Lighting systems

Abstract

An aircraft LED retrofit modular lighting system adapted to be fitted into an aircraft in place of an existing lighting system wherein the retrofit lighting system is modular and comprises at least a housing for an LED lighting unit and a plurality of fixing brackets, the housing being formed of a plurality of components and comprising an elongate tray, at least a first end connector connectable to a first end of the tray, and an elongate lid attachable to the tray wherein the first end connector comprises a power connector fitting, arranged to be selected from at least a first and a second power connector socket, the first and the second power connector sockets being adapted to be interchangeably connected to the power connector fitting, and wherein the first power connector socket is arranged to connect to a first type of aircraft power supply system and the second power connector socket is arranged to connect with a second type of aircraft power supply system.

Claims

1. An aircraft LED retrofit modular lighting system adapted to be fitted into an aircraft in place of an existing lighting systems, comprising: at least a housing for an LED lighting unit and a plurality of fixing brackets, the housing being formed of a plurality of components and comprising an elongate tray; at least a first end connector connectable to a first end of the tray; and an elongate lid attachable to the tray; wherein the first end connector comprises a power connector fitting, arranged to be selected from at least a first and a second power connector socket, the first and the second power connector sockets being adapted to be interchangeably connected to the power connector fitting; wherein the first power connector socket is arranged to connect to a first type of aircraft power supply system and the second power connector socket is arranged to connect with a second type of aircraft power supply system; and wherein the retrofit lighting system is modular.

2. The aircraft LED retrofit modular lighting system according to claim 1, wherein: the housing is modular; and the components are adapted to connect together in a plurality of configurations.

3. The aircraft LED retrofit modular lighting system according to claim 1, wherein the first end connector comprises multiple connecting locations adapted to cooperate with a respective fixing bracket.

4. The aircraft LED retrofit modular lighting system according to claim 1, wherein the power connector fitting comprises a socket arranged to receive a plug on a connector in the aircraft from a classic power supply.

5. The aircraft LED retrofit modular lighting system according to claim 1, wherein the power connector is provided with a socket arranged to receive an enhanced power supply plug.

6. The aircraft LED retrofit modular lighting system according to claim 1, wherein the housing further comprises a first and a second fixing section adapted to cooperate with a respective fixing bracket.

7. The aircraft LED retrofit modular lighting system according to claim 1, wherein at least one fixing bracket has a built in pivot.

8. The aircraft LED retrofit modular lighting system according to claim 1, wherein each fixing bracket comprises a base plate, adapted to be secured to an aircraft surface, and a stem and the stem is connected to the base plate such that the stem is able to rotate relative to the base plate.

9. The aircraft LED retrofit modular lighting system according to claim 1, wherein at least some of the components are arranged to be have a snap-fit connection.

10. The aircraft LED retrofit modular lighting system according to claim 9, wherein the snap fit connection utilises a double wall fixing method.

11. The aircraft LED retrofit modular lighting system according to claim 1, wherein the lid is provided with a seal.

12. The aircraft LED retrofit modular lighting system according to claim 1, wherein the housing further comprises a second end connector.

13. The aircraft LED retrofit modular lighting system according to claim 1, wherein the tray and at least the first end connector comprises a base unit of the housing and the lid is arranged to be attachable to the base unit.

14. The aircraft LED retrofit modular lighting system according to claim 13, wherein a connection between the lid and the base unit is a snap-fit connection.

15. An aircraft cabin comprising an LED modular lighting system, comprising: at least a housing for an LED lighting unit and a plurality of fixing brackets, the housing being formed of a plurality of components and comprising an elongate tray; at least a first end connector connectable to a first end of the tray; and an elongate lid attachable to the tray; wherein the first end connector comprises a power connector fitting, arranged to be selected from at least a first and a second power connector socket, the first and the second power connector sockets being adapted to be interchangeably connected to the power connector fitting; wherein the first power connector socket is arranged to connect to a first type of aircraft power supply system and the second power connector socket is arranged to connect with a second type of aircraft power supply system; and wherein the lighting system is modular.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will now be described by way of example only with reference to the accompanying figures in which:

