtures more ergonomic during installation, repair, or replacement. Simultaneously, any reduction in size or any change in components must always meet the stringent requirements for harsh and hazardous environments, such as, but not limited to, adequate heat dissipation, corrosion resistance, and fire resistance.

[0025] The embodiments disclosed herein present a novel LED luminaire assembly that houses various lighting components in a single housing, with optimized shape and size, while meeting the thermal performance requirements of specific types of harsh and / or hazardous environments. For example, certain embodiments according to this disclosure can provide a 30% weight reduction or a 35% reduction in packaging space. Furthermore, components with low temperature tolerance, such as LED drivers, can be thermally isolated from heat-generating characteristics similar to those of LEDs via a unique mounting plate to ensure normal function. Customers can further benefit from ease of installation, cleaning, maintenance, and operation in confined spaces through various novel constructions, such as handles, one or more anti-tipping features, streamlined heat dissipation fin designs, etc., which will be explained in more detail below. Other benefits of this disclosure will become apparent to those skilled in the art from the specification, drawings, and claims.

[0026] Figure 1-5 Embodiments of the luminaire assembly 10 according to this disclosure are shown from multiple perspectives. Typically, the luminaire assembly 10 may be configured to have a relatively high luminous flux—for example, in the range from about 17,000 lumens (im) to about 25,000 im, or in other suitable ranges—and may be rated for operation in harsh and hazardous environments, as discussed in detail above, or in other industrial and commercial spaces. In a particular embodiment, the luminaire assembly 10 may include an integrated housing 110 that houses an LED assembly 102, a driver 106, and other suitable lighting features. By way of example and not limitation, the LED assembly 102 may include a plurality of LEDs for providing the desired luminous flux and other electronic components such as an electronic board. The driver 106 may be configured to provide power to drive the LEDs of the LED assembly 102. In a particular embodiment, the integrated housing 110 may include one or more elements (e.g., one or more fins 112) designed to dissipate heat generated by the luminaire assembly and may be designed to both house these luminaire components (e.g., the LED assembly 102, the driver 106, and other electrical or electronic components) and perform heat dissipation to meet various thermal requirements. For example, during operation, LED components can heat up rapidly—luminaire components can reach temperatures as high as 120°C—especially when the luminaire components are operated in hazardous environments where ambient temperatures can reach, for example, 55°C. This temperature of the LED component is far above the operating temperature limit of the driver (e.g., 80°C). To prevent overheating of the driver 106 and other electrical components within the luminaire component, in a particular embodiment, the integrated housing 110 may house the LED component 102 on one side of the mounting plate 702 and the driver 106 on the other side of the mounting plate 702, providing separation between the LED component 102 and the driver 106 and also improving heat dissipation. When the mounting plate 702 is mounted horizontally in the integrated housing (e.g., as shown in the image), Figure 7 and Figure 8As shown), the mounting plate 702 can divide the integrated housing 110 into an upper internal cavity 706 and a lower internal cavity 708.

[0027] In a particular embodiment, the luminaire assembly 10 also includes a driver cover 108, which is mounted to the integrated housing 110 and configured to cover the interior of the integrated housing 110. For example, the driver cover 108 may cover the driver 106 and other sensitive electronic components housed within the integrated housing 110 to protect them from environmental influences and to seal the upper internal cavity 706. For example, the edge of the upper internal cavity 706 may be defined by the inner edges of the driver cover 108 and the integrated housing 110. Furthermore, a seal such as an O-ring (not shown) may be positioned along the interface between the driver cover 108 and the integrated housing 110, such that the luminaire assembly 10 is tightly sealed against dust, moisture, etc. Alternatively, in certain embodiments, the driver cover 108 may be coupled to the integrated housing 110 via a hinge, snap-fit, clip, adhesive, or other suitable coupling feature that allows the driver cover 108 to be opened relative to the integrated housing 110, thereby providing access to the interior of the integrated housing 110 for purposes such as maintenance or repair or replacement of various components (e.g., the driver 106) within the upper internal cavity 706. In certain embodiments, the driver cover 108 may be provided with one or more mounting features (such as mounting holes) on the top surface of the driver cover 108. For example, screw-like fasteners can be inserted through the holes to secure the luminaire assembly 10 to a desired mounting location or surface, such as, but not limited to, walls or ceilings in harsh and hazardous environments.

