LED luminaires and applications thereof

Abstract

Luminaires are described herein having architecture and design facilitating thermal management of critical components while simplifying assembly, production, and installation. A luminaire, in some embodiments, comprises a housing including a base coupled to a cover of the luminaire to define at least one interior cavity for receiving a driver for a LED panel, wherein the at least one interior cavity comprises a compression bracket operable to push the driver against the cover and provide an earth ground connection and / or electromagnetic interference (EMI) ground connection between the driver and the housing.

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 / 703,243 filed October 4, 2024 which is hereby incorporated 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 thermal management of critical components while simplifying assembly, production, and installation. A luminaire, in some embodiments, comprises a housing including a base coupled to a cover of the luminaire to define at least one interior cavity for receiving a driver for a LED panel, wherein the at least one interior cavity comprises a compression bracket operable to push the driver against the cover and provide an earth ground connection and / or electromagnetic interference (EMI) ground connection between the driver and the housing.

[0011] In another aspect, a luminaire comprises a base, and a mounting assembly coupled to the base, the mounting assembly comprising a conduit for passing electrical power circuitry, wherein wires of the electrical power circuity pass through apertures in a compressible grommet body residing in the conduit.

[0012] These and other embodiments are further described in the following detailed description.

[0013] BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 illustrates an exploded view of a luminaire described herein according to some embodiments.

[0015] FIG. 2 illustrates a plan view of the luminaire of FIG. 1 wherein the cover has been removed, according to some embodiments.

[0016] FIG. 3 illustrates a cut away view of the cavity in which the driver resides, according to some embodiments.

[0017] FIG. 4 illustrates assembly of the compression bracket and driver according to some embodiments.

[0018] FIG. 5 illustrates the base fitting within the perimeter of the cover according to some embodiments.

[0019] FIG. 6 illustrates airflow apertures in the luminaire cover according to some embodiments.

[0020] FIG. 7 illustrates a mounting assembly for coupling to the base of a luminaire according to some embodiments. FIG. 8 illustrates a cross-sectional view of the mounting assembly coupling with the base of the luminaire according to some embodiments.

[0021] FIG. 9 illustrates a mounting assembly secured to the luminaire base according to some embodiments.

[0022] FIG. 10 illustrates separate coupling of mounting assembly components, according to some embodiments.

[0023] FIG. 11 illustrates a luminaire comprising a mounting plate positioned over the conduit and associated compressible grommet body according to some embodiments.

[0024] DETIALED DESCRIPTION

[0025] 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.

[0026] A luminaire described herein, in one aspect, comprises a housing including a base coupled to a cover of the luminaire to define at least one interior cavity for receiving a driver for a LED panel, wherein the at least one interior cavity comprises a compression bracket operable to push the driver against the cover and provide an earth ground connection and / or EMI ground connection between the driver and the housing.

[0027] Turning now to specific components, FIG. 1 illustrates an exploded view of a luminaire described herein according to some embodiments. The luminaire 10 of FIG. 1 comprises a cover 12 and a base 11 which are coupled to define the housing of the luminaire 10. A LED panel 13 resides on an interior surface of the base 11, and a lens 14 or other optical feature engages an aperture 15 in the cover 12 for transmitting light emitted by the LED panel 13. A reflector or light shield 16 can reside between the lens 14 and the LED panel 13. In some embodiments, the reflector 16 can assist with mixing light emitted from the LED panel 13 and / or assist in achieving the desired light distribution of the luminaire 10 in conjunction with other optical components described herein. The luminaire 10 also comprises a driver 17 for the LED panel 13. As described herein, the luminaire has at least one interior cavity in which the driver 17 is positioned. In some embodiments, the luminaire has two interior cavities defined by coupling of the cover and base.

[0028] The base and cover can be coupled by any means consistent with the technical objectives described herein. In some embodiments, one or more fasteners, such as screws or bolts, can be used to couple the base and cover. FIG. 6, for example, illustrates use of screws in the face of the cover for coupling with the base. Alternatively, the cover and base can be coupled by application of adhesive to one or more locations of the cover and / or base. Additionally, in some embodiments, the base fits within the perimeter of the cover. In other embodiments, the base and cover are of the same size and couple with one another along their respective perimeters. The cover, in some embodiments, is formed of metal or alloy. In some embodiments, the cover is stamped metal or alloy, such as stamped aluminum or stamped steel. The cover, in some embodiments, can be formed of a thermoplastic, thermoset, or combinations thereof. The cover, for example, can be injection molded plastic.

