LED luminaires and applications thereof

Abstract

Luminaires are described herein having architecture and design facilitating production, installation, and maintenance. In one aspect, a luminaire comprises a monolithic body extending from a first end to a second end and defining an interior aperture. An inner frame is arranged around a perimeter of the interior aperture and secures a light transmissive cover over a light emitting diode (LED) panel positioned in the interior aperture, wherein the inner frame comprises a stop for setting compression of a seal between the light transmissive cover and the perimeter of the interior aperture. In some embodiments, the luminaire further comprises an outer frame arranged around the inner frame.

Description

[0001] LED LUMINAIRES AND APPLICATIONS THEREOF

[0002] RELATED APPLICATION DATA

[0003] The present application claims priority pursuant to Article 8 of the Patent Cooperation Treaty to United States Provisional Patent Application Serial Number 63 / 703,689 filed October 4, 2024 which is incorporated herein by reference in its entirety.

[0004] FIELD

[0005] The present application relates to luminaires and, in particular, to luminaires having architecture and lighting characteristics suitable for various outdoor applications, including canopy lighting.

[0006] BACKGROUND

[0007] In recent years, the use of light-emitting diodes (LEDs) in the development of luminaires for various lighting purposes has increased, and this trend has only accelerated as advances have been made in the field. Indeed, lighting applications, which previously had typically been served by fixtures employing high-intensity discharge (HID) lamps are now being served by LED light fixtures. Such lighting applications include, among a good many others, so-called canopy lights for gasoline stations and the like, soffit-mounted light fixtures, surface-mounted light fixtures, and a variety of factory lighting and commercial building lighting.

[0008] LED light fixtures present particularly challenging problems which relate to size and configuration, ease of installation, servicing and configurational efficiency. Achieving improvements in such characteristics while also delivering excellent heat dissipation from light fixture components can be problematic. It is desired to achieve compactness in LED light fixtures, ease of installation and ease of servicing while still allowing excellent light output and operational efficiency.

[0009] Always a major consideration in the development of LED light fixtures for various high- volume applications is controlling product cost even while delivering improved light-fixture performance. SUMMARY

[0010] In view of the foregoing considerations, luminaires are described herein having architecture and design facilitating production, installation, and maintenance. In one aspect, a luminaire comprises a monolithic body extending from a first end to a second end and defining an interior aperture. An inner frame is arranged around a perimeter of the interior aperture and secures a light transmissive cover over a light emitting diode (LED) panel positioned in the interior aperture, wherein the inner frame comprises a stop for setting compression of a seal between the light transmissive cover and the perimeter of the interior aperture. In some embodiments, the luminaire further comprises an outer frame arranged around the inner frame. The perimeter of the monolithic body can comprise a stop for setting compression of a seal when the monolithic body is coupled to a mounting surface via the outer frame. In some embodiments, the mounting surface comprises a canopy surface. Alternatively, a mounting surface comprises a soffit panel that interfaces with a canopy.

[0011] These and other embodiments are further described in the following detailed description.

[0012] BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 illustrates a perspective view of a monolithic body according to some embodiments.

[0014] FIG. 2 illustrates a cross-sectional view of the monolithic body according to some embodiments.

[0015] FIG. 3 illustrates a bottom plan view of a luminaire according to some embodiments.

[0016] FIG. 4 illustrates a cross-sectional view of a luminaire coupled to a canopy surface according to some embodiments.

[0017] FIG. 5 illustrates a cross-sectional view of a luminaire installed in a canopy according to some embodiments.

[0018] FIG. 6 illustrates a luminaire coupled to a soffit panel according to some embodiments.

[0019] FIG. 7 illustrates an asymmetric lighting distribution provided by luminaire described herein to light a transition area between the refueling areas under the canopy and the convenience store according to some embodiments.

[0020] FIGS. 8A and 8B illustrate a yoke style mounting bracket coupled to the monolithic body, according to some embodiments. FIG. 9 illustrates a bottom perspective view of the monolithic body, according to some embodiments.

[0021] FIG. 10 illustrates the monolithic body of FIG. 9 wherein compression seals have been arranged along the inner and outer frames, respectively.

[0022] FIG. 11 illustrates a bracket for securing a driver in the compartment, according to some embodiments.

