Compact Luminaire

• US 20030002279A1
• Filed: 07/16/2002
• Published: 01/02/2003
• Est. Priority Date: 10/01/1999
• Status: Active Grant

• Current Assignee: Valmet Flow Control Incorporated
• Original Assignee: Dale E. Fiene
• Inventors: Fiene, Dale E.
• Granted Patent: US 6,860,617 B2
• Time in Patent Office: Days
• US Class Current: 362/147
• CPC Class Codes: E04B 9/32 Translucent ceilings, i.e. permitting both the transmission and diffusion of light E04B9/303 and E04B9/34 takes precedence; lighting F21
• CPC Class Codes: F21S 2/00 Systems of lighting devices, not provided for in main groups F21S4/00 - F21S10/00 or F21S19/00, e.g. of modular construction
• CPC Class Codes: F21S 8/06 by suspension
• CPC Class Codes: F21V 17/007 with provision for shipment or storage
• CPC Class Codes: F21V 17/06 the fastening being onto or by the lampholder
• CPC Class Codes: F21V 17/101 permanently, e.g. welding, gluing or riveting
• CPC Class Codes: F21V 19/0075 of tubular light sources, e.g. ring-shaped fluorescent light sources
• CPC Class Codes: F21V 19/008 of straight tubular light sources, e.g. straight fluorescent tubes, soffit lamps
• CPC Class Codes: F21V 19/0095 of U-shaped tubular light sources, e.g. compact fluorescent tubes
• CPC Class Codes: F21V 19/04 with provision for changing light source, e.g. turret auxiliary devices for cleaning, placing, or removing incandescent lamps H01K3/32, fluorescent lamps H01J9/006
• CPC Class Codes: F21V 23/02 the elements being transformers, impedances or power supply units, e.g. a transformer with a rectifier
• CPC Class Codes: F21V 23/026 Fastening of transformers or ballasts
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 3/00 Globes; Bowls; Cover glasses with refracting properties F21V5/00; with reflecting properties F21V7/00; characterised by cooling arrangements F21V29/506
• CPC Class Codes: F21V 7/10 Construction
• CPC Class Codes: F21V 7/24 characterised by the material
• CPC Class Codes: F21V 7/28 characterised by coatings
• CPC Class Codes: F21Y 2103/00 Elongate light sources, e.g. fluorescent tubes
• CPC Class Codes: F21Y 2103/33 annular
• CPC Class Codes: F21Y 2103/37 U-shaped
• CPC Class Codes: F21Y 2113/00 : Combination of light sources

Abstract

A luminaire for ceilings, which permits improved packing density for warehousing and shipping. The reflector of the luminaire is designed to permit it to be shipped in a flattened or nested state. This increases the packing density and eliminates shipping and warehousing boxes whose volume is 95% air. An assembled luminaire comprises three or four parts: the reflector, a ballasted-socket, a lamp, and an optional diffuser or lens. The reflector, ballasted-socket, lamp, and optional lens are either shipped separately in bulk packs or shipped in kits containing the one or more sets of components to build the luminaire. When the luminaires are installed at the job site, a ballasted-socket is inserted into a mounting aperture in the reflector; a lamp is inserted into the ballasted-socket; the ballasted-socket is connected to a power source, and the assembly is placed into the ceiling opening.

Claims

18. A structural element adapted for mounting in a ceiling wherein said structural element:

(i) is operable as a reflector for a light source providing illumination for the space below said ceiling, (ii) has an aperture to permit the mounting of a receptacle operable to make electrical connection to a power source and to receive, provide connection to and hold an electric lamp, (iii) has a certain height, (iv) is of such a shape as to permit one such structural element to be nested within another such that two such elements, when so nested, will exhibit a combined height no more than 50 per cent higher than said certain height.