[0029] FIG. 2 illustrates a plan view of the luminaire of FIG. 1 wherein the cover has been removed. As provided in FIG. 2, the base 11 comprises a recessed region 18 for receiving the driver 17. The base 11 further comprises an additional recessed region 19. This recessed region 19 can be used to house other electrical components of the luminaire 10, such as one or more sensors 20, including motion sensor(s), temperature sensor(s), light sensor(s), and / or sensor(s) for analyzing light output of the luminaire. In some embodiments, the additional recessed region 19 can house a second driver. A second driver can be employed in luminaire having high light output which require additional power options or sources. In some embodiments, the second driver can be employed for independent control of a subset of LEDs or LED panels which are positioned on the base of the luminaire. In this way multiple lighting intensities, lighting distributions, and / or lighting colors are achievable.

[0030] The cover 12 is coupled to the base 11, thereby enclosing the two recesses 18, 19 to provide the cavities. In some embodiments, the base fits within the perimeter of the cover. In such embodiments, the base is not visible from the front and sides of the luminaire. FIG. 5 illustrates the base fitting within the perimeter of the cover according to some embodiments. The cover can comprise recesses complimentary to the recesses in the base to maintain the cavity architecture. FIG. 3 illustrates a cut away view of the cavity in which the driver resides, according to some embodiments. In the embodiment of FIG. 3, the base 11 fits within the perimeter of the cover 12, thereby defining the interior cavity 18 containing the driver 17.

[0031] As described herein, the interior cavity comprises a compression bracket operable to push the driver against the cover. Having the driver in contact with the cover can enable heat generated by the driver to be dissipated through the cover. Accordingly, the cover can be made from any material having the desired thermal conductivity for transferring heat from the driver to the external environment. In some embodiments, the cover is made from metal or alloy. Alternatively, the cover can comprise thermally conductive plastics or composites of thermally conductive plastic and metals or alloys. The compression bracket can also provide an earth ground connection and / or electromagnetic interference (EMI) ground connection between the driver and the housing. In some embodiments, the compression bracket is constructed of metal or alloy. The compression bracket can also be constructed of electrically conductive polymeric materials or polymeric composites. In some embodiments, the compression bracket comprises raised surface features for engaging the driver housing. For example, the compression bracket can comprise spikes or needle-like structures that contact the driver housing. This structural arrangement can facilitate grounding of the driver by ensuring sufficient contact between the compression plate and the driver.

[0032] The compression bracket 21 resides between driver 17 and base 11 in FIG. 3 and pushes the driver 17 in contact with the cover 12. FIG. 4 illustrates assembly of the compression bracket and driver according to some embodiments. The compression bracket 21 couples to the base 11, and the driver 17 is arranged over the compression bracket 21. Additional brackets 23 can be employed to secure the driver 17 to the base 11.

[0033] In some embodiments, the cover comprises one or more apertures to permit airflow into and out of the luminaire interior, including the cavity housing the driver. Such apertures can assist in thermal management of the driver and other components of the luminaire. FIG. 6 illustrates airflow apetures in the luminaire cover according to some embodiments. In the embodiment of FIG. 6, the apertures 60 are located adjacent to fasteners 62, such as screws, coupling the cover 12 to the base. Covers (not shown) can be placed over the apertures 61 when not in use. In some embodiments, the airflow aperture are arranged along the perimeter of the cover. A linear array of airflow apertures, such as an array of slits, can be arranged along the perimeter of the cover, in some embodiments. In other embodiments, the array of airflow apertures is arranged in the body of the cover, such as in the angle face(s) of the cover.

[0034] Returning to FIG. 2, the LED panel 13 resides on a raised platform positioned between the two recesses 18, 19. The height of the raised platform can be varied to adjust the distance between the LED panel and the lens 14 associated with the front cover 12. Distance between the LED panel 13 and the lens 14 can be adjusted according to several considerations including, type and power of LEDs employed, desired light mixing of the LED output, and / or the presence of any optics arranged between the LEDs and lens.

[0035] In some embodiments, individual optics reside over individual LEDs or groups of individual LEDs of the LED panel. 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 interior 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. Further, the optics can provide an asymmetric lighting distribution from the luminaire.

[0036] Moreover, a diffusing lens or optic can be employed in conjunction with the individual optics, such as the lens 14 illustrated in FIG. 1. 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 diffusion 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.