[0028] In a particular embodiment, the integrated housing 110 may include one or more fins 112 extending radially outward from the integrated housing 110. The integrated housing 110 may be generally cylindrical and configured to house various electrical and electronic components—such as the driver 106—within the integrated housing 110. In some embodiments, the integrated housing 110 may also house other components, such as one or more Internet of Things (IoT) boards, which enable, for example, but not limited to, communication between luminaire assemblies, lighting controls, smart features, or wireless technologies. The upper edge of the integrated housing 110 may be coupled to the driver cover 108, for example, in a sealing manner as described above, to cover the interior of the integrated housing 110. The LED assembly 102 may be attached below the bottom of the integrated housing 110 such that the LED assembly 102 is isolated from the driver 106. In a particular embodiment, the luminaire assembly 10 also includes the driver cover 108, which is mounted to the integrated housing 110 and configured to cover the interior of the integrated housing 110. For example, the LED assembly 102 may cover the bottom of the integrated housing 110 to enclose the lower internal cavity 708. For example, the edge of the lower internal cavity 708 may be defined by the LED assembly and the inner edge of the integrated housing 110.

[0029] In a particular embodiment, the fins 112 may typically be flat and oriented radially along the integrated housing 110. By way of example and not limitation, the fins 112 may be positioned around the outer periphery of the integrated housing 110 and arranged at one or more predetermined intervals from each other. Heat generated by one or more components within the luminaire assembly 10 can be dissipated into the air through the intervals and further guided away from the integrated housing 110 by the fins 112. In a particular embodiment, the interval between adjacent fins 112 may be a through interval 114, thereby providing an open passage along the axial direction of the integrated housing 110. Specifically, the fins 112 may be designed without necks or other lateral features inserted between the fins 112, thereby reducing the cross-sectional area of ​​the luminaire assembly 10 from which undesirable dust accumulation occurs. Conventionally, radiators may be designed with complex fin structures or include rib features connecting the fins, which typically extend from the integrated housing and circumferentially across the fins. This increases the complexity of the overall system and makes it difficult to manufacture and maintain, especially for cleaning, as dust, water, or other particles can accumulate on the radiator. The embodiments of this disclosure compare with and improve upon conventional fin designs because they eliminate the central rib, provide easily accessible open spaces between the fins for cleaning purposes, and simplify the fin design. With this configuration, fin 112 exhibits minimal dust or rainwater accumulation on the luminaire assembly at the installation site. This allows for easy and quick cleaning of the product during maintenance, reducing workload and water consumption.

[0030] As further shown, in a particular embodiment, the spacing between adjacent fins 112 may be a leg spacing 116, thereby providing an open passage along the axial direction of the integrated housing 110. One or more leg spacings 116 may be formed between the fins 112, separating adjacent fins 112 by a greater distance (e.g., circumferentially) than the through spacing 114. Similar to the through spacing 114, the leg spacings 116 may extend through the axial direction of the integrated housing 110, for example, to eliminate any lateral connection features that collect dust between the fins 112. In operation, when the luminaire assembly 10 is placed on a flat surface, the leg spacings 116 provide an anti-tipping feature and function as a support. This reduces or prevents tipping and product drops. Furthermore, this enhances operator safety and prevents damage to fragile parts of the luminaire assembly 10, such as lenses, sensors, glass, windows, etc. In some embodiments, two leg gaps 116 may be provided, which are separated by a 90-degree angle from each other, allowing the customer to easily place the luminaire assembly 10 in different orientations without the risk of tipping over or falling. In other embodiments, without departing from the scope of this disclosure, more or fewer leg gaps 116 may be provided as needed or depending on the location.

[0031] In a particular embodiment, a handle 118 may be formed on the exterior of the integrated housing 110, and may be configured as an extension of two or more fins 112. By way of example and not limitation, the handle 118 may extend from one fin 112, circumferentially across the leg space 116 to another adjacent fin 112. For example, in practice, the handle 118 allows a user to effortlessly carry the lighting assembly or hook it onto latches or other connectors while climbing a ladder or elevator before installation. In addition to improved ease of operation, integrating the handle 118 into the integrated housing 110 and connecting it between the fins 112 also enhances heat dissipation and improves thermal performance, as heat generated by the electronics of the integrated housing 110 can be directed away from the integrated housing 110 via the handle 118 or dissipated into the air in the leg space 116 below the handle 118. In an alternative embodiment, the handle 118 may be made of or covered with an insulating material to reduce the temperature of the handle and enable workers to operate safely during the installation or maintenance of the luminaire assembly 10 in harsh or hazardous environments.

