Light fixture with airflow passage separating driver and emitter

Abstract

An illustrative light fixture provides an emitter housing and a driver housing in a single fixture with an airflow channel defined between the emitter and driver housings. The airflow channel minimizes thermal conduction between the emitter and driver housings, and maximizes thermal convective cooling for at least one of the emitter housing and driver housing. The emitter housing includes vertical fins extending into the airflow chamber. The left and right sides of the emitter and driver housings define top and bottom edges that are respectively coplanar with the top and bottom edges of the vertical fins.

Claims

1. A light fixture, comprising: a driver section defining a left side and a right side; an emitter section connected to the driver section; a plurality of fins connected to the emitter section and disposed in the space between the driver section and the emitter section, each of the plurality of fins defining a vertical edge, the vertical edge including a top, middle and bottom portion; wherein the vertical edges of the plurality of fins are scalloped along their vertical length between the top and bottom portions, the top and bottom portions extending toward the driver section farther than the middle portion, the middle portion defining an open space extending horizontally from the left side of the driver section to the right side of the driver section.

2. The light fixture of claim 1, wherein each of the vertical edges of the plurality of fins is a rear edge that is scalloped inwardly along its vertical length.

3. The light fixture of claim 1, wherein each of the plurality of fins contacts the emitter section.

4. The light fixture of claim 1, wherein: the driver section defines a front surface and a top surface, the top surface of the driver section defines a top lip, the front surface of the driver section is recessed from the top lip, each of the plurality of fins defines at least one top notch, and an interior corner of the top lip is received within the at least one top notch.

5. The light fixture of claim 4, wherein: the driver section defines a bottom surface, the bottom surface of the driver section defines a bottom lip, the front surface of the driver section is recessed from the bottom lip, each of the plurality of fins defines at least one bottom notch, and an interior corner of the bottom lip is received within the at least one bottom notch.

6. The light fixture of claim 5, comprising: a left fin connected to the plurality of fins, the left fin being coplanar with the left side of the emitter housing and defining a structure without a top notch and without a bottom notch; and a right fin connected to the plurality of fins, the right fin being coplanar with the right side of the emitter housing and defining a structure without a top notch and without a bottom notch.

7. The light fixture of claim 1, wherein: the driver section defines a front surface and a bottom surface, the bottom surface of the driver section defines a bottom lip, the front surface of the driver section is recessed from the bottom lip, each of the plurality of fins defines at least one notch, and an interior corner of the bottom lip is received within the at least one notch.

8. The light fixture of claim 1, wherein: the emitter section defines a rear surface, the driver section defines a front surface, at least one of the plurality of fins defines a fastener tube extending between the rear surface of the emitter section and the front surface of the driver section, the fastener tube being configured to receive a fastener to secure the emitter section and the driver section together, and at least one of the plurality of fins defines a wire passageway extending between the rear surface of the emitter section and the front surface of the driver section, the wire passageway being configured to allow passage of wires through the wire passageway.

9. The light fixture of claim 1, wherein the emitter section defines a top surface, a bottom surface, and a rear surface, and wherein the top edge of at least one of the plurality of fins is coplanar with the top surface of the emitter section and the top surface of the driver section, or the bottom edge of at least one of the plurality of fins is coplanar with the bottom surface of the emitter section and the bottom surface of the driver section, or the top edge of at least one of the plurality of fins is coplanar with the top surface of the emitter section and the top surface of the driver section and the bottom edge of at least one of the plurality of fins is coplanar with the bottom surface of the emitter section and the bottom surface of the driver section.

10. The light fixture of claim 1, wherein: the emitter section defines a left side and a right side, the plurality of fins is disposed between the emitter section left side and the emitter section right side, each of the plurality of fins defining a length extending from the emitter section toward the driver section, the length of each of the plurality of fins being equal.

11. The light fixture of claim 1, wherein: the emitter section defines a left side and a right side, the driver section left side is coplanar with the emitter section left side, the driver section right side is coplanar with the emitter section right side, and the plurality of fins is disposed between the left side of the emitter section and the right side of the emitter section.

12. The light fixture of claim 1, wherein each of the plurality of fins defines at least one pin extending along the fin in a direction from the emitter section to the driver section.

13. The light fixture of claim 1, comprising: a thermal insulator disposed between the emitter section and the driver section, the thermal insulator insulating the driver section from the emitter section.

14. The light fixture of claim 1, wherein: at least one of the plurality of fins defines a fastener tube extending between the rear surface of the emitter section and the front surface of the driver section, the fastener tube being configured to receive a fastener to secure the emitter section and the driver section together, and the thermal insulator is disposed within the fastener tube.

