Self-locking heatsink hatch for luminaire

Abstract

A luminaire body (102), comprising: a housing (200) comprising a wall (206) having a receiving aperture (208) and an opening (210) formed therethrough; a hatch (300) having a first surface (300-1) and a second surface (300-2), the hatch being shaped and dimensioned to be received within the opening (210) when in a closed position, the hatch further comprising a protrusion (302) dimensioned to be received by and secured within the receiving aperture (208) of the housing (200), and a first elongated flexing arm (304) substantially coplanar with the first surface (300-1) of the hatch (300), wherein the first elongated flexing arm (304) is configured to be positioned adjacent to an interior surface (202) of the housing (200) during installation of the hatch within the opening (210) such that the protrusion (302) deflects when a locking force (F 3 ) supplied by the first elongated flexing arm(304) is applied to the hatch (300) and engages with the receiving aperture (208) of the housing (200) to secure the hatch (300) in the closed position within the opening (210), the first elongated flexing arm (304) being integrally formed with the hatch (300); and wherein the hatch (300) is comprised of a heat-conductive material.

Description

[0001] 2025P80016EP

[0002] 1

[0003] SELF-LOCKING HEATSINK HATCH FOR LUMINAIRE

[0004] FIELD OF THE INVENTION

[0005] The present disclosure is generally directed to LED-based luminaires and more specifically, to a self-locking hatch for a luminaire housing.

[0006] BACKGROUND OF THE INVENTION

[0007] An access hatch on a luminaire housing (also referred to as a door or flap) serves several important functions, such as ensuring that the housing remains securely closed to protect the internal components from dust, moisture, and other environmental factors and prevent accidental exposure to electrical components as well as allowing access to the internal components of the luminaire for maintenance, repairs, or replacement of parts.

[0008] These hatches are typically configured as rigid hinged plates, requiring a separate locking mechanism (e.g., a screw or sliding lock latch) to securely attach the hatch to the housing in a closed position.

[0009] LED-based luminaires require a heatsink to dissipate heat from the LED light sources and are typically made of materials with high thermal conductivity, such as aluminum or copper, and are attached to or integrated into luminaire housings. As LEDs become more efficient, less material is required for effective thermal management, offering new possibilities for luminaire designs.

[0010] SUMMARY OF THE INVENTION

[0011] Applicant recognized and appreciated that there is a need in the art for an innovative approach to provide a lightweight access hatch that (i) is easily secured to an LED-based luminaire housing taking advantage of existing structures therein and (ii) can serve as an effective heatsinking component of the luminaire housing, either on its own or in combination with other parts of the housing.

[0012] Accordingly, in one aspect, a luminaire is provided that includes a body comprising a housing containing a wall having a receiving aperture and an opening formed therethrough.2025P80016EP

[0013] 2

[0014] A hatch is also included that has a first surface and a second surface and is shaped and dimensioned to be received within the opening formed through the housing when in a closed position. The hatch further includes a protrusion dimensioned to be received by and secured within the receiving aperture of the housing and a first elongated flexing arm substantially coplanar with the first surface of the hatch. The first elongated flexing arm is additionally configured to be positioned adjacent to an interior surface of the housing during installation of the hatch within the opening such that the protrusion deflects when a locking force supplied by the elongated flexing arm is applied to the hatch and engages with the receiving aperture of the housing to secure the hatch in the closed position within the opening. The hatch is comprised of a material that is capable of dissipating heat.

[0015] In some embodiments, the hatch is comprised of aluminum.

[0016] In some embodiments, the protrusion is integrally formed with the hatch. In some embodiments, the protrusion and the first elongated flexing arm are opposed to one another across the first surface of the hatch.

[0017] In some embodiments, a second elongated flexing arm substantially coplanar with the first surface of the hatch is included.

[0018] In some embodiments, the first and second elongated flexing arms extend perpendicular to a longitudinal axis of the hatch.

[0019] In some embodiments, the second surface of the hatch is substantially coplanar with an exterior surface of the housing when the hatch is in the closed position.

[0020] In some embodiments, the housing and the hatch are comprised of different materials.

[0021] In some embodiments, a LED light source is contained within the luminaire body.

[0022] 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. 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.

[0023] These and other aspects of the various embodiments will be apparent from and elucidated with reference to the embodiment s) described hereinafter.2025P80016EP

[0024] 3

[0025] BRIEF DESCRIPTION OF THE DRAWINGS

[0026] 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.

[0027] FIG. 1 A depicts a close-up view schematic representation of the interior of a housing of a luminaire body, according to an aspect of the present disclosure.