[0032] Furthermore, in some embodiments, the cable router 120 may be disposed on the outer circumference of the integrated housing 110. For example, the cable router 120 may extend between two fins 112 and include holes for allowing a security cable to pass through, or holes to facilitate the attachment of other suitable wiring features or connectors. Additionally, as shown, a sensor assembly 122 may be coupled to the integrated housing 110. The sensor assembly 122 may encapsulate one or more sensors and / or electronics configured to detect and measure motion, area occupancy, illumination levels, ambient temperature, etc. It should be understood that although embodiments of the integrated housing 110 are described and illustrated in a particular manner with specific components (such as the cable router and sensor assembly), this configuration is not necessarily required. Other embodiments of the integrated housing, with or without these features, or various combinations thereof, are also contemplated, and these embodiments do not depart from the scope of this disclosure.

[0033] In certain embodiments, the integrated housing 110 may be integrated and manufactured as a single piece. For example, the integrated housing 110 may integrate the aforementioned individual components (such as fins, handles, sensor assemblies, etc.) into a single piece. In certain embodiments, the integrated housing 110 may be manufactured by casting. Alternatively, the integrated housing 110 may be manufactured by other manufacturing processes (such as molding, addition manufacturing, or other suitable methods). In certain embodiments, the integrated housing 110 may be made of aluminum (such as AL 8360) or may be made of other thermally conductive materials (such as copper) to perform the desired functions as described herein, such as heat dissipation and durability requirements for harsh and hazardous environments.

[0034] Figure 6 A top view of the integrated housing 110 is shown, with the actuator cover 108 removed to better view the interior and upper internal cavity 706 of the integrated housing 110. In the depicted embodiment, the integrated housing 110 includes a wall 604 extending upward from a substrate 602. The substrate 602 may be circular or other shapes (such as elliptical or rectangular) for performing the desired functions of this disclosure. The substrate 602 and wall 604 together define a cavity in which the actuator 106 and other internal components may be contained and covered by the actuator cover 108. The integrated housing 110 may further include one or more pillars 606 extending from the inside of the wall 604. For example, the pillars 606 may extend along the wall 604 in the height or axial direction of the wall 604. Additionally or alternatively, the inner surface of the wall 604 may be designed with a circumferentially extending step 608. The step 608 may form a platform together with the top surface of the pillar 606, allowing mounting plates (e.g., Figure 7 The mounting plate 702 (which will be further described below) is supported thereon. For example, one or more supports 606 may be drilled with holes to receive fasteners such as screws to secure the mounting plate in place. Alternatively or additionally, other coupling features may also be used to mount the mounting plate within the integrated housing 110, such as washers or adhesive sealants. As another example, O-rings or other elements may be further installed between the step 608 and the mounting plate to further seal or isolate the upper internal cavity 706 from the lower internal cavity 708.

[0035] In certain embodiments, the thicknesses of the substrate 602 and wall 604 of the integrated housing 110 can be adjusted according to the desired cooling effect and thermal performance of the luminaire assembly 10. For example, reducing the thickness can reduce the heat transferred from the integrated housing 110 to the surrounding environment, while increasing the thickness can increase the heat transferred from the integrated housing 110 to the surrounding environment. In certain embodiments, the wall 604 can be straight, tapered, stepped, or other shapes to meet different manufacturing requirements or operating parameters.

