LED lamp retrofit system, kit, and method
09841155 ยท 2017-12-12
Assignee
Inventors
Cpc classification
F21Y2103/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/27
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21W2131/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2115/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S4/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2113/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F21S4/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S9/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/27
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An LED lamp retrofit system, kit, and method is presently disclosed. The LED retrofit system comprises at least one longitudinally extending LED lamp having a length substantially greater than a width and open longitudinal ends. A first LED lamp support rail holds and covers a first open longitudinal end of each of the at least one longitudinally extending LED lamps and is configured to electrically connect each of the at least one longitudinally extending LED lamps to a power source. A second LED lamp support rail holds and covers a second open longitudinal end of each of the at least one longitudinally extending LED lamps held with the first LED lamp support rail. A system holder on each of the first and second LED lamp support rails is configured and disposed to hold the retrofit system to a portion of a lamp fixture being retrofitted.
Claims
1. A cover comprising a top wall, a first sidewall extending from the top wall, a second sidewall extending from the top wall and the first sidewall, a third sidewall extending from the top wall and the second sidewall, and a fourth sidewall extending from the top wall, the first sidewall and the third sidewall, the cover being configured to cover an electrical junction or component parts of an electrical system and comprising at least one magnet configured and disposed to hold the cover in place.
2. The cover of claim 1, wherein the at least one magnet is held with the first sidewall, the second sidewall, the third sidewall, the fourth sidewall, or the top wall and is configured to hold the cover to the electrical system.
3. The cover of claim 2, wherein the at least one magnet has a surface in a plane with an outer edge of one of the sidewalls.
4. The cover of claim 1 further comprising at least one mechanical holding device.
5. The cover of claim 4, wherein each mechanical holding device comprises at least one flange extending outwardly from the cover in a substantially common plane with an outer surface of the at least one magnet, wherein each flange has an aperture configured to receive a fastener.
6. The cover of claim 1, wherein the electrical system is a lighting system having a troffer and the cover is an electrical junction box configured to cover an electrical junction between the lighting system and a power source, the at least one magnet being configured and disposed to hold the electrical junction box to the troffer.
7. The cover of claim 1 comprising at least two of the magnets, wherein each of the magnets is held substantially equidistantly within the cover.
8. The cover of claim 1 further comprising a cavity configured to receive power lines.
9. The cover of claim 1, wherein the electrical system is a lighting system and the cover is configured to cover component parts of an emergency lamp module.
10. The cover of claim 9, wherein the cover is an emergency lamp module comprising and holding an emergency module and a battery, the emergency module and battery are held with an inner surface of the cover, the emergency lamp module is configured to supply power to the lighting system in the event of a disruption in supplied power from a power source.
11. An electrical junction box comprising a cover configured to magnetically attach to a portion of an electrical system and cover an electrical junction between the electrical system and a power source, the cover having at least one magnet held therein, wherein each of the magnets has a surface substantially in a plane with an outer edge of the electrical junction box.
12. The electrical junction box claim 11 comprising at least one cavity configured to receive power lines.
13. The electrical junction box claim 11 further comprising at least one mechanical holding device.
14. The electrical junction box claim 13, wherein each mechanical holding device comprises at least one flange extending outwardly from the electrical junction box and in a substantially common plane with an outer surface of the at least one magnet, wherein each flange has an aperture configured to receive a fastener.
15. An emergency lamp module comprising an emergency module and a battery held within a housing, the emergency lamp module comprising at least one magnet and being configured to be magnetically held to a portion of a lighting system and to supply power to the lighting system in the event of a disruption in supplied power from a power source.
16. The emergency lamp module claim 15, wherein the housing comprises: a top wall; a first sidewall extending from the top wall; a second sidewall extending from the top wall and the first sidewall; a third sidewall extending from the top wall and the second sidewall; a fourth sidewall extending from the top wall, the first sidewall and the third sidewall; and wherein the at least one magnet is held with the first sidewall, the second sidewall, the third sidewall, the fourth sidewall, or the top wall and is configured to hold the emergency lamp module to a troffer.
