LED light fixtures having a disposable antenna for bulk programming of LED drivers

Abstract

The present disclosure is directed to a programmable light fixture. The programmable light fixture is disposed in a packaging enclosure having a first opening formed therein and includes a housing having a second opening formed therein. An LED driver is mounted on a circuit board that is positioned within the housing. An antenna is coupled to the circuit board in communication with the LED driver and has a portion that extends through the second opening in the housing and the first opening in the packaging enclosure. The antenna is configured to have at least the portion of it that extends through the housing be separable from the light fixture.

Description

[0001] Led light fixtures having a disposable antenna for bulk programming of LED drivers

[0002] FIELD OF THE INVENTION

[0003] The present disclosure is generally directed to lighting technology and more specifically, to LED light fixtures having a disposable antenna for bulk programming of LED drivers prior to on-site installation.

[0004] Background

[0005] LED-based light fixtures commonly include LED driver circuitry responsible for regulating the electrical power supplied to the LED light sources (LEDs). These drivers ensure that the LEDs receive the correct voltage and current for optimal performance. The programming of LED drivers before installation is an essential step in configuring the lighting system to meet specific requirements. LED drivers typically include microcontrollers or programmable chips that control various parameters, such as brightness, color temperature, and dimming capabilities, and translate control signals into appropriate electrical signals for the LED light sources.

[0006] LED drivers often come with a programming interface, which can be a physical port (e.g., a USB or UART port) or a wireless communication method (e.g., Bluetooth, Zigbee). The programming interface allows for communication between a programming device (such as a computer, tablet or a dedicated programming tool) and the LED driver.

[0007] By programming LED drivers prior to installation, users have the flexibility to customize the lighting environment to suit specific applications, such as a commercial space, residential setting, or architectural lighting design. This customization enhances energy efficiency, lighting quality, and overall user satisfaction.

[0008] Furthermore, programming LED drivers to different outputs allows light fixture manufacturers to streamline inventory and reduce complexity. However, LED drivers are typically programmed before they are assembled inside the light fixture housings, which are frequently made of metal, and then the fixture is packaged inside a shipping carton and stacked for shipping on a pallet with other similar fixtures. All of this additional material surrounding the fixture and LED driver circuitry disposed therein interferes with electromagnetic transmissions and can prevent the LED driver from receiving a clear signal from the programming transmitter. If light fixtures could be fully assembled, stored, shipped and then programmed on-site as needed, particularly in bulk prior to delivery to an end user and / or prior to installation, it would allow for even greater manufacturing and distribution flexibility.

[0009] BACKGROUND OF THE INVENTION

[0010] Accordingly, Applicant recognized and appreciated that there is a need in the art for an antenna that can extend out of a light fixture and, optionally, its packaging to prevent the interference with wireless transmissions and allow an LED driver to receive a clear signal from a wireless programming device, enabling programming of light fixtures in the supply chain, such as bulk programming of packaged light fixtures assembled on a shipping pallette. Applicant also recognized and appreciated that it is advantageous to have the antenna introduced for such post-manufacturing programming purpose be easily removable and safely disposable, such that a user can remove and discard it prior to installing the programmed light fixture so that the antenna does not become a safety concern or compromise visual appearance of the light fixture once installed.

[0011] Accordingly, in one aspect, a packaged programmable light fixture is provided and includes a packaging enclosure having a first opening formed therein; a housing having a second opening formed therein and disposed within the packaging enclosure; an LED driver mounted on a circuit board positioned within the housing; and an antenna in communication with the LED driver and configured to receive a programming signal therefor, the antenna extending through the first opening and the second opening outside the packaging enclosure, wherein at least a portion of the antenna that extends through the opening in the housing is separable from the light fixture.

[0012] In many embodiments, the packaged programmable light fixture further includes a power supply in electrical communication with the LED driver.

[0013] In some embodiments, the antenna includes a partial cutout positioned adjacent to the first opening in the housing for facilitating separation of the portion of the antenna that extends through the housing from the light fixture.

[0014] In some embodiments, the antenna is removably coupled to the circuit board by attaching a distal end thereof to the circuit board via at least one pin. In other embodiments, the antenna is removably coupled to the circuit board by having a distal end thereof wrapped around a conductive post mounted to the circuit board. In still other embodiments, the antenna is removably coupled to the circuit board by retaining a distal end thereof by a spring-loaded clip mounted to the circuit board.