[0023] DETIALED DESCRIPTION

[0024] Embodiments described herein can be understood more readily by reference to the following detailed description and examples and their previous and following descriptions. Elements, apparatus and methods described herein, however, are not limited to the specific embodiments presented in the detailed description and examples. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptations will be readily apparent to those of skill in the art without departing from the spirit and scope of the invention.

[0025] In one aspect, a luminaire comprises a monolithic body extending from a first end to a second end and defining an interior aperture. An inner frame is arranged around a perimeter of the interior aperture and secures a light transmissive cover over a LED panel positioned in the interior aperture, wherein the inner frame comprises a stop for setting compression of a seal between the light transmissive cover and the perimeter of the interior aperture.

[0026] Turning now to specific components, the monolithic body can comprise any geometry consistent with the technical objectives described herein. FIG. 1 illustrates a perspective view of a monolithic body according to some embodiments. As provided in FIG. 1, the monolithic body 10 extends longitudinally between and first end 11 and a second end 12. The monolithic body 10 also extends in the lateral direction to define a light emitting face 13 in conjunction with the longitudinal extension of the body 10. As described further herein, the monolithic body comprises a vertically arranged compartment 14 for housing the driver of the LED panel. The vertically arranged compartment 14 can comprise an aperture or junction 16 for receiving cord(s) from an external power source. Additionally, the monolithic body 10 comprises end caps 17. The end caps 17, in some embodiments, are removable to provide access to the vertically arranged compartment 14 and the electrical components therein. In some embodiments, the end caps can support one or more structural features, including features for engaging with the mounting surface or adapter plate. In some embodiments, the end caps comprises one or more structures operable to suspend the luminaire in a lighting environment.

[0027] The monolithic body can be fabricated of any desired material. In some embodiments, the monolithic body can be metal or alloy. In some embodiments, the monolithic body is plastic or plastic composite. To achieve the monolithic nature, the body can be extruded, in some embodiments. For example, the monolithic body can be extruded aluminum or extruded plastic. In being monolithic, the body can be cut or sized to the desired dimensions. This permits tailoring luminaires described herein to size requirements of various lighting applications. Moreover, the lumen output of the LED panel can also be varied according to luminaire size. The ability to vary size and lumen output while maintaining the same luminaire architecture and design provides efficient solutions to a number of lighting needs. FIG. 9 illustrates a bottom perspective view of the monolithic body, according to some embodiments. The monolithic body 90 comprises an inner frame 91 encircling an aperture 92. In some embodiments, the inner frame 91 defines the aperture 92. An outer frame 93 is arranged at least partially around in the inner frame 91. In the embodiment of FIG. 9, the inner frame 91 is surrounded by the outer frame 93. FIG. 10 illustrates the monolithic body of FIG. 9 wherein compression seals 94, 95 have been arranged along the inner 91 and outer 93 frames, respectively. The compression seals can be any material consistent with the technical objectives described herein. In some embodiments, the compression seals are foam, such as foam-in-place technology. Alternatively, the compression seals may comprise an elastomeric material. The inner 94 and outer 95 compression seals may be fabricated of the same material. In some embodiments, the inner 94 and outer 95 compression seals are formed of differing materials. The light transmissive cover of the luminaire, for example, may require a different compression setting relative to the outer seal engaging the mounting surface, such as a canopy surface. Differing compression settings can necessitate differing materials for the inner 94 and outer 95 compression seals.

[0028] In some embodiments, the body extending from a first end to a second end is not monolithic and is segmented in one or more dimensions or formed of independent sections or parts. With reference to FIG. 9, the body 90 can comprise multiple pieces. The body 90 for example can comprise a top piece 97 for housing the driver assembly, as described herein. The top piece 97 is coupled to a bottom plate 98 comprising the inner frame 91 and the outer frame 93. In some embodiments, the inner frame 91 is a separate piece from the outer frame 93. Forming the inner 91 and outer 93 frames as independent pieces can facilitate assembly and maintenance of the luminaire, in some embodiments. As described further herein, the inner frame can be independently removed from the luminaire to permit access to the driver assembly without having to uninstall or removed the luminaire from the mounting surface, such as a canopy surface.