17. The emergency lamp module claim 15 comprising at least one magnet having a surface substantially in a plane with an outer surface of the emergency lamp module.
18. The emergency lamp module claim 17 further comprising at least one mechanical holding device.
19. The emergency lamp module claim 18, wherein each mechanical holding device comprises at least one flange extending outwardly from the emergency lamp module and in a substantially common plane with the outer surface of the at least one magnet, wherein each flange has an aperture configured to receive a fastener.
Description
BRIEF DESCRIPTIONS OF THE DRAWINGS
(1) The following figures, which are idealized, are not to scale and are intended to be merely illustrative of aspects of the present disclosure and non-limiting. In the drawings, like elements may be depicted by like reference numerals. The drawings are briefly described as follows.
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DETAILED DESCRIPTION
(16) Reference will now be made in detail to the present exemplary embodiments and aspects of the present invention, examples of which are illustrated in the accompanying figures. The same reference numbers may be used in the figures to refer to the same or like parts. The presently disclosed embodiments, aspects, and features of the present invention are not to limit the presently claimed invention as other and different embodiments, aspects, and features will become apparent to one skilled in the art upon reading the present disclosure.
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(18) First and second LED lamp support rails 120 and 125 are configured and disposed to hold retrofit system 100 to a portion of a lamp fixture being retrofitted. For example, first and second LED lamp support rails 120 and 125 may each have a system holder. The system holder may comprise at least one mechanical holding device and/or at least one magnetic holding device configured and disposed to hold retrofit system 100 to a portion of a lamp fixture being retrofitted, for example a central portion of a troffer. In at least one aspect of the present disclosure, LED retrofit system 100 comprises at least one magnet 110 on first LED lamp support rail 120 and at least one magnet 110 on second LED lamp support rail 125. Magnets 110 are configured and disposed to hold retrofit system 100 to a portion of a lamp fixture being retrofitted. In at least one other aspect of the present disclosure, LED retrofit system 100 has mechanical holding devices 160. Mechanical holding device 160 may have an aperture 161 in a portion of each first and second support rail, 120 and 125. The portion of the first and second support rails 120 and 125 having aperture 161 may be disposed in a plane parallel to a plane of each longitudinally extending lamp 130. In at least one aspect of retrofit system 100, both mechanical and magnetic system holders may be provided.
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(20) LED lamp support rail fastening leg 114 may extend substantially perpendicular from lamp holder and end cover 112. Supports 168 may extend between LED lamp support rail fastening leg 114 and lamp holder and end cover 112 to provide support in maintaining a substantially perpendicular extension of LED lamp support rail fastening leg 114 from lamp holder and end cover 112. Magnets 110 may be disposed with or fastened to LED lamp support rail fastening leg 114. Alternatively, LED lamp support rail fastening leg 114 may have apertures disposed to provide mechanical fastening to a troffer of a fluorescent lamp fixture being retrofitted.
(21) LED lamp support rail extension 116 may extend from LED lamp support rail fastening leg 114 and may be configured to dispose a mechanical holding device. For example, a mechanical holding device 160 may have a tab extending in a plane substantially parallel with an outer surface of magnets 110 and may have a mechanical holding aperture 161 configured to receive a fastener, such as a screw, for mechanically holding LED retrofit system 100 to a fluorescent light fixture being retrofitted.
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(25) In at least one embodiment of the LED retrofit system of the present disclosure, the system comprises at least one longitudinally extending LED lamp 130 having a length substantially greater than a width and open longitudinal ends 137. It is to be understood that the LED retrofit system of the present disclosure may comprise one, two, three, or more longitudinally extending LED lamps 130. For example, aspects of the LED retrofit system of the present disclosure may comprise four, five, six, eight, twelve, or more LED lamps 130. In at least one aspect, LED retrofit system 100 comprises an equivalent number of LED lamps 130 as the fluorescent lamps in a lamp fixture being retrofitted.