(2) FIG. 1 is an exploded view of a housing of a lighting system in accordance with the invention;

(3) FIG. 2 is a view of the lid of the housing of FIG. 1;

(4) FIG. 3 is a cross section view of a connection between the tray and the lid;

(5) FIG. 4 is a perspective view of a classic power connector;

(6) FIG. 5 is a view of an enhanced power connector;

(7) FIGS. 6A, 6B and 6C are a perspective view of three alternative fixing brackets in accordance with the invention,

(8) FIG. 7 is a perspective view of an underside of the fixing bracket of FIG. 6C;

(9) FIG. 8 is a perspective view of an end of an elongate tray and a first end connector prior to connection;

(10) FIG. 9 is a perspective view of a connection between the elongate tray and the first end connector of FIG. 8 when connected; and

(11) FIG. 10 is a side view of the connection of FIG. 9.

DETAILED DESCRIPTION

(12) FIG. 1 is an exploded view of an LED lighting system in accordance with the invention and comprises a housing 1 for an LED lighting unit, the housing 1 having a plurality of components and comprising an elongate tray 2, a first end connector 4 connectable to a first end 6 of the tray and an elongate lid 8 attachable to the tray 4. The housing 1 further comprises a second end connector 10 connected to a second end of the tray. The first end connector 4 is a power end connector and the second end connector 10 comprises a simple end housing 7. A printed circuit board (PCB) 12 is provided mounted in the elongate tray 2. The PCB 12 further extends into a housing 9 of the power connector 4.

(13) The LED lighting housing 1 is modular and at least some of the components are arranged to be have a snap-fit connection. The components are arranged to be connected together in a plurality of configurations such that the same components can be arranged to connect to multiple aircraft configurations. The different configurations may be referred to as alternative configuration variants.

(14) Utilising snap fitting of components has greatly reduced housing assembly times. A particular advantage of the invention is that the housing 1 may be assembled from component parts in a matter of minutes and in some cases prototype systems have been assembled in about 5 minutes. The housing 1 allows a number of variants to be assembled from standard and interchangeable components. It has been found that a number of required variants can be formed from a small number of standard components so reducing the components required in order to retrofit an LED lighting system in a number of different types of aircraft.

(15) The components are injection moulded and formed of plastics such as polycarbonate. Other suitable plastics may be used

(16) The elongate tray 2 is arranged to mount the printed circuit board (PCB) assembly. The elongate tray 2 has a length which typically in preferred embodiments may be from 10 cm to 100 cm and the PCB may be arranged to extend for the length of the tray. The PCB further comprises a number of LED lighting units 14 which form a string that is mounted on a separate strip 16. The housing 1 may be arranged to contain one or more LED strings. The LED lighting units can be arranged to emit a white light or a coloured light or the PCB may comprise a mixture of light emitting units. The PCB is arranged such that a white light is emitted or a coloured light is emitted or the colour of the emitted light may be changed. The PCB 12 further comprises a controller unit which can be arranged to control the colour of emitted light. The controller may be arranged to change the colour of emitted light in response to a user controlled input.

(17) The controller may also comprise an interface unit in the form of an IR board 13 which may be arranged to programme the PCB unit. In some cases a shield 15 may additionally be provided. The shield 15 may be arranged to dissipate static charge that builds up over time and that can interfere with IR communication between the IR unit and a remote interface.

(18) The lid 8 is transparent or translucent. In this embodiment the lid is transparent to UV light. In this embodiment the lid 8 has a length that is greater than the length of the elongate tray and the lid 8 is arranged to be attachable to the first end connector housing. The first 4 and second 10 end connectors are arranged to be a snap-fit connection to respective first 6 and second 11 ends of the tray.

(19) The tray 2 and the first and second end connectors 4, 10 form a base unit 18 of the housing. A connection between the lid 8 and the base unit 18 is a snap-fit connection. The snap fit connection utilises a double wall fixing method.