[0029] FIG. 2 illustrates a cross-sectional view of the monolithic housing according to some embodiments. As illustrated in FIG. 2, the monolithic body 20 defines an interior aperture 23 for receiving a LED panel and cover for the LED panel (not shown). The compartment 24 for the driver (not shown) resides over the aperture 23 in the monolithic body 20. The compartment 24 comprises flanges or rails 25 for supporting the driver.

[0030] The luminaire 30 also comprises an inner frame 31 arranged around the perimeter of the interior aperture which secures a light transmissive cover 32 over the LED panel 33 positioned in the aperture 39, as illustrated in the bottom plan view of FIG. 3. In the cross-sectional view of FIG. 4, the inner frame 41 comprises a stop 44 for setting compression of a seal 45 between the light transmissive cover 42 and the perimeter 46 of the aperture 49. In the embodiment of FIG. 4, the inner frame 41 has an L-shaped structure, wherein the lateral extending portion 41a of the inner frame 41 supports the light transmissive cover 42. The vertically extending portion 41b of the inner frame 41 abuts against the monolithic body 47 defining the aperture 49, thereby acting as the stop 44 for setting compression of the seal 45 coupled to the monolithic body 47. The seal 45 interfaces with the interior side of the light transmissive cover 42 facing the LED board 46. The length of the vertically extending portion 41b is set to provide the desired compression of the seal 45. The inner frame 41 can be secured to the monolithic body 47 via one or more fasteners, such as screws. When the fasteners are in place, the inner frame 41 provides the desired compression to the seal 45 to preclude moisture and / or particulate matter from contacting the LED panel 46. In some embodiments, the fasteners are screws or bolts that hit a predetermined torque limit for setting the desired compression to the seal 45.

[0031] Luminaires described herein can further comprise an outer frame arranged around the inner frame. FIG. 3 illustrates an embodiment of the outer frame 34 is arranged around the inner frame 31. In some embodiments, the monolithic body comprises a stop for setting compression of a seal when the monolithic body is coupled to a mounting surface via the outer frame. Returning to the cross-sectional view of FIG. 4, the outer frame 50 engages a surface of the monolithic body 47 and a surface 51 to which the luminaire is mounted. The mounting surface 51 can be the surface of a canopy surrounding an aperture in the canopy for receiving the luminaire. Alternatively, the mounting surface 51 can be a soffit panel sized to fit within an aperture in a canopy. The perimeter of the monolithic body 47 comprises a stop 52 for setting compression of a perimeter seal 53 when the monolithic body 47 is coupled to the mounting surface 51. In the embodiment of FIG. 4, the perimeter seal 53 would be in a compressed state, residing above the mounting surface 51 extending into the interior 54 of the outer frame 50. As with the inner frame 41, the outer frame 50 can be coupled to the monolithic body 47 via one or more fasteners, such as screws. In some embodiments, the fasteners are screws or bolts that hit a predetermined torque limit for setting the desired compression to the perimeter seal 53.

[0032] Notably, in the embodiment of FIG. 4, the outer frame 50 comprises vertically extending legs 55, 56 of differing length. The inner leg 56 can be longer than the outer leg 55 to provide the outer frame 50 requisite structural support while enabling the outer leg 55 to have an appropriate length for engaging with the mounting surface 51 and setting the desired compression of the perimeter 53 relative to the stop 52, while maintaining a low profile of the outer frame 50.