36. A field assembled luminaire for a ceiling comprising:

a ballasted-socket assembly for compact fluorescent and other single-ended gas-discharge lamps;

said ballasted-socket assembly including;

a power input connection, ballasting circuitry to properly power a gas-discharge lamp, a lamp socket adapted to receive and hold such a lamp, and an enclosure that contains and completely encloses;

said ballasting circuitry, the connections to said lamp socket, and the interconnection between the output of said ballasting circuitry and said lamp socket;

said enclosure not including a gas-discharge lamp;

a reflector which is supported by the ceiling;

said reflector capable of receiving said ballasted-socket assembly; and

a gas-discharge lamp.

37. A luminaire for a ceiling;

said luminaire having a gas-discharge lamp, a lens, and a reflector;

said lens permanently attached to said reflector at the time of luminaire installation.

40. A luminaire for a ceiling comprising:

a lamp, a reflector and a ballasting circuit with an integral lamp socket;

said ballasting circuit with integral lamp socket, lamp, and reflector each shipped separately; and

said luminaire is assembled at the time of installation into the ceiling.

41. A functional luminaire for a ceiling comprising:

a connection to a source of power, a lamp socket, a lamp, a reflector, ballasting circuitry and an enclosure;

said enclosure completely enclosing the ballasting circuitry and the connections to the lamp socket;

said luminaire being supplied with no output wiring to the lamp existing outside of said enclosure;

said enclosure not enclosing the lamp.

42. A ballasted-socket assembly comprising:

a power input connection suitable for connection to a source of power, ballasting circuitry to properly power a gas-discharge lamp, a gas-discharge lamp socket, and an enclosure;

said enclosure containing and completely enclosing;

said ballasting circuitry, the connections to said gas-discharge lamp socket, and the interconnection between the output of said ballasting circuitry and said gas-discharge lamp socket;

said enclosure not containing or completely enclosing a gas-discharge lamp.

1. A luminaire for a ceiling comprising:

a reflector having a tapered side wall or walls which allow it to be stacked on top of an identical reflector, such that, the total height of the two nested reflectors is less than 50% taller than the height of a single reflector, the reflector having at least one aperture for the insertion of a ballasted-socket assembly; and

a ballasted-socket assembly comprising;

a power input connection, ballasting circuitry to properly power a gas-discharge lamp, a gas-discharge lamp socket, and an enclosure that contains and completely encloses;

said ballasting circuitry, the connections to said gas-discharge lamp socket, and the interconnection between the output of said ballasting circuitry and said gas-discharge lamp socket; and

a gas-discharge lamp.

2. The luminaire recited in claim 1, wherein the ballasted-socket assembly is connected to and powered from a power source;

said power source having an output which is limited to 250 volt-amperes or less.

3. The luminaire recited in claim 1, wherein the ballasted-socket assembly is connected to and powered from an output of a power source;

said output being turned off for at least 90% of the time if the current drawn from the output exceeds a predetermined limit while said output is turned on.

4. The luminaire recited in claim 1, wherein the ballasted-socket assembly is connected to the wiring from the power source using an insulation displacement connection.

5. The luminaire recited in claim 1, wherein the ballasted-socket assembly is disconnectably connected to a power source using a power plug.

6. The luminaire recited in claim 1, wherein the reflector is non-metallic.

7. The luminaire recited in claim 1, wherein the reflective side of the reflector includes a textured surface.

8. The luminaire recited in claim 1, wherein the power input connection is connected to a source of high-frequency power.

9. The luminaire recited in claim 1, wherein the ballasted-socket assembly clips or snaps into the reflector aperture.

10. The luminaire recited in claim 1, wherein the ballasted-socket assembly is inserted into said aperture and then rotated in order to affix it to the reflector.

11. The luminaire recited in claim 1, wherein the luminaire contains multiple gas-discharge lamps.

12. The luminaire recited in claim 1, wherein the luminaire is so constructed to permit relamping from the back or the side of the luminaire.

13. The luminaire recited in claim 12, wherein the luminaire is provided with a lens that is permanently affixable to the luminaire during field assembly.