[0036] Figure 7-8Different cross-sections of the luminaire assembly 10 in a particular embodiment are shown. As shown, in a particular embodiment, a mounting plate 702 is horizontally mounted within an integrated housing 110, such that the interior of the integrated housing 110 is divided into an upper internal cavity 706 and a lower internal cavity 708. The driver 106 and other components 802 are mounted to the upper surface of the mounting plate 702 within the upper internal cavity 706. For example, the mounting plate 702 may be secured to a support 606 via fasteners and mates with the inner surface of the integrated housing 110 on a step 608 of the wall 604. On the other hand, the LED assembly 102 is secured to the underside of a substrate 602 of the integrated housing 110 below the lower internal cavity 708. Although not shown, other components, such as, but not limited to, an Internet of Things (IoT) board, may be mounted within the lower internal cavity 708. The underside of the substrate 602 may be structurally concave to receive the LED assembly 102. A lens 704 may be secured to the underside of the substrate 602 via fasteners such as screws and covers the LED assembly 102.

[0037] Figure 9 A heat dissipation flow path for the luminaire assembly 10 in a particular embodiment is illustrated. Thermal isolation is improved by mounting the driver 106 on a mounting plate 702 and separating the mounting plate 702 from the substrate 602 via a lower internal cavity 708, allowing the driver 106 to operate at a lower temperature compared to the temperature of the LED assembly 102. For example, during operation at an ambient temperature of 65°C, the LED of the LED assembly 102 may heat up to 90°C, while the driver surface temperature can be kept below its operating limits (e.g., approximately 80°C) due to the improved thermal isolation. In a particular embodiment, the mounting plate 702 may be made of a thermally conductive metal or alloy (e.g., aluminum, copper, or other suitable material). This creates a heat flow path 902 from the driver 106 to the wall 604 and further to the fins 112, allowing heat to dissipate from the integrated housing 110 and contributing to increased heat dissipation, particularly for components within the upper internal cavity 706. A separate heat flow path 904 for cooling the LED assembly 102 is created, separated from the heat flow path 902 by the substrate 602. As shown in the figure, the heat generated by the LED can be conducted through the substrate 602 to the wall 604 and dissipated to the outside via the fins 112. The isolated heat flow paths 902 and 904 improve heat dissipation and allow the system to operate at higher ambient temperatures while still meeting the different thermal requirements of various lighting components.

[0038] The aforementioned features, components, and designs, when used alone or in combination, contribute to and provide a luminaire assembly with reduced weight and height according to this disclosure. Specifically, for example, the luminaire assembly 10, as described in detail above, may have a weight of approximately 13 pounds (7L) and a height of 5 inches. Even with its compact size, the luminaire assembly 10 meets the thermal requirements for use in typical harsh and hazardous environments.

[0039] Figure 10A-12D Other possible embodiments of the luminaire assembly according to this disclosure are shown, particularly those with different fin designs to suit a variety of ambient environments, operating requirements, and usage conditions. It should be understood that although this disclosure describes and illustrates luminaire assemblies having specific fin configurations in a particular manner, the various embodiments disclosed herein are provided merely for illustrative purposes and are not an exhaustive list of all possibilities. This disclosure contemplates luminaire assemblies having any suitable fin configuration in any suitable manner, which may or may not be described in detail herein or illustrated.

[0040] exist Figure 10A-10D In the embodiments shown, a luminaire assembly 1010 is illustrated, which is generally similar to luminaire assembly 10 in that it includes an integrated housing 1012 for housing various luminaire components, such as drivers and LED assemblies, and a driver cover 1014 coupled to and covering the interior of the integrated housing 1012. Although not shown in the illustrated embodiment, in some implementations, luminaire assembly 1010 may be provided with a handle or cable router. Furthermore, the plurality of fins 1016 of the integrated housing 1012 may have a different shape than fins 112. By way of example and not limitation, the fins 1016 may be trapezoidal in shape with their upper edges sloping downwards. This further prevents the accumulation of dust or water, as these can easily detach from the slope due to gravity. Furthermore, the number and arrangement of the fins 1016 can be configured differently. For example, there may be more or fewer fins 1016 around the integrated housing 1012. As another example, the fins 1016 may be spaced with larger or smaller intervals and / or provided with more or fewer anti-tipping features. In certain embodiments, variations in the shape, size, and number of fins in the integrated housing can depend on one or more of weight considerations, thermal management requirements of a specific environment, ergonomics, dust management, water management, maintenance considerations, and / or aesthetics. Although in Figure 10A-10D As not shown in the diagram, the luminaire assembly may also include, Figure 1-9 The luminaire assembly shown includes one or more internal or external components, shapes, and features.