(20) As detailed in FIG. 2 the lid 8 comprises an arch 20 formed of a longitudinally extending top 22 and first and second side walls 24, 26. Each side wall further comprises a laterally extending flange 28. Each side wall 24, 26, comprises an additional portion 30 extending beyond the flange 28. The laterally extending flange 28 has at least one clip 32 comprising a skirt 33 extending substantially parallel to the side walls 26, 38 and additional portions 30. The skirt 33 has a clip projection 34 extending from a distal end of the skirt 33 towards the side wall additional portion 30. The clip projection 34 is arranged to engage with a corresponding clip portion on the base unit 18. The laterally extending flange 28 and the skirt 33 with the clip projection 34 extend longitudinally for substantially the whole length of the lid 8.

(21) In FIG. 3 it can be seen that the base unit 18 comprises at least a portion of a wall 36 having an outwardly extending clip portion 38 which is arranged to be at a distal end of the wall 36. The outwardly extending clip portion 38 is arranged to engage with the skirt 33 and clip projection 34 and the outwardly extending clip portion is received within a channel 40 formed between the skirt 33 and the additional portion 30 of the side walls 24, 26.

(22) The lid 8 is unitary and the top 22, first and second side walls 24, 26, flange 28, skirt 33 and clip projection 34 are formed of the same material and may be injection moulded. The lid is formed of a transparent plastics material such as polycarbonate or crystal styrene. Other suitable materials may be used instead.

(23) In one embodiment the lid 8 is provided with a seal comprising a rubber material. The seal provides a more secure fit.

(24) The base unit has a first end connector 4 and a second end connector 10. The first and second end connectors each comprise a housing that may be the same or different. The or each end housing has a fixing section 42 adapted to cooperate with a respective fixing bracket 44. The fixing section 42 comprises a latch on a first side wall and a second lug on a second side wall opposed to the first side wall. Each end connector has a plurality of fixing sections such that a suitable fixing section can be selected in order to co-operate with mounting locations in the aircraft cabin. Typically suitable fixing locations are an outer pair, an intermediate pair or an inner pair of fixing locations on the end connector housing and/or in the power connector housing.

(25) As described above the lighting system is modular and is arranged to be connected together from component parts. A simple end housing 100 may be connected to one end of the elongate tray 102. The system may comprise more than one elongate tray component. Each tray may comprise a length. The length may be a first length or a second length. The second length may be longer than the first length. The system may be assembled from an elongate tray selected from a tray 102 comprising a first length or from a tray comprising a second length. A power connector housing may be connected to a second end of the elongate tray.

(26) Referring now to FIGS. 8-10, a novel interconnection method and arrangement is provided. The interconnection arrangement is provided to allow for the mating and secure engagement of the modular tray parts. The interconnection arrangement comprises a combination of tab 104, boss 106, lug 108 and slot 110 features. One end of the elongate tray 102 comprises a tab 104 extending along a plane of a base 112 of the tray. A locking boss 106 is provided on an outer surface of the tab 104.

(27) The end housing 100 is provided with cut away section 114 into which the lug 108 extends. The tab 104 on the tray 100 extends under the lug 108 on the end housing 102. A slot 110 is provided in the lug 108. The locking boss 106 is arranged to engage with the slot 110 in the lug to lock the tray 100 to the end housing 102.

(28) The end housing 102 further comprises an extending casing 116 arranged to extend over the base 112 and side walls 118 of the end of the tray. Either side wall 120 of the casing 116 comprises extending lugs 122 which are arranged to interact and lock with outwardly extending locking bosses 124 on side walls of the tray. It has been found that the described arrangement has a particular advantage in providing a space efficient connection between the tray and the end connector or end connectors. This is particularly advantageous in the restricted space of an aircraft cabin in which space is at a premium. Additionally where the lighting system is being retrofitted into an existing cabin the system has to fit within the same space envelope as that of the system being replaced. This can be a problem as newer systems contain more electronics than older systems. It will be appreciated that the described interconnection is provided substantially within the thickness of the housing and so space within the tray and end connector is not reduced and additionally the interconnection is within a footprint of the housing. It has been found that the described interconnection is able to fit within the space envelope of an existing system and also to provide internal space for additional electronics.