[0015] In various embodiments, the antenna includes a thin metal film, a thin metal wire having a gauge from 18 to 24, electrically conductive plastic film, non-conductive film fiber impregnated with conductive material, or fiber impregnated with conductive material.

[0016] In another aspect, the disclosure relates to a method for enabling bulk programming of LED light fixtures. The method includes packaging two or more light fixtures in separate packaging enclosures, each enclosure having a first opening formed therein, each light fixture including a housing having a second opening formed therein and disposed within the packaging enclosure; an LED driver mounted on a circuit board positioned within the housing, a power supply in electrical communication with the LED driver, an an antenna in communication with the LED driver and configured to receive a programming signal therefor from a programming device, the antenna extending through the first opening and the second opening outside the packaging enclosure, wherein at least a portion of the antenna that extends through the opening in the housing is separable from the light fixture, and assembling the two of more light fixtures on a shipping pallette proximate to each other.

[0017] It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein. It should also be appreciated that terminology explicitly employed herein that also may appear in any disclosure incorporated by reference should be accorded a meaning most consistent with the particular concepts disclosed herein.

[0018] These and other aspects of the various embodiments will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.

[0019] BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the various embodiments.

[0021] FIG. 1 A is an isometric view of an exemplary programmable light fixture, according to aspects of the present disclosure. FIG. IB is an isometric view of the exemplary programmable light fixture shown in FIG. 1 A in a packaging enclosure, according to aspects of the present disclosure.

[0022] FIG. 2 is an isometric view of an LED driver module for use with the programmable light fixture shown in FIGs. 1 A-1B, according to some aspects of the present disclosure.

[0023] FIG. 3A is an isometric view of an LED driver module for use within the programmable light fixture, according to other aspects of the present disclosure.

[0024] FIG. 3B is a close-up isometric view of the LED driver module shown in FIG. 3 A,.

[0025] FIG. 4 is a close-up isometric view of an antenna positioned on a circuit board in communciation with an LED driver, according to some aspects of the present disclosure.

[0026] FIG. 5 is a close-up isometric view of an antenna positioned on a circuit board in communciation with an LED driver, according to other aspects of the present disclosure.

[0027] FIG. 6A is a close-up isometric view of an antenna positioned on a circuit board in communciation with an LED driver, according to yet other aspects of the present disclosure .

[0028] FIG. 6B is a close-up isometric view of the antenna positioned on the circuit board, as shown in FIG. 6A.

[0029] FIG. 7 is an isometric view of a shipping pallet of exemplary programmable light fixtures in packaging enclosures shown in FIG. IB, according to aspects of the present disclosure.

[0030] DETAILED DESCRIPTION OF THE EMBODIMENTS

[0031] The present disclosure is directed to a programmable light fixture. The programmable light fixture is disposed in a packaging enclosure having a first opening formed therein and includes a housing having a second opening formed therein. An LED driver is mounted on a circuit board that is positioned within the housing. An antenna is coupled to the circuit board in communication with the LED driver and has a portion that extends through the second opening in the housing and the first opening in the packaging enclosure. The antenna is configured to have at least the portion of it that extends through the housing be separable from the light fixture.

[0032] FIG. 1A is an isometric view of a programmable light fixture 10. Referring to FIG. 1, the programmable light fixture 10 includes a housing 12 containing at least an LED driver module including a power supply, and an antenna 14. The housing 12 advantageously has an opening 16a that is configured to allow a portion 14a of the antenna 14 to extend through the opening 16a outside the housing 12, thereby allowing the antenna 14 to receive an electromagnetic signal without the housing 12 interfering with the signal.

[0033] FIG. IB illustrates an isometric view of the programmable light fixture 10 shown in FIG. 1A contained within a packaging enclosure 17. In this example, the packaging enclosure 17 has an opening 16B that is formed in the side of the enclosure 17, preferrably in the side adjacent to the side of housing having the opening 16a, and more preferrably substantially aligned with the opening 16A and is similarly dimensioned to allow the portion 14a of the antenna 14 to securely extend through the opening 16a in the housing 12 and the opening 16B in the packaging enclosure 17, thereby allowing the antenna 14 to receive an electromagnetic signal without the packaging enclosure 17 interfering with the signal. In some embodiments, the portion 14a of the antenna 14 extending outside the packaging enclosure is folded to abut the side of the enclosure 17, as shown in FIG. IB, to avoid it being caught and accidentally dislodged during shipping and handling.