14. The luminaire recited in claim 1, wherein the luminaire is a troffer.

15. The luminaire recited in claim 1, wherein power is provided by a power-limited voltage source.

16. The luminaire recited in claim 1, wherein power is provided by a voltage with an rms magnitude less than 60 volts.

17. The luminaire recited in claim 1, wherein power is provided by a voltage with an rms magnitude less than 150 volts.

19. The structural element recited in claim 18, wherein said electrical connection is to a power source having an output current that is limited to a value that is less than 2.5 amps rms and a voltage that is less than 60 volts rms.

20. The structural element recited in claim 18, wherein said electrical connection is to a power source having an output current that is limited to a value that is less than 2.5 amps rms and a voltage that is less than 150 volts rms.

21. The structural element recited in claim 18, wherein the receptacle is connected to the wiring from the power source using an insulation displacement connection.

22. The structural element recited in claim 18, wherein said electrical connection is made using plug-in connectors.

23. The structural element recited in claim 18, wherein said structural element is non-metallic.

24. The structural element recited in claim 18, wherein the reflective side of said structural element includes a textured surface.

25. The structural element recited in claim 18, wherein a lens is placed between the ceiling and said structural element.

26. The structural element recited in claim 18, wherein said receptacle clips or snaps into the aperture.

27. The structural element recited in claim 18, wherein said receptacle must be placed into said aperture and then rotated in order to affix it to the structural element.

28. The structural element recited in claim 18, wherein said structural element contains multiple electric lamps.

29. The structural element recited in claim 18, wherein said structural element is constructed to permit relamping from the back or the side of said structural element.

30. The structural element recited in claim 18, wherein the structural element is provided with a lens that is permanently affixed to the structural element during field assembly.

31. The structural element recited in claim 18 wherein said electrical connection is made to a source of voltage and the structural element is used as a troffer.

32. The structural element recited in claim 18, wherein the structural element is used as a troffer.

33. The structural element recited in claim 18 wherein said electrical connection is made to a source of power limited voltage.

34. The structural element recited in claim 18, wherein said electrical connection is made to a source of power;

said source of power having an output current that is limited to a value that is less than 2.5 amps rms and a voltage that is less than 60 volts rms.

35. The structural element recited in claim 18, wherein said electrical connection is made to a source of high-frequency power;

said source of high-frequency power having an output current that is limited to a value that is less than 2.5 amps rms and a voltage that is less than 150 volts rms.

38. The luminaire recited in claim 37 wherein, said permanent attachment being accomplished with adhesively coated gasket material that is provided as part of the reflector or lens.

39. The luminaire recited in claim 37 wherein, said lamp is replaced from the rear of the luminaire.

43. A combination comprising:

the assembly described in claim 42; and

a source of voltage, said source of voltage having its output power limited to 250 volt-amperes or less.

44. The assembly described in claim 42, wherein the power input connection is provided via an integral power cable;

said power cable having a power plug;

the power plug having two or more plug terminals;

the assembly including a power receptacle;

the power receptacle having two or more receptacle terminals;

each receptacle terminal being electrically connected to a corresponding plug terminal.

45. The assembly described in claim 42, wherein said ballasted-socket assembly is used in combination with a luminaire for installation into a ceiling;

said luminaire having a reflector;

said reflector being of such shape to allow a second reflector to be stacked on top of the first reflector;

the two reflectors when so stacked having a combined height no more than 50% higher than that of a single reflector.

46. The assembly described in claim 42, wherein the ballasted-socket assembly does not contain an electronic inverter circuit.

48. The assembly described in claim 47, wherein said enclosure is formed at least in part by the cover plate.

49. The assembly described in claim 47, wherein the power input connection is provided via an integral power cable;

said power cable having a power plug;

the power plug having two or more plug terminals;

the assembly including a power receptacle;

the power receptacle having two or more receptacle terminals;

each receptacle terminal being electrically connected to a corresponding plug terminal.