(29) Each end of the tray may be arranged to have a tongue. Alternatively one end of the tray may be provided with a tab and the other end of the tray may be provided with a cut-away section and tongue.

(30) The end connectors will be described in more detail below.

(31) One of the end connectors is a simple end connector 10 formed of a housing 50 arranged to have a base 46, first and second side walls 48. The simple end housing 50 has an end wall and may have interior fixings arranged to receive a part of the PCB or a support for an LED strip. The simple end housing 50 is arranged and adapted to have a snap fit connection to the tray 2. The second end connector forms a part of the base unit 18 once connected to the tray. The first and the second side walls of the simple end housing 50 comprise a laterally extending flange at a distal end and the first and second side walls 48 are arranged to be a snap fitting to the lid.

(32) One of the end housings is a power connector housing 4, shown in FIG. 5. The power connector housing 4 is arranged to have a base 52, first and second side walls 54. The power connector housing has an end wall 55 and has interior fixings arranged to receive a part of the PCB 12 or a support 16 for an LED strip. The controller is provided on the PCB 12 and the PCB 12 is arranged to clip into the end housing.

(33) The power connector housing 4 further comprises at least one power connector fitting 57. The power connector fitting 57 is arranged to mate with the power supply delivery system in the aircraft. Power supply delivery systems in aircraft systems have power supplied by classic or enhanced fittings. The power connector fitting 57 is arranged or adapted to mate with a classic power supply system or is arranged to mate with an enhanced power supply system. For connection to a classic power system, shown in FIG. 4, the housing has a classic connector fitting 56 that has a supply end 58 arranged to mate with a socket of the power supply system in the aircraft and a flexible lead 60, such as a cable, that extends to the connector end housing 4. A delivery end of the lead is provided with a plug 62 arranged to connect to a socket 64 in the power connector fitting 57 in connector end housing 4. A combination of supply end 58, cable 60 and plug 62 may be defined as a harness.

(34) The housing can be provided with a classic power connector 57 fitting in the form of the socket 64 arranged to receive a plug 62 on an existing connector in the aircraft. Alternatively the housing is provided with a socket 64 and a replacement connector 56 adapted to connect to the socket 64 in the connector end housing and having a supply end 58 adapted to mate with a socket of the power supply in the aircraft.

(35) In other embodiments the connector end housing 4 is provided with an enhanced socket 66 arranged to receive an enhanced power supply plug 68. The plug 68 may be provided with the housing 4 or the housing may be arranged to connect to an existing plug in the aircraft.

(36) The connector end housing 4 is arranged and adapted to have a snap fit connection to the tray 2 and forms a part of the base unit 18 once connected to the tray. The first and second side walls 54 of the power connector housing have a laterally extending flange at a distal end and are arranged to be a snap fitting to the lid 8.

(37) In retrofitting an LED housing in accordance with the invention a power connector fitting may be selected to match the power supply system in the aircraft and fitted to a tray and a simple end housing may be connected to a second end of the tray to form a base unit. The parts are readily snap fitted to together to form the base unit and a lid is connected to the base unit.

(38) In retrofitting an LED housing unit and LED lighting system to an aircraft having fluorescent fittings account has to be taken of the existing aircraft connection system and fixing locations in a body of the aircraft. Each fixing location is provided at a predetermined distance from the power connection location. In prior art systems an LED housing has to be designed to replace a fluorescent fitting in either a classic connection system or an enhanced connection system and it has been found that location of the fixing points is such that an end housing which is adapted to connect to a classic system then the housing cannot be fixed to an aircraft having an enhanced system. The predetermined distance from the power connection system to the fixing point is such that the fixing is typically located over the power connection socket.

(39) The system in accordance with the invention further comprises a plurality of the fixing brackets 44. Each fixing bracket 44 comprises a base plate 70 adapted to be secured to an aircraft wall. The base plate 70 is in use secured to the aircraft wall by means of a screw (not shown). The base plate further comprises a socket 72. The fixing bracket comprises a stem 74, a frame 76 and first and second arms 78 extending from opposed sides of the frame 76. The stem 74, frame 76 and arms 78 are unitary.