15. A method of manufacturing a lighting fixture, comprising the acts of: connecting an emitter section to a plurality of fins, each of the plurality of fins defining a vertical edge that is scalloped; and connecting the emitter section to a driver section, wherein the driver section defines a left side and a right side, and wherein the plurality of fins is disposed in a space between the driver section and the emitter section with the plurality of scalloped edges defining a top portion and a bottom portion, the top and bottom portions extending toward the driver section farther than a middle portion between the top and bottom portions, the middle portion defining a horizontal open space extending between the plurality of scalloped edges and from the left side of the driver section to the right side of the driver section.

16. The method of claim 15, wherein the outer surface of the driver housing defines a lip, a front surface of the driver section is recessed from the lip, each of the plurality of fins defines at least one notch, and an interior corner of the lip is received within the plurality of notches.

17. The method of claim 15, wherein: the top edges of the plurality of fins adjacent the emitter housing are flush with the top surface of the emitter housing; or the bottom edges of the plurality of fins adjacent the emitter housing are flush with the bottom surface of emitter housing, or the top edges of the plurality of fins adjacent the emitter housing are flush with the top surface of the emitter housing, and the bottom edges of the plurality of fins adjacent the emitter housing are flush with the bottom surface of emitter housing.

18. The method of claim 15, wherein: the emitter housing defines a left side and a right side, the driver housing left side is coplanar with the left side of the emitter housing, the driver housing right side is coplanar with the right side of the emitter housing, and the plurality of fins is disposed between the left side of the emitter housing and the right side of the emitter housing.

19. The method of claim 15, wherein: the top edges of the plurality of fins are coplanar with the top surface of the driver housing and with the top surface of the emitter housing, or the bottom edges of the plurality of fins are coplanar with the bottom surface of driver housing and with the bottom surface of emitter housing, or the top edges of the plurality of fins are coplanar with the top surface of the driver housing and with the top surface of the emitter housing, and the bottom edges of the plurality of fins are coplanar with the bottom surface of driver housing and with the bottom surface of emitter housing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The detailed description particularly refers to the accompanying figures in which:

(2) FIG. 1 is a top perspective view of a first illustrative lighting fixture according to the present invention;

(3) FIG. 2 is a top, front perspective view of the lighting fixture of FIG. 1;

(4) FIG. 3 is a top, right side perspective view of the lighting fixture of FIG. 1;

(5) FIG. 4 is an exploded perspective view of the lighting fixture of FIG. 1;

(6) FIG. 5 is an exploded top, rear perspective view of the emitter section of the lighting fixture of FIG. 1;

(7) FIG. 6 is an exploded rear, top perspective view of the emitter section of the lighting fixture of FIG. 1;

(8) FIG. 7 is a right side view of the lighting fixture of FIG. 1;

(9) FIG. 8 is a bottom view of the lighting fixture of FIG. 1;

(10) FIG. 9 is a top perspective view of a second illustrative lighting fixture according to the present invention;

(11) FIG. 10 is a right side perspective view of the lighting fixture of FIG. 9;

(12) FIG. 11 is a rear perspective view of the emitter section of the lighting fixture of FIG. 9;

(13) FIG. 12 is a top view of the lighting fixture of FIG. 9;

(14) FIG. 13 is a left, rear perspective view of the lighting fixture of FIG. 9;

(15) FIG. 14 is a left side view of the lighting fixture of FIG. 9; and

(16) FIG. 15 is a bottom view of the lighting fixture of FIG. 9.

DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

(17) For the purposes of promoting and understanding the principals of the invention, reference will now be made to one or more illustrative embodiments illustrated in the drawings and specific language will be used to describe the same.

(18) Referring to FIGS. 1-8, a first illustrative embodiment of a light fixture 30 according to the present invention is illustrated. Referring to FIG. 4, the light fixture 30 includes a light source 32, including an emitter 34 (as used herein, “emitter” refers to a single emitter or an array of emitters) and a driver 36 (as used herein, “driver” refers to a single driver or an array of drivers). For example, light source 32 may be, but is not limited to, an LED emitter 34 and associated driver 36, as are typically used in the commercial lighting industry. For example, the associated driver 36 converts AC power to appropriate DC power and may also include additional LED power and control features. The fixture 30 can further include an emitter section 50, a driver section 100, a mount 38, and an airflow passage 40 located between the emitter section and the driver section.