50. The assembly described in claim 47, wherein the input power is provided via either of two parallel connected receptacles.

51. The assembly described in claim 47, wherein the bulk of the ballasted-socket assembly is located external to the luminaire;

said ballasted-socket assembly being a separately packaged assembly that does not contain an inverter.

52. The assembly described in claim 47, wherein the cover plate makes up part of said enclosure;

the assembly being provided with a gas-discharge lamp;

said cover plate removably mounted to the outside of a reflector;

the cover plate when so mounted providing access for the replacement of said gas-discharge lamp.

53. The assembly described in claim 47, wherein the ballasted-socket assembly does not contain an electronic inverter circuit.

43-1. The assembly described in claim 42, wherein the input power is provided via either of two parallel connected power receptacles.

44-2. The assembly described in claim 42, wherein the bulk of the ballasted-socket assembly is designed to be located external to the luminaire;

said ballasted-socket assembly being a separately packaged assembly that does not contain an inverter.

47. A ballasted-socket assembly comprising:

a power input connection suitable for connection to a source of electrical power, ballasting circuitry to properly power a gas-discharge lamp, lamp socket, an enclosure and a cover plate;

said enclosure containing and completely enclosing;

said ballasting circuitry, the connections to said lamp socket, and the interconnection between the output of said ballasting circuitry and said lamp socket;

said enclosure not containing or completely enclosing a gas-discharge lamp.

54. A ceiling including:

a plurality of luminaires;

said luminaires suitable for placement directly into the openings of said ceiling;

said luminaire having a reflector with a certain shape;

said certain shape allowing one reflector to be nested within another reflector;

the combined height of two nested reflectors being no higher than 1.9 times the height of a single reflector;

said luminaire being provided with a ballasted-socket assembly;

said ballasted-socket assembly having an enclosure; and

said ballasted-socket assembly containing all electrical components required to power an electric lamp.

55. The luminaire recited in claim 54 wherein the reflector has a top plane;

the reflector being constructed to permit the luminaire to accommodate a lamp that has a total length that is greater than the length of the top plane of the luminaire.

56. The luminaire recited in claim 54 wherein the reflector contains an aperture;

said aperture being capable of receiving a ballasted-socket assembly;

said ballasted-socket assembly including a recess; and

said recess being capable of engaging an edge of the aperture for the purpose of retaining the ballasted-socket.

57. The luminaire recited in claim 54 wherein the reflector contains apertures;

one of said apertures being capable of receiving a ballasted-socket assembly;

said ballasted-socket assembly including a remote bi-pin lampholder;

a second aperture being capable of receiving a remote bi-pin lampholder;

one side of each said aperture being a flexible member; and

said flexible member being capable of moving sufficiently to permit a standard length linear lamp to be inserted within the lampholders of the ballasted-socket.

59. The structural element recited in claim 58, wherein said electrical connection is to an energy limited circuit;

and

said limit being less than 250 volt-amperes

60. The structural element recited in claim 58, wherein a lens is placed between the ceiling;

and

said structural element.

61. The structural element recited in claim 58, wherein said structural element is constructed to permit relamping from the back or the side of said structural element.

62. The structural element recited in claim 58, wherein the structural element is provided with a lens that is permanently affixed to the structural element during field assembly.

63. The structural element recited in claim 58 wherein said electrical connection is made to a source of high-frequency AC voltage.

58. A structural element adapted for mounting in an opening in a ceiling wherein the structural element:

(i) is operable as a reflector for a light source providing illumination for the space below said ceiling, (ii) has an aperture to permit the mounting of a receptacle operable to receive, provide electrical connection to, contain all electronic components required to properly power and hold an electric lamp, (iii) has a certain height, and (iv) is of such a shape as to permit one such structural element to be nested within another, such that two such elements, when so nested, will exhibit a combined height no more than 1.9 times said certain height.