[0028] FIG. IB depicts a close-up view schematic representation of the exterior of the housing of the luminaire body, according to an aspect of the present disclosure.

[0029] FIG. 1C depicts a luminare including the luminaire body of FIGS. 1 A-1B and a LED light source contained therein.

[0030] FIG. 2 depicts a front view schematic representation of an unloaded selflocking heatsink hatch, according to an aspect of the present disclosure.

[0031] FIG. 3 depicts a close-up view schematic representation of the self-locking heatsink hatch positioned within the housing of the luminaire, according to an aspect of the present disclosure.

[0032] FIG. 4A depicts a close up view of the self-locking heatsink hatch engaged with the housing, according to an aspect of the present disclosure.

[0033] FIG. 4B depicts another close up view of the self-locking heatsink hatch engaged with the housing, according to an aspect of the present disclosure.

[0034] FIG. 5 A depicts a perspective view schematic representation of the selflocking heatsink hatch secured within the housing, according to an aspect of the present disclosure.

[0035] FIG. 5B depicts a side view schematic representation of the self-locking heatsink hatch within the housing, according to an aspect of the present disclosure.

[0036] FIG. 6A depicts a finite element analysis of the displacement of the selflocking heatsink hatch during insertion into the housing, according to an aspect of the present disclosure.

[0037] FIG. 6B depicts a finite element analysis of the stress of the self-locking heatsink hatch during insertion into the housing, according to an aspect of the present disclosure.

[0038] DETAILED DESCRIPTION OF THE EMBODIMENTS

[0039] The present disclosure is generally directed to a luminaire such as an outdoor roadway luminaire and a body therefor. The luminaire body includes a housing comprising a2025P80016EP

[0040] 4

[0041] wall having a receiving aperture and an opening formed therethrough. The luminaire body further includes a hatch is included that is shaped and dimensioned to be received within the opening of the housing when in a closed position. The hatch further includes a protrusion that is dimensioned to be received by and secured within the receiving aperture of the housing. One or more flexing arms are included that are substantially coplanar with the hatch and are dimensioned to extend beyond the perimeter of the opening in the housing when in a closed position.

[0042] Referring to the figures, in FIGS. 1 A and IB a close-up interior view and exterior view of a luminaire body 102 including a housing 200 is shown, respectively. The housing 200 has an interior surface 202, an exterior surface 204, a wall 206, a receiving aperture 208, and an opening 210 formed through the interior and exterior surfaces 202 and 204. In this example, the receiving aperture 208 is a small opening in the proximal end of the housing 200 that is dimensioned to receive a protrusion of a hatch, as explained below. In many embodiments, a pair of contact bumps 212 are positioned on the distal end of the housing 200, as explained below and shown in FIG. 3. In yet other embodiments, a pair of stopper mechanisms 214 are included on each side of the housing (see FIG. 1 A) to prevent the first surface of the hatch 300-1 from being inserted too far into the interior of the housing 200, as explained below. In other embodiments, instead of or in conjunction with the stopper mechanisms 214, a portion of the casting of the housing 200 (e.g., a ledge) is provided that the hatch can rest on when positioned within the housing 200 (not shown).

[0043] Referring to FIG. 1C, a luminaire 100 includes the luminaire body 102 with a hatch 300 and a LED light source contained within the luminaire body.

[0044] Referring to FIG. 2, a front profile view of the self-locking heatsink hatch 300 is shown in an unloaded (i.e., engaged and locked in place) stage. In this example, the hatch 300 includes a first surface 300-1, a second surface (300-2, see FIG. 5B), a protrusion 302, a first elongated flexing arm 304, a second elongated flexing arm 306, and a longitudinal axis A. The material and in-plane flexion of the elongated flexing arms 304 and 306 (e.g., thin, flexible aluminum sheet metal) allow them to provide a “push back” or springing force (F3 described below) by contacting the contact bumps 212 on the housing 200 and forcing the hatch 300 towards the proximal end of the housing 200. This further allows the protrusion 302 to be inserted and secured into the receiving aperture 208 of the housing. The force of the flexing arms 304 and 306 F3 is enough to prevent the protrusion 302 from being removed from the receiving aperture 208 and withstand any environmental vibrations (e.g., wind). The contact bumps 212 are advantageously positioned adjacent to the point where the elongated2025P80016EP

[0045] 5

[0046] flexing arms 304 and 306 are connected to the hatch 300 when in the closed position.