(19) The emitter section 50 includes an emitter housing 52, for example, die cast aluminum or an aluminum alloy. The emitter 34 is thermally coupled and mounted to the emitter housing 52. As it typical of commercial lighting fixtures, the emitter section 50 may also include components that enclose the emitter 34 with emitter housing 52, for example, including a light reflector 54, water seal 56, lens 58, and frame and hood 60, and fasteners 62 for securing the frame and hood, lens, water seal, and light reflector to the emitter housing.

(20) The driver section 100 includes a driver housing 102, for example, die cast from aluminum or an aluminum alloy. The driver housing 102 is coupled with the emitter housing 52, for example, with fasteners 108. Thermal insulator 104 may be located between the emitter housing 34 and driver housing 32, for example, either partially, or fully insulating the driver housing from thermal conduction with the emitter housing. As it typical of commercial lighting fixtures, the driver section 100 may also include components that enclose the driver 36 with driver housing 102, for example, including a driver cover 110, water seal 112, and fasteners 114 for securing the water seal and cover to the driver housing. Advantageously, the fasteners 108 can be enclosed within the emitter housing 34, driver housing 32, and driver cover 110, providing a more aesthetically pleasing look to the light fixture 30.

(21) The emitter housing 52 defines one or more emitter mounts 66 on a front surface 68 of the emitter housing. The emitter mounts 66 provide structural mass for increased conduction of heat away from the emitter 36, and also provide relative mounting orientation for the emitter 36. The emitter 36 is coupled to the one or more emitter mounts 66.

(22) Referring to FIGS. 2 and 6, the emitter housing 52 also defines a rear surface 70, a left side 72, and a right side 74, and each of the left and right side define a top edge 76 and a bottom edge 78. The driver housing 102 defines a front surface 120, a left side 122, and a right side 124, and each of the left and right side define a top edge 126 and a bottom edge 128.

(23) Referring to FIGS. 1, 3, 6, and 8, the airflow passage 40 is defined by a space between the rear surface 70 of the emitter housing 52, including an intermediate protruding portion 71 of the rear surface, and the front surface 120 of the driver housing 102. A plurality of fins 90 (FIG. 3) are located in the airflow passage 40 and define vertical oriented airflow channels 41, the vertical oriented airflow channels open to a top side 42 (FIG. 3) and a bottom side 44 (FIG. 8) of the fixture 30. The plurality of fins 90 can be defined by the rear surface 70 of the emitter housing 52, thus, the plurality of fins 90 are in thermal conductivity with the emitter mount 66 and emitters 34. At least a portion of each of the fins 90 can span the space between the emitter housing 52 and the driver housing 102, whether or not the fins 90 are in actual contact with the front surface 120 of the driver housing.

(24) Referring to FIGS. 3 and 8, a top 42 and a bottom 44 of the light fixture 30 can be planar, without recesses other than the airflow channels 41. More specifically, top edges 96 and bottom edges 98 are defined by each of the first plurality of fins 90. The top edges 96 of the first plurality of fins 90 are coplanar with the top edges 76, 126 of the left side 72, 122 and the right side 74, 174 of each of the emitter housing 52 and the driver housing 102. Similarly, the bottom edges 98 of the first plurality of fins are coplanar with the bottom edges 78, 128 of the left side 72, 122 and the right side 74, 124 of each of the emitter housing 52 and the driver housing 102.

(25) In the first illustrative embodiment 30, where a planar top 42 is defined by a top surface 86 of the emitter housing, and the top edges 96 of the plurality of fins 90 are coplanar with the top surface 86 of the emitter housing. Additionally, the planar top 42 is further defined by a top surface 136 of the driver housing 102, and the top edges 96 of the plurality of fins 90 and the top surface 86 of the emitter housing are also coplanar with the top surface 136 of the driver housing. The top edges 96 of fins 90 being flush with the top surfaces 86 and 136 provides a more aesthetically pleasing appearance, and lessen the likelihood that debris will catch among the interface between the fins 90 and the top surface 86 and 136 since they join and are flush rather than recessed or otherwise non-planar.

(26) Referring to FIGS. 7 and 8, in the first illustrative embodiment 30, a planar bottom 44 is similarly defined by coplanar bottom surface 88 of the emitter housing 52, bottom surface 136 of the driver housing 102, and bottom edges 98 of the plurality of fins 90.

(27) The planes defined by top 42 and bottom 44 can be flat, about flat, for example as in the first illustrative light fixture 30, or curvilinear, for example as shown in the second illustrative light fixture 230, discussed below. Additionally, the left sides 72 and 122 of the emitter and driver housings 52 and 102 can be coplanar, and the right sides 74 and 124 of the emitter and driver housings can be coplanar.