[0034] FIG. 2 illustrates a close-up isometric view of the LED driver module for use within the programmable light fixture 10, according to some embodiment of the invention. In this example, the LED driver module 18 is positioned within the housing (not shown) and further includes a circuit board 20 and a power supply (not shown). An antenna 14 having its distal end (not shown) is attached and electrically coupled to the circuit board 20. In some embodiments, the distal end is soldered to the circuit board 20. In some versions of these embodiments, the antenna 14 includes a notch 14B adjacent to the opening 16, when the LED driver module 18 is disposed within the housing 12 shown in FIG. 1, providing an indication to an end user to cut the extended portion 14a of the antenna 14 at the notch 14b using scissors or snips. In other versions of these embodiments, the notch 14b is sufficiently deep to introduce a structural weakness within the portion 14a for the antenna 14 to enable the end user to simply break off the extended portion 14a.

[0035] FIGS. 3 A and 3B illustrate an LED driver module 18 for use within the programmable light fixture 10 according to other embodiments of the invention. In this example, the antenna 14 includes at least one partial cutout 22 formed therein proximate to the outside surface of the LED driver module 18 and adjacent to the opening 16a, when the LED driver module 18 is disposed within the housing 12 shown in FIG. 1. This is advantageous because the partial cutout 20 creates a structural weakness in the material of the antenna at the location of the partial cutout, and therefore a sharp pulling or twisting motion applied to the antenna 14 will cause the portion 14a of the antenna 14 to readily detach from the programmable light fixture 10 at the partial cutout 22 once the antenna served its purpose of receiving a programming signal for the LED driver.

[0036] FIGs. 4-6 illustrate alternative embodiments for the attachment of the distal end of the antenna 14 to the circuit board 20. As discussed below in connection with these Figures, in these embodiments, the antenna is temporarily secured to the circuit board and maintains reliable electrical connection during shipping and pre-installation programming of the LED driver. Following the programming operation, the antenna is completely removed by the user by separating it from the circuit board without any damage to the circuit board or any electronic components mounted thereon.

[0037] For example, FIG. 4 illustrates a close-up isometric view of the circuit board 20 for use in the programmable light fixture 10 according to one embodiment. In this example, the antenna 14 is removably coupled to the circuit board 20 by one or more pins 24 mounted or soldered to the circuit board 20 that pierce the distal end 21 of the antenna 14, securing it in place. A user could pull on the antenna 14 to dislodge it from the pins 24 and pull it out enterily from the programmable light fixture 10.

[0038] As another example, FIG. 5 illustrates a close-up isometric view of the circuit board 20 for use in the programmable light fixture 10, according to another embodiment. In this example, the antenna 14 is a thin wire and its distal end 21 is wrapped around a post 26 mounted or soldered onto the circuit board 20. A user could pull on the antenna 14 to unwrap and dislodge it from the post 26 and pull it out enterily from the programmable light fixture 10.

[0039] FIGS. 6A and 6B illustrate a close-up isometric view of the LED driver module 18 and the circuit board 20 for use within the programmable light fixture 10, according to yet another embodiment. In this example, the antenna 14 is removably coupled to the circuit board 20 by means of a spring-loaded clip 28 mounted or soldered onto the circuit board 20, retaining the distal end 21. This is advantageous because the antenna 14 could be easily pulled back out of the clip 28 when the antenna 14 is no longer needed. Although a spring-loaded clip 28 is illustrated, other clips or pressure-based means to secure the antenna 14 have been contemplated, including but not limited to catches, clamps, latches, and clasps.

[0040] FIG. 7 illustrates an isometric view of a plurality of programmable light fixtures 10 in packaging enclosures 17, as shown in FIG. IB, stacked on a pallet 30 proximte to each other. As explained above, the portion 14a of the antenna 14 is configured to extend through the opening 16A in the housing (not shown) that substantially aligns with opening 16b in the packaging 17, such that the antenna extends through both the housing (not shown) and the packaging 17. This is further advantageous because a group of programmable light fixtures 10 on a pallet 30 can be wirelessly programmed in bulk, i.e. simultaneously, by a programming device 32 prior to the installation with their antennas 14 able to receive the programming signal without interference from the housing or packaging materials.