(40) The frame may extend in a plane 80. In one embodiment as illustrated in FIGS. 6A and 6B the plane in which frame extends is transverse to the direction X in which the stem 74 extends. In another embodiment illustrated in FIG. 6C the plane 80 in which the frame 76 extends is obliquely angled relative to the direction X in which the stem 74 extends. In such an arrangement the housing is held at an oblique angle relative to the wall of the aircraft cabin in which the housing is fitted. The arms 78 are formed in a generally U shape and are arranged to extend in a direction transverse to the plane in which the frame extends. The arms may be angled or parallel relative to the stem 74.

(41) The arms 78 are relatively flexible having a U shape. A cross piece 82 of the arms are arranged to be received in retaining portions in side walls of the connector housing. The arms may be moved apart as the end connector housings are inserted into the fixing bracket 44. The arms snap into place as the cross pieces 82 are received into the retaining portions on the end connector housings.

(42) As can be seen in FIGS. 6C and 7, each base plate 70 comprises an element 84 arranged to be mounted on a surface of the aircraft cabin. The base plate 70 comprises a central aperture 86 through which a screw may secure the base plate to the surface. A side wall 88 is arranged to extend from either side of the base plate to a wall 90 surrounding the aperture. In this embodiment the walls 88 extend across a relatively shorter dimension of the base plate 70. A semi-circular slit aperture 92 is provided on either side of the walls 88. A deflecting portion 94 is provided on opposing edges of the first and second apertures 92.

(43) The stem 74 is rotatably connected to the base plate 70. The stem and base plate are connected by an interaction between pins 100 provided on lugs 102 of the stem 74.

(44) In assembling the bracket fixing the lugs on the stem 74 deflect inwards such that the pins 100 are able to move past the deflecting portions 94 to an under surface of the base plate. The under surface of the base plate is arranged to be adjacent the surface of the aircraft cabin. The lugs 102 spring out once the pins have passed through the slit aperture and the lugs are arranged to extend through and rotate within the slit aperture. The pins 100 are retained against the under surface of the base plate and the stem 74 is able to rotate relative to the base plate. Each end of the slit aperture acts as a stop to rotation such that there is limited rotation of the stem relative to the base. Up to 90 of rotation may be achieved from one end stop to the other end.

(45) The stem 74 can be a short fixing in which the frame is spaced relatively close to the base plate as illustrated in FIG. 6A or the stem may be relatively longer such that the frame is spaced further from the base plate as illustrated in FIG. 6B. In another embodiment the stem is formed separately from the frame and arms and the stem is angled as illustrated in FIG. 6C. Depending on a space envelope available in the aircraft a longer stem or a shorter stem or an angled stem may be selected. The stem and frame may be connected to the base plate in order to locate the housing at a desired distance from a wall of the aircraft. The arms are arranged to clip to the LED housing and to locate the LED housing between the arms and adjacent the frame. A particular advantage has been found in the preferred arrangement in that the LED housing can be push fitted into a first fixing bracket 44. As a second fixing bracket is connected to the LED housing the first fixing bracket is able to rotate to allow the LED housing to self-align rather than requiring manual adjustment.

(46) It has been found that the system in accordance with the invention has advantages in that the housing can be rapidly built from snap fitting together component parts from a modular system. A suitable power connector may be selected or a suitable power connector fitting may be inserted in the power connector housing to connect to the existing power supply system. The fixing brackets are simple and straightforward to fit to the aircraft wall and a suitable fixing bracket can be selected according to the available space envelope in the aircraft. The end connector housings are arranged to have multiple connection points for engagement with the fixing brackets. The fixing brackets have a rotatable connection and so are self-aligning and improve the ease of fitting the LED housing to the aircraft.

(47) Use of modular components that may be snap fitted together has significantly reduced the time for building the housing and allowed the components to be used to connect the LED housing to separate power supply systems.