[0041] exist Figure 11A-11DIn the embodiments shown, a luminaire assembly 1110 is illustrated, which is generally similar to luminaire assembly 10 in that it includes an integrated housing 1112 for housing various luminaire components, such as drivers and LED assemblies, and a driver cover 1114 coupled to and covering the interior of the integrated housing. Although not shown in the illustrated embodiment, in some implementations, luminaire assembly 1110 may be provided with a handle or cable router. Furthermore, the plurality of fins 1116 of the integrated housing 1012 may differ in shape from the fins 112. By way of example and not limitation, the fins 1116 may be designed to have an increased width (e.g., in the radial direction) near the bottom of the integrated housing 1112 or near the substrate 1120. With this configuration, heat generated by the LED assemblies 1122 attached to the substrate 1120 can be rapidly dissipated by the increased heat flow area provided by the fins 1116, thereby further enhancing the thermal performance of luminaire assembly 1110. Alternatively or additionally, the integrated housing 1112 may be configured with increased height, such that the driver (not visible in these figures) is spaced further from the substrate 1120. This further improves thermal isolation, ensuring that the driver operates at a temperature much lower than that of the LED assembly 1122. This configuration of the embodiment can be particularly useful for harsh and hazardous locations with particularly high ambient temperatures (e.g., 65°C or higher). Furthermore, although shown as having a substantially horizontal upper edge, the fins may alternatively include a downwardly sloping upper edge similar to fin 1016, for example, to reduce dust accumulation. Furthermore, the number and arrangement of fins 1116 can be configured differently. For example, there may be more or fewer fins 1116 around the integrated housing 1112. As another example, the fins 1116 may be spaced with larger or smaller intervals and / or provided with more or fewer anti-tipping features. In particular embodiments, variations in the shape, size, and number of fins in the integrated housing may depend on one or more of weight considerations, thermal management requirements of a particular environment, ergonomics, dust management, water management, maintenance considerations, and / or aesthetics. Despite Figure 11A-11D As not shown in the diagram, the luminaire assembly may also include, Figure 1-9 The luminaire assembly shown includes one or more internal or external components, shapes, and features.

[0042] exist Figure 12A-12DIn the embodiments shown, a luminaire assembly 1210 is illustrated, which is generally similar to luminaire assembly 10 in that it includes an integrated housing 1212 for housing various luminaire components, such as drivers and LED assemblies, and a driver cover 1214 coupled to and covering the interior of the integrated housing. Although not shown in the illustrated embodiment, in some implementations, luminaire assembly 1210 may be provided with a handle or cable router. Furthermore, the plurality of fins 1216 of the integrated housing 1212 may have a different shape than fins 112. By way of example and not limitation, fins 1216 may have a significantly shorter axial length than fins 112 and are positioned at the bottom of the integrated housing around a substrate 1220. The radial width of fins 1216 may also be reduced such that fins 1216 remain flush with the outer surface of the integrated housing 1212. This simplifies the product structure and provides a lighter design variation, making it more cost-effective to manufacture. However, due to the reduced effective area for dissipating heat from the LED components, luminaire assembly 1210 may have poorer thermal performance compared to other embodiments (e.g., luminaire assemblies 10, 1010, and 1110), and is therefore unsuitable for sites with lower ambient temperatures (e.g., approximately 55°C or lower). Furthermore, given the colder operating environment, the height of luminaire assembly 1210 can also be shortened, resulting in a smaller product size, which is desirable in space-constrained operating environments. In certain embodiments, variations in the shape, size, and number of fins in the integrated housing can depend on one or more of weight considerations, thermal management requirements of the specific environment, ergonomics, dust management, water management, maintenance considerations, and / or aesthetics. Although in Figure 12A-12D As not shown in the diagram, the luminaire assembly may also include, Figure 1-9 The luminaire assembly shown includes one or more internal or external components, shapes, and features.