[0047] Additionally, enough clearance exists between the arms 304 and 306 and the contact bumps 212 in the same plane to allow the arms 304 and 306 to move once a push back force F2 is applied. Further, the distance provided (see, e.g., B’ FIG. 3) allows for adequate flexion of the flexing arms 304 and 306 toward the distal end of the housing 200 while the hatch 300 is being installed. If the contact bumps 212 are positioned too far from the attachment point, the “push back” or force constant F3 would be too large and would make disconnecting the hatch 300 from the housing 200 difficult. In this embodiment, the elongated flexing arms 304 and 306 are integrally formed with the first surface of the hatch 300 and in some embodiments are dimensioned to extend beyond a perimeter of the opening formed through the housing 200 (see FIG. 5B) when the hatch is in the closed position to provide an additional securing means. Additionally, in this embodiment, the elongated flexing arms 304 and 306 each have a first portion 304A and 306A that runs substantially parallel to the longitudinal axis of the hatch A and a second portion 304B and 306B that runs substantially perpendicular to the longitudinal axis of the hatch A. At least some of the first portion 304A and 306A of each arm is coupled to the distal end of the first surface 300-1 of the hatch 300, while the second portion 304B and 306B is positioned in spaced relation from the first surface 300-1 of the hatch 300, but the arms 304 and 306 are substantially aligned in plane with the hatch 300. In some embodiments, a grabbing mechanism 308 (including but not limited to a hole formed through the surfaces of the hatch, pin, handle, or PCB / optical detail extension) is coupled to the second surface 300-2 (or formed through the surfaces) of the hatch 300 to allow the assembler or field installer to generate an upward force Fi (see FIG. 5B) to flex and install the hatch 300 onto the luminaire housing 200. As shown in FIG. 3, there is space B between the two arms 304 and 306 that advantageously allow for flexion of the arms 304 and 306 as explained above. Additionally, in a preferred embodiment, there is sufficient room between the arms 304 and 306 and the first surface 300-1 of the hatch such that the second surface 300-2 of the hatch 300 can be substantially flush with the exterior surface 204 of the luminaire housing when inserted therein.

[0048] In a preferred embodiment, the hatch 300 is made of aluminum sheet metal to provide proper heat dissipation and proper flexion in the vertical plane to ensure the stress during and after engagement with the luminaire housing (described below) remains low. In other embodiments, other metallic materials are used such as steel, stainless steel, or copper. The stress on the selected material ideally remains below its max yield stress during and after engagement with the housing.2025P80016EP

[0049] 6

[0050] As mentioned above, conventional luminaires often use rigid and hefty metal heatsinks. As LEDs become more efficient and require less power, less heat is generated and thus less heatsinking is needed. Therefore, a lightweight flexible hatch that dissipates heat as disclosed herein is advantageous. Referring again to FIG. 1C, in some embodiments, the housing and the hatch are made of different materials, such that the hatch provide most of the heat dissipation from the LED light sources of the luminaire 100 due to its heat-conductive properties. In other embodiments, both the housing and hatch materials contribute to heat dissipation. In yet other embodiments, the housing and the hatch are made of the same heat-conductive material. In another embodiment, the housing is made of a thermoplastic or similar material. In yet another embodiment, the primary circuit board (PCB) with LED light sources itself serves as the hatch to further reduce component count.

[0051] Referring now to FIG. 3, a close-up view of the distal end of the hatch 300 is shown with the elongated flexing arms 304 and 306 coupled thereto. In some embodiments, a ground wire 400 is coupled to the housing 200 at one end and the hatch 300 at the other end and can act as a means to connect the two since the hatch 300 has a relatively low weight (i.e., laser cut sheet metal).

[0052] Referring to FIGS. 4A-4B, close-up views of the self-locking hatch 300 coupled to the housing 200 are shown. In this example, the protrusion 302 is dimensioned to be accepted by the receiving aperture 208 (see also FIG. IB). The protrusion 302 serves to secure the hatch 300 to the housing 200 (i.e., self-locking) and prevent it from displacement (i.e., falling out of the opening opposite force Fi). As mentioned above, the flexing arms 304 and 306 are configured to be positioned adjacent to the interior surface 202 of the housing during installation of the hatch within the opening 210 such that the protrusion deflects when the locking force F3 is applied to the hatch and engages with the receiving aperture of the housing to secure the hatch in the closed position within the opening.

[0053] Referring to FIGS. 5A-5B, alternate views of the self-locking hatch 300 coupled to the housing 200 are provided. As shown, the arms 304 and 306 (and wire 400 in some embodiments) and the protrusion 302 obviate the need for a hinging mechanism and a securing mechanism (e.g., hinge and screw), respectively. Since those parts are no longer required, this design advantageously saves on the costs and labor associated with providing a screw and tapping strip and avoiding potential torquing issues.