(28) The plurality of fins 90 can be evenly spaced between sides 72 and 74, thus providing equal or about equal sized airflow channels 41. Because the fins 90 are also equal or about equal in length between the top edges 96 and bottom edges 98, the light fixture 30 can provide uniform or about uniform cooling across the span between the sides 72 and 74. Thus, if as in the illustrative light fixture 30, the emitter 34 includes a horizontally arranged array, the emitters 34 can also be spaced to receive equal or about equal conductive and convective cooling from the heat transfer through mounts 66 and fins 90.

(29) Referring to FIGS. 1-3, in the first illustrative embodiment of the light fixture 30, the left sides 72 and 122 of the emitter and driver housings 52 and 102 define a left side opening 46 of the airflow passage 40, and the right sides 74 and 124 of the emitter and driver housings define a right side opening 48 of the airflow passage. Referring to FIGS. 5 and 7, additionally, the rear edges 92 of the fins 90 are scalloped inwardly toward the emitter housing along their vertical length, providing an open space 43 that extends horizontally between the left side opening 46 and right side opening 48 of the fixture 30, thus visually reducing the mass of the light fixture 30 from the sides, and providing an additional path through which air may flow to further advance cooling.

(30) Referring to FIGS. 4 and 5, the emitter housing 52 defines fastener tubes 73, and the driver housing defines 102 defines mating fastener tubes 75 (FIG. 4), which together receive fasteners 108 that secure the emitter housing together with the driver housing, and seals 106 that provide a watertight seal between each respective pair of tubes 73 and 75 to prevent water intrusion into the interior of the emitter housing and driver housing. The emitter housing 52 further defines wire passageway 77 and mating wire passageway 79 (FIG. 4), which together allow passage of wires connecting the emitter 34 to the driver 36, while the seal 106 in combination with the passageways 77 and 79 provide a watertight seal.

(31) Referring to FIGS. 3, 5, and 7, in the illustrative light fixture 30, notches 93 are defined by fins 90 adjacent the rear edge 92 and both the top edge 96 and the bottom edge 98. The notches 93 contact with an interior corner of a top lip 123 and bottom lip 125 of the driver housing 102. The contact provides added stability of the emitter housing 52 relative to the driver housing 102 that is otherwise coupled at tubes 73 and 75 and passageways 77 and 79 by seals 106, for example, elastomeric o-rings that allow some relative movement. The contact of notches 93 and lips 123 and 125 provide minimal thermal conductivity since the contact areas are small, and the notches 93 are distal on the fins 90 of the heat generated by emitters 34. In other alternative embodiments, the fins 90 do not contact the driver housing 102, thus further maximizing thermal isolation between the emitter housing 52 and driver housing 102.

(32) Referring to FIG. 6, extraction pins 95 defined by fins 90 aid in extracting the emitter housing 52 from the die or mold used to cast or otherwise for it without damaging the long, thin fins 90.

(33) In one illustrative embodiment the left sides of the emitter and driver housings enclose a left end of the airflow passage and the right sides of the emitter and driver housings enclose a right end of the airflow passage.

(34) Referring to FIGS. 9-15, a second illustrative embodiment of a light fixture 230 according to the present invention is illustrated. Many of the features of the first illustrative light fixture 30 discuss above are or can be incorporated into the second light fixture 230; therefore, for brevity, many of the specific features that are the same for light fixtures 30 and 230 will not be repeated below.

(35) Referring to FIGS. 9 and 10, the light fixture 230 includes an emitter 234 and a driver 236 (not shown). The fixture 230 can further include an emitter section 250, a driver section 300, a mount 238, and an airflow passage 240 located between the emitter section and the driver section.

(36) The emitter section 250 includes an emitter housing 252, for example, die cast from aluminum or an aluminum alloy. The emitter 234 is thermally coupled and mounted to the emitter housing 252. As it typical of commercial lighting fixtures, the emitter section 250 may also include components that enclose the emitter 234 with emitter housing 252, for example, including a light reflector 254, lens 258, and frame and hood 260.

(37) The driver section 300 includes a driver housing 302, for example, die cast from aluminum or an aluminum alloy. The driver housing 302 is coupled with the emitter housing 352, for example, with fasteners (not shown). As it typical of commercial lighting fixtures, the driver section 300 may also include components that enclose the driver 236 within driver housing 302.