[0041] In some examples, the antenna 14 is composed of a flexible material to allow it to be manipulated through the opening in the programmable light fixture housing 12 and / or product packaging 17. In some examples, the antenna 14 is composed of commercially available thin metal film or small gauge wire, e.g. 18 to 24 gauge. In some examples, the antenna 14 is composed of a conductive material, including but not limited to copper or aluminum. Other materials have been contemplated, such as electrically conductive plastic film, non-conductive film impregnated with conductive material, and non-conductive fiber impregnated with conductive material. In some examples, when a metal light fixture is used, an insulating layer of material including but not limited to paper, plastic, enamel, and lacquer, could be used.

[0042] In some examples, the antenna 14 is a thin metal film as shown in FIG. 4 or a metal wire as shown in FIG. 5. In some examples, the antenna 14 is a loop, wherein a second attachment mechanism could be provided to attach the antenna 14 to the circuit board 20.

[0043] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0044] The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”

[0045] The phrase “and / or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements can optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified.

[0046] As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of’ or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i. e. , “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”

[0047] As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements can optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

[0048] It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.

[0049] In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of’ and “consisting essentially of’ shall be closed or semi-closed transitional phrases, respectively.

[0050] Other implementations are within the scope of the following claims and other claims to which the applicant can be entitled.

[0051] While various examples have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and / or structures for performing the function and / or obtaining the results and / or one or more of the advantages described herein, and each of such variations and / or modifications is deemed to be within the scope of the examples described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and / or configurations will depend upon the specific application or applications for which the teachings is / are used. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific examples described herein. It is, therefore, to be understood that the foregoing examples are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, examples can be practiced otherwise than as specifically described and claimed. Examples of the present disclosure are directed to each individual feature, system, article, material, kit, and / or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and / or methods, if such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent, is included within the scope of the present disclosure.

Claims

CLAIMS:

1. A packaged programmable light fixture (10), comprising: a packaging enclosure (17) having a first opening (16b) formed therein; a light fixture housing (12) having a second opening (16a) formed therein, wherein the light fixture housing is disposed within a cavity of the packaging enclosure (17); an LED driver mounted on a circuit board (20) positioned within the light fixture housing (12); and an antenna (14) in communication with the LED driver and configured to receive a programming signal therefor, the antenna (14) extending through the second opening (16a) of the light fixture housing and at least a portion of the antenna is disposed proximal to or through the first opening (16b) of the packaging enclosure, wherein the portion (14a) of the antenna (14) is both disposable and separable from the light fixture (10) when the light fixture is removed from the packaging enclosure.

2. The programmable light fixture of claim 1, further comprising a power supply in electrical communication with the LED driver.

3. The programmable light fixture of claim 1, wherein the antenna (14) further comprises a partial cutout (22) positioned adjacent to the second opening (16a) in the light fixture housing (12) for facilitating separation of the portion (14a) of the antenna that extends through the light fixture housing.

4. The programmable light fixture of claim 1, wherein the antenna (14) is removably coupled to the circuit board (20) by attaching a distal end thereof to the circuit board via at least one pin (24).

5. The programmable light fixture of claim 1, wherein the antenna (14) is removably coupled to the circuit board (20) by having a distal end (21) thereof wrapped around a conductive post (26) mounted to the circuit board (20).

6. The programmable light fixture of claim 1, wherein the antenna (14) is removably coupled to the circuit board by retaining a distal end thereof by a spring-loaded clip (28) mounted to the circuit board (20).

7. The programmable light fixture of claim 1, wherein the antenna comprises a thin metal film, a thin metal wire having a gauge from 18 to 24, electrically conductive plastic film, non-conductive film fiber impregnated with conductive material, or fiber impregnated with conductive material.

8. The programmable light fixtur of claim 1, wherein the antenna is attached to the packaging enclosure and at least a portion of the antenna separates from the light fixture during removal of the light fixture from the packaging.

9. The programmable light fixtur of claim 8, wherein the packaging enclosure is disposable.

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