[0054] Referring to FIGS. 6A-6B, finite element analyses of the hatch 300 while being inserted into the housing 200 are shown for displacement and stress, respectively. In a preferred embodiment, with a reasonable human hand force applied, an arm displacement of2025P80016EP

[0055] 7

[0056] approximately 0.080 inches (2 mm) would be expected as a minimum in order to engage with the housing 200 (FIG. 6A). This ensures there is enough displacement for a reasonably small detail in the housing to secure the protrusion and hatch. The stress results in FIG. 6B show that the hatch will not permanently deform with such applied force and displacement as the results depicted are below the stress yield point of the material (i.e., sheet metal in this example).

[0057] To install the hatch 300 into the housing 200, a user can insert the elongated flexing arms 304 and 306 into the opening 210 in the housing 200. The hatch 300 can then be pushed toward the distal end of the housing 200 with force F2 (i.e., opposite force F3) (see FIGS. 6A-6B) causing the elongated flexing arms 304 and 306 to interface with the contact bumps 212 and flex (i.e., the first portions of each flexing arm 304A and 306A move towards the distal end of the housing 200). Once the protrusion 302 of the hatch 300 is substantially aligned with the receiving aperture 208 of the housing 200, the pushing force F2 can be relieved (i.e., unloading) and the protrusion 302 can be secured within the receiving aperture 208 via locking force F3. To remove the hatch 300 from the housing 200, the user can apply force F2 on the hatch 300 to disengage the protrusion 302 from within the receiving aperture 208 and pull down on the hatch 300 (using force opposite Fi) using the grabbing mechanism 308, for example.

[0058] In accordance with an alternative embodiment, an additional part is provided at the distal end of the hatch 300 to facilitate pushing the hatch toward the proximal end of the housing, such as a spring (not shown).

[0059] In accordance with an alternative embodiment, a screw (not shown) can be included to secure the hatch 300 to the housing 200. In accordance with an alternative embodiment, the protrusion is positioned on one or both sides of the hatch 300 rather than at the center portion of the proximal end.

[0060] 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.

[0061] 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.”

[0062] 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. Multiple2025P80016EP

[0063] 8

[0064] 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.

[0065] 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.”

[0066] 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.

[0067] 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.

[0068] 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.

[0069] Other implementations are within the scope of the following claims and other claims to which the applicant can be entitled.2025P80016EP

[0070] 9

[0071] 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.

Claims

2025P80016EP10CLAIMS1. A luminaire body (102), comprising:a housing (200) comprising a wall (206) having a receiving aperture (208) and an opening (210) formed therethrough;a hatch (300) having a first surface (300-1) and a second surface (300-2), the hatch being shaped and dimensioned to be received within the opening (210) when in a closed position, the hatch further comprisinga protrusion (302) dimensioned to be received by and secured within the receiving aperture (208) of the housing (200), anda first elongated flexing arm (304) substantially coplanar with the first surface (300-1) of the hatch (300), wherein the first elongated flexing arm (304) is configured to be positioned adjacent to an interior surface (202) of the housing (200) during installation of the hatch within the opening (210) such that the protrusion (302) deflects when a locking force (F3) supplied by the first elongated flexing arm(304) is applied to the hatch (300) and engages with the receiving aperture (208) of the housing (200) to secure the hatch (300) in the closed position within the opening (210), the first elongated flexing arm (304) being integrally formed with the hatch (300); andwherein the hatch (300) is comprised of a heat-conductive material.

2. The luminaire body (102) of claim 1, wherein the hatch (300) is comprised of aluminum.

3. The luminaire body (102) of claim 1, wherein the protrusion (302) is integrally formed with the hatch (300).

4. The luminaire body (102) of claim 1, wherein the protrusion (302) and the first elongated flexing arm (304) are opposed to one another across the first surface (300-1) of the hatch (300).2025P80016EP115. The luminaire body (102) of claim 1, further comprising a second elongated flexing arm (306) substantially coplanar with the first surface (300-1).

6. The luminaire body (102) of claim 5, wherein the first and second elongated flexing arms (304, 306) extend perpendicular to a longitudinal axis A of the hatch (300).

7. The luminaire body (102) of claim 1, wherein the second surface (300-2) of the hatch (300) is substantially coplanar with an exterior surface (204) of the housing (200) when the hatch (300) is in the closed position,8. The luminaire body (102) of claim 1, wherein the housing (200) and the hatch (300) are comprised of different materials.

9. A luminaire (100) comprising the luminaire body (102) of claim 1 and a LED light source contained therein.

10. The luminaire body (102) of claim 1, wherein the first elongated flexing arm (304) is configured to experience only in-plane flexion within a plane of the first surface (300-1) of the hatch (300).

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