[0039] Having the LED panel associated with the base permits thermal management of the LED panel by the base. Heat generated by the LED panel can be conducted through the base and dissipated in the environment external to the luminaire. As with the cover, the base can be constructed of any material having the desired thermal conductivity for thermal management of the LED panel. The base, for example, can be constructed of metal, alloy, polymer, and / or polymer composite. Employing the base for thermal management of the LED panel enhances thermal efficiency of the luminaire by decoupling thermal management of the LED panel from thermal management of the driver. As described herein, thermal management of the driver occurs in conjunction with the cover of the luminaire. Luminaires described herein can further comprise a mounting assembly comprising a conduit for passing electrical power circuitry, wherein wires of the electrical power circuity pass through apertures in a compressible grommet body residing in the conduit. When the mounting assembly is secured to the luminaire, such as the base of the luminaire, walls of the conduit place the grommet body in compression thereby sealing the apertures around the wires of the electrical power circuitry. The tight sealing provided by the compressed apertures of the grommet can preclude the necessity for more complex sealing techniques, including those using potting material and / or gaskets.

[0040] The mounting assembly can also comprise a plate positioned to interface with surfaces surrounding an aperture in a canopy for receiving the luminaire. The plate can comprise one or more gaskets for interfacing with canopy surfaces depending on size of the aperture. In some embodiments, the gaskets are concentrically arranged.

[0041] FIG. 7 illustrates a mounting assembly for coupling to the base of a luminaire according to some embodiments. The mounting assembly is employed to connect the luminaire to a mounting surface such as that of a canopy. The mounting assembly 70 comprises a conduit 71 in conjunction with a plate 72. The plate 72 comprises concentric gaskets 73, 74 enabling sealing with canopy surfaces depending on aperture size in the canopy for receiving the luminaire. If the aperture size is smaller, the inner gasket 73 can effectuate the sealing. If the aperture size is larger, the outer gasket 74 can effectuate sealing with the canopy surface. Walls of the conduit 71 can also be threaded for coupling to an electrical conduit in the canopy. A grommet 75 having a compressible body with apertures extending therethrough is positioned to fit within the conduit 71 for sealing wires of electrical circuitry delivering power to the luminaire.

[0042] FIG. 8 illustrates a cross-sectional view of the mounting assembly 80 coupling with the base of the luminaire according to some embodiments. As provided in FIG. 8, wires of electrical power circuity 83 extend from the luminaire electrical components, such as the driver, through an aperture 88 in the base 81. The wires 83 are threaded through apertures in the compressible body 82 of the grommet and pass through the conduit 84. A plate 85 comprising sealing gaskets 86, 87 radially extends from the conduit 84. A portion of the conduit 84 has walls define an interior matching the shape of grommet 82. When the mounting assembly 80 is secured to the base 81, the walls of the conduit 84 compress the grommet body 82 to restrict or further tighten the apertures through which the wires 83 pass, thereby providing a seal to the wires 83. Sealing the wires 83 in this manner can inhibit or preclude water, dust, and / or other particulate matter from entering the interior of the luminaire along the path of the power circuitry. The mounting assembly can be secured to the base via screws, bolts, or other fasteners. FIG. 9 illustrates the mounting assembly 90 secured to the luminaire base 91 according to some embodiments. In the embodiment of FIG. 9, the base 91 comprises a recessed region 92 for receiving the mounting assembly 90.

[0043] In the embodiment of FIG. 8, the mounting assembly components are coupled to the base as a single architecture. Components of the mounting assembly can also be coupled to the base in a piecewise manner. FIG. 10 illustrates separate coupling of mounting assembly components, according to some embodiments. As provided in FIG. 10, the plate 17 of the mounting assembly is coupled to the base 11. The compressible grommet body 13 is then placed in the aperture 14 of the base for passing wires (not shown) to the grommet body 13. The conduit 15 is placed over the grommet body 13 and secured to the base 11 with fasteners 16, such as screws. Fastening the conduit 15 to the base 11 compresses the grommet body 13, thereby constricting the apertures therein and sealing the wires passing through the grommet body 13. FIG. 10 additionally illustrates the base 11 fitting within the perimeter of the cover 12.

[0044] Luminaires having architectures and properties described herein, in some embodiments, do not employ mounting assemblies configured to interface the luminaire with mounting surfaces, such as that of a canopy. Luminaires, in some embodiments, can be mounted in a suspended format or a pendant format. In such embodiments, one or more gaskets for sealing to a mounting surface are not needed. For embodiments not requiring sealing gaskets, the mounting assembly retains a conduit for passing electrical power circuitry, wherein wires of the electrical power circuity pass through apertures in a compressible grommet body residing in the conduit. In some embodiments, a plate can be arranged over the grommet wherein the plate provides the compression to the grommet for sealing the wires passing therethrough. The plate, for example, can comprise a conduit for receiving the grommet and associated electrical connection wires passing therethrough. When the mounting plate is coupled to the luminaire, walls and / or other structure of the conduit compress the grommet. The plate can also comprise architecture for coupling with a junction box, hooks, and / or other support structures for mounting the luminaire. FIG. 11 illustrates a mounting assembly secured to the luminaire base according to some embodiments. In the embodiment of FIG. 11, a plate I l l is coupled to the luminaire base 110. The plate 111 comprises various structures 112 operable to receiving a junction box, a pendant, hooks, or other supports. The plate comprises I l l a conduit or receptacle for receiving the compressible grommet located in an aperture of the base 110. The conduit or receptacle on the underside of the plate 111 compresses the grommet when the plate I l l is coupled to the base 110, thereby sealing the wires passing through the grommet, in a manner similar to that illustrated in FIG. 8.