(26) First and second LED lamp support rails, 120 and 125, are configured to hold and cover open longitudinal ends of each longitudinally extending LED lamp. First LED lamp support rail 120 is configured for the electrical connection of each longitudinally extending LED lamp with a power source or with electrical wire and connector 140. LED retrofit system 100 comprises a system holder on each LED lamp support rail configured and disposed to hold the retrofit system to a portion of a lamp fixture being retrofitted. The system holder may comprise apertures in each LED lamp support rail for receiving fasteners. Alternatively or additionally, the system holder may comprise magnets disposed with each LED support rail. The LED lamp retrofit system of the present disclosure may comprise other and/or additional holders or fasteners as are known by persons having ordinary skill in the art.
(27) In at least one aspect of the LED retrofit system of the present disclosure, each system holder comprises at least one magnet 110 on first LED lamp support rail 120 and at least one magnet 110 on the second LED lamp support rail 125, wherein the magnets 110 are configured and disposed to hold the retrofit system to a portion of a lamp fixture being retrofitted. Alternatively, or additionally, each of the first and second support rails 120 and 125 may comprise apertures in a portion thereof to be placed adjacent a troffer of the fluorescent lamp fixture being retrofitted. Each of the apertures may be configured and disposed to receive a fastener, such as a screw, for fastening LED retrofit system 100 to the fluorescent lamp fixture being retrofitted.
(28) LED lamps 130 may have an optical and visual outlook substantially similar to that of one or more fluorescent lamps to be removed from the lamp fixture to be retrofitted. LED retrofit system 100 may comprise one or more longitudinally extending LED lamps 130 having a longitudinally extending array of LEDs with power inputs extending out of the first open longitudinal end configured and disposed to electrically connect to a power source. First and second open longitudinal ends of each LED lamp 130 may comprise female helical threads configured and disposed to threadingly engage with fasteners for holding and covering the open ends with the first and second lamp support rails, 120 and 125.
(29) LED retrofit system 100 may comprise an electrical junction box 200 configured to cover an electrical junction between LED retrofit system 100 and existing electrical wiring in the lamp fixture being retrofitted. In at least one embodiment, electrical junction box 200 may be a cover 200. Cover 200 may be configured to cover an electrical junction or component parts of an electrical system and may comprise at least one magnet configured and disposed to hold the cover in place. For example, cover 200 may be an electrical junction box configured to magnetically attach to a portion of an electrical system and cover an electrical junction between the electrical system and a power source. Cover 200 may be configured to cover an electrical junction in a lighting system or component parts of the lighting system and may comprise at least one magnet configured and disposed to hold cover to a portion of the lighting system. Electrical junction box 200 may comprise at least one magnet 210 configured and disposed to hold electrical junction box 200 to a lighting system being retrofitted.
(30) Cover 200 may comprise a sole rounded or semi-spherical wall or may be rectangular in shape. For example, cover 200 may comprise a top wall 216, a first sidewall 212 extending from the top wall, a second sidewall 214 extending from the top wall and the first sidewall, a third sidewall 212 extending from the top wall and the second sidewall, and a fourth sidewall 214 extending from the top wall, the first sidewall and the third sidewall. Cover 200 may comprise at least one magnet 210 held with the first sidewall, second sidewall, third sidewall, fourth sidewall, or top wall and may be configured to hold the cover to a ferromagnetic surface. For example, the at least one magnet may be configured and disposed to hold cover 200 to a lighting system troffer.
(31) Cover 200 may have a surface of the at least one magnet 210 substantially in a plane with an outer edge of one of the sidewalls. Cover 200 may further comprise at least one mechanical holding device 260. For example, a mechanical holding device 260 may comprise at least one flange extending from a sidewall in a substantially common plane with an outer surface of the at least one magnet 210, wherein each flange may have an aperture 261 configured to receive a fastener.
(32) In at least one embodiment, cover 200 is an electrical junction box configured to cover an electrical junction between a lighting system and a power source and the at least one magnet 210 may be configured and disposed to hold the electrical junction box to the lighting system. In at least one other embodiment, cover 200 may comprise at least two of the magnets 210, wherein each of the magnets is held proximate a different sidewall. Each of the at least one magnet 210 may be held with an inner surface of cover 200. One of the sidewalls, 212 or 214, may have at least one cavity 218. Cavity 218 may be configured to receive power lines.