[0043] Figure 13-14A luminaire assembly 1310 is shown installed in place, with a driver cover 1312 secured to a ceiling 1316 and an integrated housing 1314 open relative to the driver cover 1312. For example, by opening the integrated housing 1314, a user can easily access the interior of the integrated housing 1314 to perform maintenance, repair, or replacement of lighting components located within the integrated housing 1314, such as a driver mounted on a mounting plate. In a particular embodiment, the free-hanging angle of the integrated housing 1314 relative to the driver cover 1312 may be 70 degrees, although other degrees are also contemplated. For example, as used herein, the free-hanging angle can be the degree to which the integrated housing is open relative to the driver cover when it is unlocked from the driver cover and no force (e.g., other than gravity) is applied to the integrated housing. In a particular embodiment, the maximum opening angle of the integrated housing 1314 relative to the driver cover 1312 may be 128 degrees, although other degrees are also contemplated. This design provides more opening space for user access, thereby facilitating access, viewing, and maintenance of the luminaire assembly 1310. In a particular embodiment, this improved opening angle can be achieved through a compact luminaire design according to the present disclosure, since the height of the luminaire assembly is advantageously reduced, thereby allowing the integrated housing 1314 to open to a greater extent before hitting the ceiling 1316.

[0044] Figure 15-17 Another embodiment of the mounting plate according to this disclosure is shown. Figure 15 and 16 In the image, the mounting plate is depicted as being installed within the integrated housing. Figure 17-19 In this illustration, the mounting plate is depicted as removable and separate from the integrated housing. In the illustrated embodiment, the mounting plate 1502 may include a flat base 1504 and a skirt or edge 1506 extending from the flat base 1504. As described herein, the mounting plate 1502 may be made of a thermally conductive metal or alloy, such as aluminum or copper, or other suitable materials. Figure 9As shown and described herein, heat generated by electronic or electrical components (e.g., driver 1518) mounted on mounting plate 1502 can be dissipated to the surroundings via the flat base 1504 and edge 1506. In a particular embodiment, edge 1506 may be oriented at an angle relative to the vertical direction. Accordingly, the inner wall 1508 of integrated housing 1510 may be shaped with angled steps 1512 to mate with edge 1506 for placement and support of mounting plate 1502. By way of example and not limitation, edge 1506 may be press-fitted or interference-fitted to wall 1508 for coupling mounting plate 1502 to integrated housing 1510. Additionally or alternatively, fasteners such as screws, pins, or snap-fits may be provided to secure mounting plate 1502 within integrated housing 1510. In a particular embodiment, edge 1506 may be configured with multiple cutouts 1514, which may help maintain maximum contact with wall 1508 to enhance thermal conductivity. For example, during manufacturing, the mounting plate 1502 may be made from a sheet of metal with a notch 1514, formed by machining, casting, stamping, or other methods. Furthermore, the edge 1506 with the notch 1514 may be flexible and spring-back to ensure close contact between the mounting plate 1502 and the integrated housing 1510. This reduces thermal resistance and allows for better conductivity. It also helps release stress or strain that may accumulate, for example, due to rapid heating or cooling cycles. Other benefits may include, but are not limited to, allowing the mounting plate 1502 to better adapt to structural irregularities on the walls 1508 of the integrated housing 1510.

[0045] At least as Figure 15-19 As shown, mounting plate 1502 may also include a central hole 1702 disposed at the center of a flat base 1504 and one or more mounting holes 1704 disposed in the flat base 1504 (e.g., near its circumference). By way of example and not limitation, cables, wires, connectors, or other features associated with luminaire components may extend through the central hole 1702 to reach LED assemblies on the other side of the integrated housing, for example, to provide power, data communication, etc., to drive and control the LED assemblies as needed. Mounting holes 1704 may be used to receive fasteners (such as screws) for securing mounting plate 1502 in place, or otherwise deployed for wire routing, etc. Although this disclosure describes mounting plates having specific features (such as various holes) in a particular manner, this disclosure contemplates mounting plates having any suitable features in any suitable manner.

[0046] Figure 18-19 Other design alternatives for the mounting plate according to this disclosure are shown. Figure 18 In some embodiments, the mounting plate 1802 may be provided with a continuous edge 1804 (i.e., without any cuts) extending from a flat base 1806 and angled relative to the vertical direction. Figure 19 In the embodiments, mounting plates 1902, 1904, and 1906 may be triangular, rectangular, square, polygonal, or of various shapes, and are provided with cutouts along their edges. Similarly, it should be understood that although this disclosure describes and illustrates luminaire assemblies having specific mounting plate configurations in particular ways, the various embodiments disclosed herein are provided merely for illustrative purposes and are not an exhaustive list of all possibilities. This disclosure contemplates luminaire assemblies having any suitable mounting plate configuration in any suitable manner.