64. A module suitable for receiving voltage on its power input terminals and properly powering a lamp connected to its output terminals;

said output terminals being contained in one or more lamp sockets or lampholders;

said module having an enclosure;

said enclosure completely enclosing all circuitry, connections to lamp sockets or lampholders, and internal wiring between the circuitry and the lamp sockets or lampholders;

said enclosure not enclosing lamp; and

said circuitry not being enclosed in a separate additional enclosure required to provide protection from fire or shock hazard.

65. The module recited in claim 64 wherein the module contains a single circuit connected to multiple lamp sockets;

and

each lamp socket being capable of powering a single lamp.

66. The module recited in claim 64 wherein the module has multiple lamp sockets;

a given lamp requiring connection to two lamp sockets to be properly powered.

68. The module disclosed in claim 67 wherein two separate lampholders are required to properly power a given lamp;

the second lamp socket or lampholder being connected to the module with more than one conductor;

the conductors having an electrical voltage between them; and

said voltage between any two conductors being at all times less than 30 volts.

69. The module disclosed in claim 67 wherein two separate lampholders are required to properly power a given lamp;

said lamp having lamp terminals;

both lampholders having openings to receive said lamp terminals; and

said module so constructed to provide said openings facing the same direction.

70. The module disclosed in claim 67 wherein two separate lampholders are required to properly power a given lamp;

said lamp having lamp terminals;

both lampholders having openings to receive said lamp terminals; and

said module so constructed to provide said openings facing opposite directions.

67. A module suitable for receiving voltage on its power input terminals and properly powering a lamp connected to its output terminals;

said output terminals being contained in two or more lamp sockets or lampholders;

said module having an enclosure;

said enclosure completely enclosing all circuitry, connections to at least one lamp socket or lampholder, and the internal wiring between the circuitry and said lamp socket or lampholder;

said enclosure not enclosing any lamp;

said circuitry not being enclosed in a separate additional enclosure required to provide protection from fire or shock hazard;

said module having a second lamp socket or lampholder; and

said second lamp socket or lampholder being connected to the module by one or more conductors.

71. A luminaire for a ceiling;

said luminaire having a reflector;

said reflector including multiple apertures to accommodate one or more ballasted-socket assemblies;

said different types of ballasted-socket assemblies possessing different physical shapes and configurations to accommodate a variety of gas discharge lamps; and

said apertures being of various shapes to permit said reflector to be used with more than one type of ballasted-socket assembly.

72. The luminaire recited in claim 71 wherein the apertures in the reflector are not open;

position of said apertures being indicated by having at least the perimeter of the aperture formed by the material of the reflector being at least 10% thinner than the material of the reflector adjacent to the outline of the aperture; and

the reduction in material thickness around the perimeter of the aperture allowing the material within the perimeter to be dislodged from the reflector if said aperture is used for the insertion of a ballasted-socket assembly.

73. The luminaire recited in claim 71 wherein the aperture of the reflector is not open;

the aperture having a perimeter; and

said perimeter being sheared or partially sheared to allow the material within the aperture to be dislocated from the reflector if said aperture is used for the insertion of a ballasted-socket assembly.

74. A module;

said module having an input connection comprising two conductors;

said module having multiple output connections;

the multiple output connections being incorporated within one or more sockets;

the socket being so constructed to prevent the possibility of human contact directly with any of the output conductors;

the module containing a ballasting circuit capable of properly ballasting a gas discharge lamp, but only when the conductors of the input connection are connected to a voltage source;

said voltage source having a frequency of 0 to 25 Hertz or greater than 400 Hertz;

said module including an enclosure;

the enclosure completely enclosing the ballasting circuit, and the electrical connections to the socket; and

said enclosure not enclosing any lamp.

75. The module recited in claim 74, wherein the ballasting circuit comprises only passive components.

76. The module recited in claim 74, wherein the ballasting circuit does not include a high frequency inverter.

77. The module recited in claim 74, wherein the module includes lamp sockets for linear fluorescent lamps.

78. The module recited in claim 74, wherein the module is used in combination with a reflector of a luminaire;

the module being mounted onto the reflector of a luminaire such that more than 50% of the volume of the module is external to the luminaire.