(33) It is to be understood that even though cover 200 is herein described as having four sidewalls and a top wall, cover 200 may comprise a sole wall. For example, cover 200 may comprise a sole rounded or spherical wall. Cover 200 may be configured to cover component parts of an emergency lamp module of a lighting system. For example, cover 200 may be configured to cover and/or hold component parts of an emergency lamp module. An emergency lamp module may comprise an emergency module and a battery, which may be configured to supply power to a lighting system in the event of a disruption in supplied power from a power source.
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(35) Emergency lamp module 300 may further comprise bottom wall 316 which may be removably held to the sidewalls. For example, bottom wall 316 may comprise portions of a fastener 322 proximate its corners. Other fastener portions 323 may be disposed proximate corners of the sidewalls. Fastener portions 322 and 323 may be configured to removably fasten with each other to provide a removable bottom wall 316. Bottom wall 311 may comprise one or more apertures 309.
(36) Emergency lamp module 300 comprises at least one magnet 310 and configured to be magnetically held to a portion of a lighting system and to supply power to the lighting system in the event of a disruption in supplied power from a power source. The at least one magnet 310 may have a surface substantially in a plane with an outer edge of emergency lamp module 300. Each magnet 310 may be held within the sidewalls with a magnet holder 312.
(37) Emergency lamp module 300 may further comprise at least one mechanical holding device 360. Mechanical holding device 360 may comprise a flange extending outwardly from emergency lamp module 300 and in a substantially common plane with the outer surface of the at least one magnet 310, wherein each flange has an aperture 361 configured to receive a fastener. Each magnet 310 may be held with the first 313, second 314, third 315, fourth 317 sidewall, or top wall 311 and magnets 310 may be configured to hold emergency lamp module 300 to a troffer.
(38) One of the sidewalls, 313, 314, 315, or 317 may have at least one cavity 318. Cavity 318 may be configured to receive power lines. One of the sidewalls, 313, 314, 315, or 317 may comprise apertures or electrical connectors 320, configured to electrically connect battery 340 and/or emergency module 350 with an external power source.
(39) In at least one other aspect of the present disclosure, an LED retrofit kit is provided. The LED retrofit kit may comprise a first LED lamp support rail 120 configured to hold and cover a first longitudinal open end 137 of at least one longitudinally extending LED lamp 130 and to electrically connect each of the at least one longitudinally extending LED lamps 130 to a power source. A second LED lamp support rail 125 may also be provided and may be configured to hold and cover a second longitudinal open end 137 of each of the at least one longitudinally extending LED lamps 130 held with the first LED lamp support rail 120. First and second LED lamp support rails 120 and 125 may have similar configurations. At least one magnet 110 may be on the first LED lamp support rail 120 and at least one magnet 110 may be on the second LED support rail 125, wherein magnets 110 may be configured and disposed to hold the retrofit kit to a portion of a lamp fixture being retrofitted.
(40) The LED retrofit kit may also comprise one, two, three, or more longitudinally extending LED lamps 130 having a length substantially greater than a width and open longitudinal ends. Longitudinally extending LED lamp 130 may have an optical and visual outlook substantially similar to that of one or more fluorescent lamps to be removed from a lamp fixture to be retrofitted. LED lamp 130 may comprise a longitudinally extending array of LEDs with power inputs extending out of one of the open longitudinal ends configured and disposed to electrically connect to a power source. Both open longitudinal ends of longitudinally extending LED lamp 130 may comprise female helical threads configured and disposed to cooperate with fasteners for holding and covering the open ends with the first and second lamp support rails.
(41) First and second LED lamp support rails, 120 and 125, may also comprise at least one mechanical holding device configured and disposed to mechanically hold the retrofit kit to a portion of a lamp fixture being retrofitted. For example, in at least one aspect of the LED retrofit kit of the present disclosure, each mechanical holding device comprises an aperture 161 in a flange 160 extending from each LED lamp support rail, 120 and 125, in a substantially common plane with an outer surface of magnets 110.