[0033] As described herein, the monolithic body comprises a compartment over the aperture for receiving a driver for the LED panel. FIG. 5 illustrates a cross-sectional view of a luminaire installed in a canopy according to some embodiments. As provided in FIG. 5, the driver 61 resides in a compartment 62 over the LED panel 63. The inner frame 64 secures the light transmissive cover 65 over the LED panel 63, and the outer frame 66 secures the luminaire 60 to a canopy surface 67 or a soffit panel 67 for interfacing with an aperture in a canopy. FIG. 6 illustrates a luminaire coupled to a soffit panel according to some embodiments. In the embodiment of FIG. 6, the luminaire 70 couples to a soffit panel 71 via the outer bracket, as described hereinabove. In addition to facilitating coupling of the luminaire to the desired mounting surface, such as a canopy surface, the soffit panel can further comprise additional components, such as a junction box 74 and / or other electrical components for the luminaire 70. The soffit panel 71 can also comprise brackets 75 and other structures for securing the soffit panel in a canopy or other structure in which the luminaire is to be mounted. In some embodiments, a bracket is employed to secure the driver against one or more walls of the compartment housing the driver. Such positioning permits cooling of the driver via transfer of heat to the wall(s) for dissipation into the external environment. In some embodiments, the driver bracket is a compression bracket for pushing the driver against one or more walls of the compartment. The compression bracket can be spring bracket. Alternatively, compression provided by the bracket can be controlled by tightening or loosening a fastener that secures the bracket in place. FIG. 11 illustrates a bracket for securing a driver in the compartment, according to some embodiments. In the embodiment of FIG. 11, the bracket 110 traverses the width of the compartment 112. The bracket 110 has a coupling region 113 for accepting a fastener (not shown), such as a screw for securing the bracket 110 to the body 115 and pushing the driver against one or more walls of the compartment 112. The opposing end of the bracket 110 may comprise a hinge assembly permitting the bracket 110 to assume a vertical open position for insertion of the driver into the compartment 112.

[0034] The light emitting panel, in some embodiments, contacts one or more surfaces of the monolithic body for heat dissipation. In the embodiment of FIG. 4, for example, the LED board interfaces with rails 48 defining the driver compartment and / or supporting the driver. Such contact can draw heat away from the LED board for dissipation into the luminaire surrounding environment.

[0035] In some embodiments, the inner frame and outer frame can be removed from the luminaire independent of one another. Independent coupling of the inner and outer frames can facilitate installation and maintenance of the luminaire. When installing the luminaire, for example, the inner frame and cover are locked-in prior to the installation procedure. The luminaire, for example, can be shipped for installation wherein the inner frame and cover are in a locked-in position. As a result, only the outer frame is requires coupling to the canopy surface or soffit plate. Moreover, once the luminaire is installed, the inner frame can be removed without removing the luminaire from the canopy. Removal of the inner frame provides access to the LED panel. Once the LED panel is removed, access is provided to the driver and / or any electronics. Therefore, the light transmissive cover, LED panel, driver, and / or any other electronics can be replaced or serviced without disturbing placement of the luminaire in the canopy or other mounting arrangement. In some embodiments, individual optics reside over individual LEDs or groups of individual LEDs of the LED panel. Such optics 35 are illustrated in FIG. 3. The individual optics can include various arrangements of refractive structures and total internal reflection (TIR) surfaces. In some embodiments, the individual optics have structure and / or properties, including lighting distributions, described in United States Patents 10,468,566, 10,804,448, and 11,393,961 and United States Patent Application Publication 2022 / 0231207, each of which is incorporated herein by reference in its entirety. The optics can have interior cavities for receiving individual LEDs. The interior cavities can comprise one or more interior surfaces for receiving light from the LEDs. The one or more surfaces can comprise microstructures, nanostructures and / or nanofacets that are refractive, have TIR surfaces or combinations thereof. Interior surfaces of the optics direct light to one or more exterior features of the optic to provide the desired light distribution pattern form the optics, including asymmetric distributions or symmetric distributions. Exterior features can include microstructures, nanostructures and / or nanofacets that are refractive, have TIR surfaces or combinations thereof. In some embodiments, the optics provide a Type II, Type III, or Type IV lighting distribution from the luminaire. Alternatively, the optics can provide a Type I or Type V lighting distribution from the luminaire.

[0036] Moreover, a diffusing lens or optic can be employed in conjunction with the individual optics. A diffusing lens, for example, can be positioned over the light emitting panel. In some embodiments, a diffusing lens is used in the absence of individual LED optics. The diffusing lens, in some embodiments, comprises various arrangements of refractive structures and TIR surfaces. In some embodiments, the diffusion lens comprises microstructures, nanostructures and / or nanofacets that are refractive, have TIR surfaces or combinations thereof. Such optical structures can be arranged on interior surfaces and / or exterior surfaces of the lens. Interior optical structures, for example, can work in conjunction with the exterior optical structures to provide the desired lighting distribution from the luminaire, including any of the Type I-V distributions and / or asymmetric distributions. Additionally, the individual optics, diffusing lens, and / or combinations thereof can reduce glare from the luminaire. In some embodiments, the individual optics, diffusing lens, and / or combinations thereof diffuse the light emitted from the LEDs such that individual LED point light sources are not visible from the luminaire. Moreover, the individual optics, diffusing lens, and / or combinations thereof can provide desired color mixing of light emitting from the LEDs resulting in a uniform color and intensity light distribution from the luminaire. Luminaires described herein, in some embodiments, provide a color temperature of 2000-4000K. In other embodiments, luminaire described herein provide a color temperature of 4500-10, 000K.