[0047] Figure 20 A method for manufacturing a luminaire assembly according to a specific embodiment described herein is illustrated. This document can be referenced in its entirety. Figure 6-9 Method 2000 is described herein to better explain the invention. It should be understood that the embodiments disclosed herein are merely examples, and the scope of this disclosure is not limited thereto. Specific embodiments may include all or some of the steps or features of the embodiments disclosed below, or may not include these steps or features. Furthermore, details familiar to those skilled in the art are not described exhaustively.

[0048] In a particular embodiment, method 2000 may begin at step 2010, in which an integrated housing is provided. Figure 6-9During the manufacturing process of the illustrated luminaire assembly 10, the integrated housing may employ the same structure as integrated housing 110. By way of example, and not limitation, integrated housing 110 includes a substrate 602 and a wall 604 extending upward from the substrate 602. A plurality of fins 112 are disposed around the outer surface of the wall 604 and configured to dissipate heat from integrated housing 110. For example, the fins 112 may be integrally formed with integrated housing 10, or may be manufactured and assembled separately as needed. At step 2020, mounting plate 702 may be coupled within integrated housing 110 and is horizontally oriented. By way of example, and not limitation, mounting plate 702 may be secured in place using fasteners or other coupling features or methods (e.g., welding, soldering, bonding, etc.). For example, mounting plate 702 may be supported and secured by support pillars 606 (e.g., via screws, etc.), or alternatively may mate with a step 608 of wall 604 (e.g., by form fit, friction fit, press fit, etc.). In a particular embodiment, the mounting plate 702 may be spaced apart from the substrate 602 at a defined distance in a manner that divides the integrated housing 110 into an upper internal cavity 706 and a lower internal cavity 708. At step 2030, the driver 106 may be mounted onto the mounting plate 702 within the upper internal cavity 706 (e.g., on the upper side of the mounting plate 702). Additionally, other lighting components, such as IoT boards, may also be mounted onto the mounting plate 702. At step 2040, the driver cover 108 may be coupled to the integrated housing 110 to form the upper internal cavity 706. For example, the upper internal cavity 706 may be closed by the driver cover 108 after the electronic and electrical components are mounted. For example, the driver cover 108 may be coupled to the integrated housing 110 along its upper edge via a hinge or other suitable structure. At step 2050, the LED assembly 102 may be coupled to the integrated housing 110 to form the lower internal cavity 708. For example, the LED assembly 102 may be coupled to the lower side of the substrate 602 below the lower internal cavity 708. This can be achieved, for example, by securing the LED and lens 704 to the lower surface of the substrate 602 via screws or other suitable fasteners. With this configuration, the luminaire assembly according to this disclosure uses a single integrated housing to house all lighting components with compact packaging and optimized thermal performance. It is also easier to manufacture, operate, and maintain, and provides additional operational benefits.

[0049] In this document, "or" is inclusive rather than exclusive unless otherwise expressly indicated or the context otherwise indicates. Therefore, in this document, "A or B" means "A, B, or both" unless otherwise expressly indicated or the context otherwise indicates. Furthermore, "and" is both common and separate unless otherwise expressly indicated or the context otherwise indicates. Therefore, in this document, "A and B" means "A and B, commonly or separately" unless otherwise expressly indicated or the context otherwise indicates.

[0050] The scope of this invention encompasses all changes, substitutions, variations, alterations, and modifications to the exemplary embodiments described or illustrated herein that are readily understood by those skilled in the art. The scope of this disclosure is not limited to the exemplary embodiments described or illustrated herein. Furthermore, although this disclosure describes and illustrates various embodiments herein as including specific components, elements, features, functions, operations, or steps, any of these embodiments may include any combination or arrangement of any of any of the components, elements, features, functions, operations, or steps described or illustrated anywhere herein, as will be understood by those skilled in the art. Moreover, references in the appended claims to a device or system or a component of a device or system adapted to, arranged to, capable of, configured to, enable, operate, or function properly to perform a particular function cover that device, system, or component, whether or not it or the particular function is activated, turned on, or unlocked, provided that the device, system, or component is so adapted, arranged, capable of, configured, enable, operate, or function properly. Furthermore, although this disclosure describes or illustrates particular embodiments to provide particular advantages, particular embodiments may not provide these advantages, provide some advantages, or provide all of these advantages.