(42) The LED retrofit kit may further comprise an electrical junction box 200 configured to cover a junction between the retrofit kit and existing electrical wiring in the lamp fixture being retrofitted. The electrical junction box may comprise at least one magnet 210 configured and disposed to hold the electrical junction box to the lamp fixture being retrofitted.
(43) In at least one additional aspect of the present disclosure, a method of retrofitting a fluorescent lamp fixture with at least one LED lamp is provided. The method comprises the steps of turning off the power to the fluorescent lamp fixture being retrofitted and accessing the fluorescent lamps in fluorescent lamp fixture. Removal of a cover or light reflector or refractor may need be performed to access the fluorescent lamps. Upon accessing the fluorescent lamps, the fluorescent lamps are removed from the fluorescent lamp fixture. Then a ballast cover is removed from the fluorescent lamp fixture and wires leading to and from a ballast, in the fluorescent lamp fixture, are cut. The ballast may then be removed from the fluorescent lamp fixture. An electrical connector may then be attached to the cut wire leading to a power source.
(44) The method further comprises assembling a retrofit system. The retrofit system may be assembled by placing a first LED lamp support rail on a substantially flat surface. A second LED lamp support rail may be placed on the substantially flat surface and in a substantially parallel orientation with the first LED lamp support rail. A first end of at least one longitudinally extending LED lamp may be connected and held with the first LED lamp support rail and a second end of each longitudinally extending LED lamp may be connected and held with the second LED lamp support rail. Each connected and held longitudinally extending LED lamp may be electrically connected with a power lead wire. The assembled retrofit system may then be magnetically attached to a central portion of a troffer box cavity of the fluorescent lamp fixture being retrofitted. An electrical junction may then be made between the first end of each of the at least one longitudinally extending LED lamps and the cut wires extending into the troffer box. The power to the LED lamp retrofitted fluorescent lamp fixture may then be turned on.
(45) The method of retrofitting a fluorescent lamp fixture with at least one LED lamp may further comprise a step of covering the electrical junction between the retrofit system and power source with an electrical junction box by magnetically attaching an electrical junction box to the troffer box cavity of the fluorescent lamp fixture being retrofitted. The method may further comprise fastening the assembled retrofit system to the central portion of the troffer box cavity of the fluorescent lamp fixture being retrofitted with fasteners extending through apertures in the first and second LED lamp support rails.
(46) Aspects of the LED retrofit system, kit, and/or method of the present disclosure may have additional features or capabilities. For example, the LED retrofit system may be configured to operate using AC or DC power. The presently disclosed system may provide for dimming of one or more of the LED lamps. The system may be a multi-channel which may allow one or more LED lamps to be powered independent of other LED lamps in the LED retrofit system. One or more of the LED lamps may have its energy transmissible cover positioned upward and one or more of the LED lamps may have its energy transmissible cover positioned downward, allowing for up light and down light from a single LED retrofit system, which may be desired in some applications, such as high bay or sign applications for example. Aspects of the LED retrofit system may have multicolored LED lamps which may provide for color changing applications. In as least one aspect of the present disclosure, battery backup units may be provided for emergency operation such as in the event of a power failure.
Nomenclature
(47) TABLE-US-00001 Retrofit system 100 Magnet 110 LED lamp holder and end cover 112 LED lamp support rail fastening leg 114 LED lamp support rail extension 116 First LED lamp support rail 120 Second LED lamp support rail 125 LED lamp 130 Fastener 132 Fastener aperture 133 Wiring aperture 134 Female helical threads 135 Heat sink 136 Open longitudinal end of LED lamp 137 LED lamp energy transmissible cover 138 Electrical wire and connector 140 LED substrate 142 LED 144 LED power wires 146 Electrical wire cover 150 Electrical wire cover sidewall 152 Electrical wire cover end wall 154 Electrical wire cover top wall 156 Electrical wire cover mechanical holder 158 Electrical wire cover holder aperture 159 Mechanical holding device 160 Mechanical holding aperture 161 Supports 168 Electrical junction box 200 Magnet 210 Electrical junction box sidewall 212 Electrical junction box end wall 214 Electrical junction box top wall 216 Electrical junction box end wall cavity 218 Electrical junction box mechanical holder 260 Electrical junction box holder aperture 261