[0045] Mounting assemblies described herein comprising the conduit and compressible grommet body having wireways therethrough can be employed with luminaires having a variety of architectures in addition to those described herein. Accordingly, the mounting assemblies are not limited to the specific luminaires described in the present application.

[0046] 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: housing including a base coupled to a cover of the luminaire to define at least one interior cavity for receiving a driver for a light emitting diode (LED) panel, wherein the at least one interior cavity comprises a compression bracket operable to push the driver against the cover and provide an earth ground connection and / or electromagnetic interference (EMI) ground connection between the driver and the housing.

2. The luminaire of claim 1, wherein a face of the compression bracket comprises one or more surface features facilitating the earth ground connection and / or EMI ground connection.

3. The luminaire of claim 2, wherein the surface feature comprise raised surface features.

4. The luminaire of claim 3, wherein the raised surface features comprise spikes or needlelike structures.

5. The luminaire of claim 1, wherein the cover is thermally conductive for removing heat from the driver.

6. The luminaire of claim 1, wherein the spring plate is metal or alloy.

7. The luminaire of claim 1, wherein the LED panel is in thermal communication with the base for heat removal from the LED panel.

8. The luminaire of claim 1, wherein the LED panel is mounted on raised platform of the base.

9. The luminaire of claim 1, wherein the base fits within the cover perimeter.

10. The luminaire of claim 1, wherein the base is coupled to a mounting assembly of the luminaire.

11. The luminaire of claim 1, wherein the base coupled to the cover defines at least one additional interior cavity.

12. The luminaire of claim 11, wherein the at least one additional cavity contains additional electrical components of the luminaire.

13. The luminaire of claim 12, wherein the additional electrical components comprise one or more sensors.

14. The luminaire of claim 1, wherein the cover comprises one or more holes for the passage of air into and out of the at least one interior cavity.

15. The luminaire of claim 1 further comprising a mounting assembly comprising a conduit for passing electrical power circuitry, wherein wires of the electrical power circuity pass through apertures in a compressible grommet body residing in the conduit.

16. The luminaire of claim 15, wherein interior walls of the conduit are shaped to transfer compressive force to walls of the grommet body.

17. The luminaire of claim 15, wherein the conduit comprises a threaded portion.

18. The luminaire of claim 15, wherein the mounting assembly further comprises a plate comprising at least one sealing gasket.

19. The luminaire of claim 18, wherein the plate is positioned to interface with a canopy surface.

20. The luminaire claim 15, wherein the mounting assembly is coupled to a rear surface of the base.

21. The luminaire of claim 20, wherein the base has a recessed region for receiving the mounting assembly.

22. The luminaire of claim 1, wherein individual LEDs of the LED panel are covered by individual optics.

23. The luminaire of claim 22 having an asymmetric lighting distribution.

24. A luminaire comprising: a base; and a mounting assembly coupled to the base, the mounting assembly comprising a conduit for passing electrical power circuitry, wherein wires of the electrical power circuity pass through apertures in a compressible grommet body residing in the conduit.

25. The luminaire of claim 24, wherein the base comprises an aperture in which a portion of the compressible grommet is positioned.

26. The luminaire of claim 25, wherein the aperture provides access to a light emitting panel comprising light emitting diodes located on a side of the base opposite the mounting assembly.

27. The luminaire of claim 24, wherein the mounting assembly further comprises a plate comprising two or more concentric sealing gaskets.

28. The luminaire of claim 26, wherein the mounting assembly further comprises a plate having a junction box coupled thereto.

29. The luminaire of claim 26 further comprising a diffusing lens arranged over the light emitting panel.

30. The luminaire of claim 29, wherein the diffusing lens comprises refractive structures, total internal reflection structures, or combinations thereof.

31. The luminaire of claim 30, wherein the refractive structures, total internal reflection structures, or combinations thereof are arranged on interior surfaces of the diffusing lens.

32. The luminaire of claim 30, wherein the refractive structures, total internal reflection structures, or combinations thereof are arranged on exterior surfaces of the diffusing lens.

33. The luminaire of claim 24 further comprising a cover in which the base is positioned.

34. The luminaire of claim 24, wherein the mounting assembly resides in a recess of the base.

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