Claims

1. A light-emitting diode (LED) lamp assembly, comprising: Integrated housing, comprising: The mounting plate is horizontally installed inside the integrated housing and divides the integrated housing into an upper internal cavity and a lower internal cavity; A driver, configured to provide power to the LED assembly, and mounted to the mounting plate within the upper internal cavity; and Multiple fins extend radially outward from the integrated housing, wherein heat from the actuator is dissipated through the mounting plate and the multiple fins; A drive cover, wherein the drive cover is coupled to the integrated housing to form the upper internal cavity; and The LED assembly includes a plurality of LEDs, wherein the LED assembly is coupled to the integrated housing to form the lower internal cavity.

2. The LED lighting assembly according to claim 1, wherein the integrated housing further includes a handle.

3. The LED luminaire assembly of claim 2, wherein the handle extends from two or more of the plurality of fins.

4. The LED luminaire assembly of claim 1, wherein two or more of the plurality of fins are separated from each other by a through-space.

5. The LED lighting assembly of claim 4, wherein two or more of the plurality of fins are separated from each other by a leg spacing to provide an anti-tipping feature, the separation distance of the fins in the leg spacing being greater than the separation distance of the fins in the through-space.

6. The LED luminaire assembly of claim 5, wherein the integrated housing includes two anti-rollover features positioned 90 degrees apart from each other.

7. The LED luminaire assembly of claim 1, wherein the mounting plate is made of a thermally conductive material.

8. The LED luminaire assembly of claim 1, wherein the mounting plate has an edge configured with a plurality of cutouts.

9. The LED luminaire assembly of claim 1, wherein the driver cover is coupled to the integrated housing via a hinge.

10. The LED luminaire assembly of claim 9, wherein the maximum opening angle of the driver cover relative to the integrated housing is 128 degrees.

11. The LED lighting assembly of claim 1, wherein heat from the LED assembly is dissipated through the plurality of fins.

12. The LED luminaire assembly of claim 1, wherein the integrated housing further includes an occupancy sensor.

13. The LED lighting assembly of claim 1, further comprising one or more Internet of Things (IoT) boards mounted in the lower internal cavity of the integrated housing.

14. The LED luminaire assembly of claim 1, wherein the inner surface of the integrated housing includes a step for coupling the mounting plate to the integrated housing.

15. An integrated housing for a light-emitting diode (LED) luminaire assembly, the integrated housing comprising: The mounting plate is horizontally installed inside the integrated housing and divides the integrated housing into an upper internal cavity and a lower internal cavity; A driver, configured to provide power to the LED assembly, and mounted to the mounting plate within the upper internal cavity; and Multiple fins extend radially outward from the integrated housing, wherein heat from the actuator is dissipated through the mounting plate and the multiple fins.

16. The integrated housing of claim 15, wherein the integrated housing further comprises a handle.

17. The integrated housing of claim 16, wherein the handle extends from two or more of the plurality of fins.

18. The integrated housing of claim 15, wherein two or more of the plurality of fins are separated from each other by a through-space.

19. The integrated housing of claim 18, wherein two or more of the plurality of fins are separated from each other by a leg spacing to provide an anti-rollover feature, the separation distance of the fins in the leg spacing being greater than the separation distance of the fins in the through-space.

20. A method for manufacturing a light-emitting diode (LED) lamp assembly, the method comprising: An integrated housing is provided, the integrated housing including a plurality of fins extending radially outward from the integrated housing; The mounting plate is horizontally coupled within the integrated housing, such that the mounting plate divides the integrated housing into an upper internal cavity and a lower internal cavity; A driver is mounted to the mounting plate within the upper internal cavity. The driver is configured to provide power to the LED assembly, wherein heat from the driver is dissipated through the mounting plate and the plurality of fins during operation. The driver cover is coupled to the integrated housing to form the upper internal cavity; as well as The LED assembly is coupled to the integrated housing to form the lower internal cavity.

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