(38) Referring primarily to FIG. 14, and also for reference, FIGS. 10, 12, and 13, the emitter housing 252 also defines a rear surface 270, a left side 272, and a right side 274, and each of the left and right side define a top edge 276 and a bottom edge 278. The driver housing 302 defines a front surface 320, a left side 122, and a right side 124, and each of the left and right side define a top edge 326 and a bottom edge 328.

(39) Referring to FIGS. 9 and 12, the airflow passage 240 is defined by a space between the rear surface 270 of the emitter housing 252, including intermediate protruding portions 271 of the rear surface, and the front surface 320, including intermediate protruding portions 321, of the driver housing 302. A first plurality of fins 290 are located in the airflow passage 240 and define vertical oriented airflow channels 241, the vertical oriented airflow channels open to a top side 242 and a bottom side 244 (FIG. 15) of the fixture 230. The plurality of fins 290 can be defined by the rear surface 270 of the emitter housing 52, thus, the plurality of fins 290 are in thermal conductivity with the emitter 234 mounted to the opposite side of the emitter housing 52.

(40) In a second illustrative light fixture 230, a second plurality of fins 340 is defined by the driver housing 302. Top edges of the second plurality of fins can be coplanar with the top edges of the first plurality of fins.

(41) Referring to FIG. 13, a top 242 of the light fixture 230 can be planar and defined by the top of first plurality of fins 290, the top of the second plurality of fins 340, and the top surface 286 of the emitter housing 252, which are all coplanar. The same can be true for a bottom 244 of the light fixture 230. More specifically, top edges 296 and bottom edges 298 are defined by each of the first plurality of fins 290. The top edges 296 of the first plurality of fins 290, the top edges 346 of the second plurality of fins, the top edges 276, 326 of the left side 272, 322 and the right side 274, 324 of the emitter housing 252 and the driver housing 302, are all coplanar, in this case on a curvilinear surface curving downward along a single axis in the direction from the hood 260 to the driver housing. Similarly, the bottom edges 298 of the first plurality of fins 290, the bottom edges 348 of the second plurality of fins 290, and the bottom edges 278, 328 of the left side 272, 322 and the right side 274, 324 of each of the emitter housing 252 and the driver housing 302, are coplanar, in this case on a curvilinear surface curving upward along a single axis in the direction from the hood 260 to the driver housing.

(42) In the second illustrative embodiment 230, where a planar top 242 is defined by a top surface 286 of the emitter housing 252, and the top edges 296 of the plurality of fins 290 and the top edges 346 of the plurality of fins 340 are coplanar with the top surface 286 of the emitter housing. The top edges 296, 346 of fins 290, 340 being flush with one another and the top surfaces 286 provides a more aesthetically pleasing appearance, and lessen the likelihood that debris will catch among the interface between the fins 290, 340 and the top surface 286 they join and are flush rather than recessed or otherwise non-planar.

(43) Referring to FIGS. 11 and 15, in the second illustrative embodiment 230, a planar bottom 244 is similarly defined by coplanar bottom surface 288 of the emitter housing 252, the bottom edges 298, 348 of the plurality of fins 290, 340.

(44) The planes defined by top 242 and bottom 244 can be flat, about flat, or curvilinear, for example as in the case of the second illustrative light fixture 230. Additionally, the left sides 272 and 322 of the emitter and driver housings 252 and 302 can be coplanar, and the right sides 274 and 324 of the emitter and driver housings can be coplanar.

(45) Referring to FIGS. 10, 13, and 14, in the second illustrative embodiment of the light fixture 230, the left sides 272 and 322 of the emitter and driver housings meet or nearly meet to enclose the airflow passage 240 on a left side, and the right sides 274 and 324 of the emitter and driver housings meet to enclose a right side of the airflow passage. The enclosing of the left sides 272, 322 and right sides 274, 324, and the top edges 276, 346 being coplanar with the top plane 242 and the bottom edges 278, 328 being coplanar with the bottom plane 244, provide visual shielding of the fins 290, 340 from the sides of the light fixture 230, enhancing its visual aesthetics as well as restricting airflow vertically within airflow passage 240, and preventing debris from entering airflow passage 240 from the left or right sides 272 and 274.

(46) Although this invention has been described in certain specific illustrative embodiments, many additional modifications and variations would be apparent to those skilled in the art in light of this disclosure. It is, therefore, understood that this invention may be practiced otherwise than as specifically described. Thus, the illustrative embodiments should be considered in all respects to be illustrative and not restrictive, and the scope of the invention determined by any claims supportable by this application and equivalents thereof, rather than determined solely by the foregoing description.