[0037] The individual lenses and diffusing lens can be formed of molded, printed or extruded polymeric material, in some embodiments. The individual lenses and / or diffusing lens can provide symmetric or asymmetric lighting distributions from the luminaire.

[0038] Luminaires described herein can find use in canopy lighting applications. In some embodiments, an asymmetric lighting distribution from the luminaire can be employed to light areas underneath the canopy as well as areas extending beyond the canopy perimeter. For example, luminaires having asymmetric lighting distributions described herein can light refueling areas at a gas station under the canopy and transition areas extending beyond the canopy to the convenience store. Such an arrangement can enhance safety of pedestrians walking from the refueling area to the convenience store. FIG. 7 illustrates an asymmetric lighting distribution provided by luminaire described herein to light a transition area between the refueling areas under the canopy and the convenience store according to some embodiments.

[0039] In some embodiments, luminaire described herein are employed in outdoor lighting applications other than canopy lighting, including lighting of signage, tunnels, underpasses, and / or other transportation applications. In such embodiments, the monolithic body can further comprise structure, such as holes, slots or combinations thereof for receiving one or more mounting brackets. FIGS. 8A and 8B illustrate a yoke-style mounting bracket coupled to the monolithic body, according to some embodiments. The yoke-style mounting bracket traversed the raised driver compartment. Additionally, various electrical components can be coupled to the mounting bracket, such as a junction box.

[0040] Various embodiments of the invention have been described in fulfillment of the various objects of the invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptations thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the invention.

Claims

CLAIMS1. A luminaire comprising: a monolithic body extending from a first end to a second end and defining an interior aperture; an inner frame arranged around the perimeter of the aperture and securing a light transmissive cover over a light emitting diode (LED) panel positioned in the aperture, wherein the inner frame comprises a stop for setting compression of a seal between the light transmissive cover and the perimeter of the interior aperture.

2. The luminaire of claim 1 further comprising an outer frame arranged around the inner frame.

3. The luminaire of claim 1, wherein a perimeter of the monolithic body comprises a stop for setting compression of a seal when the monolithic body is coupled to a mounting surface via the outer frame.

4. The luminaire of claim 3, wherein the seal is adjacent to the stop at the perimeter of the monolithic body.

5. The luminaire of claim 3, wherein the mounting surface is a surface of a canopy.

6. The luminaire of claim 3, wherein the mounting surface is a soffit panel.

7. The luminaire of claim 1, wherein the light transmissive cover is adhered to the inner frame.

8. The luminaire of claim 2, wherein the inner frame and light transmissive cover are removable from the monolithic body independent of the outer frame.

9. The luminaire of claim 2, wherein the outer frame comprises a first leg engaging the mounting surface and a second leg engaging the monolithic body.

10. The luminaire of claim 9, wherein the first and second legs are of unequal length.

11. The luminaire of claim 10, wherein the second leg is longer than the first leg.

12. The luminaire of claim 1 further comprising a compartment positioned over the aperture for receiving a driver for the LED panel.

13. The luminaire of claim 12, wherein the driver is accessible by removing the inner frame, light transmissive cover, and LED panel.

14. The luminaire of claim 1, wherein the monolithic body is extruded.

15. The luminaire of claim 1, wherein the monolithic body is coupled to a soffit panel.

16. The luminaire of claim 15, wherein the soffit panel comprises a junction box arranged thereon.

17. The luminaire of claim 15, wherein the soffit panel comprises one or more brackets for coupling with canopy architecture.

18. The luminaire of claim 1, wherein the monolithic body further comprises structure for receiving one or more mounting brackets.

19. The luminaire of claim 18, wherein the structure comprises holes, slots or combinations thereof.

20. The luminaire of claim 1 further comprising a mounting bracket coupled to the monolithic body.

21. The luminaire of claim 1 having an asymmetric lighting distribution.

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