79. The module recited in claim 74, wherein the module is used in combination with a reflector of a luminaire;

the module being mounted onto the reflector of a luminaire such that more than 50% of the volume of the module is internal to the luminaire.

80. The module recited in claim 74, wherein the voltage source is DC.

81. A structural element for installation into a ceiling;

the structural element having a reflector;

said reflector having four hinged panels;

each of the hinged panels being connected to a different edge of a common rectangular panel via a hinge;

the structural element being further characterized by;

(i) being operable as a reflector for a light source providing illumination for the space below said ceiling, (ii) having an aperture to permit the mounting of a receptacle operable to receive, provide electrical connection to and hold an electric lamp, (iii) having a certain height immediately prior to being mounted in said ceiling, and (iv) being of such construction as to permit the height during shipment to be substantially less than said certain height.

82. The structural element recited in claim 81, wherein a non-hinged lens is placed between the ceiling and said structural element.

83. The structural element recited in claim 81, wherein the height during shipment is less than 25% of said certain height immediately prior to being mounted in said ceiling.

84. The structural element recited in claim 81, wherein said electric lamp is replaceable;

said electric lamp is fluorescent; and

the structural element is provided with a lens that is permanently affixed to the structural element during field assembly.

85. The structural element recited in claim 81, wherein said receptacle is a separate self-contained assembly that is removable from said structural element.

86. The structural element recited in claim 81, wherein said hinged panels are substantially trapezoidal in shape.

87. The structural element recited in claim 81, wherein two of the hinged panels are rectangular and two of the hinged panels are trapezoidal.

88. The structural element recited in claim 81, wherein the structural element has adjoining edges;

said adjoining edges having a gap separating one from the other at some time prior to installation; and

said gap being substantially reduced prior to installation into the ceiling.

89. The structural element recited in claim 81, wherein said hinged panels are substantially trapezoidal in shape.

90. A luminaire for a ceiling comprising:

a reflector having at least one aperture for the attachment of a ballasted-socket assembly;

said reflector having four hinged panels;

each of the hinged panels being connected to a different edge of a common rectangular panel via a hinge;

said reflector having a certain height immediately prior to being installed into the ceiling;

said certain height being substantially greater than the height of the reflector during shipment;

a ballasted-socket assembly comprising;

a power input connection, ballasting circuitry to properly power a gas-discharge lamp, a gas-discharge lamp socket, and an enclosure that contains and completely encloses;

said ballasting circuitry, the connections to said gas-discharge lamp socket, and the interconnection between the output of said ballasting circuitry and said gas-discharge lamp socket; and

a gas-discharge lamp.

91. The luminaire recited in claim 90, wherein said hinged panels are substantially rectangular in shape.

92. The luminaire recited in claim 90, wherein a non-hinged lens is placed between the ceiling grid and the reflector.

93. The luminaire recited in claim 92, wherein said gas-discharge lamp is replaceable;

and

the luminaire is provided with a lens that is permanently affixed to the luminaire during field assembly.

94. The luminaire recited in claim 90, wherein said certain height immediately prior to being mounted into the ceiling is 25%, or more, greater than the height of the reflector during shipment.

95. The luminaire recited in claim 90, wherein said hinged panels are substantially trapezoidal in shape.

96. A field assembled luminaire for a ceiling comprising:

a ballasted-socket assembly for a gas-discharge lamp;

said ballasted-socket assembly including;

a power input connection, ballasting circuitry to properly power a gas-discharge lamp, a lamp socket adapted to receive and hold such a lamp, and an enclosure that contains and completely encloses;

said ballasting circuitry, the connections to said lamp socket, and the interconnection between the output of said ballasting circuitry and said lamp socket;

a reflector which is supported by a ceiling grid system;

said reflector having four hinged panels;

each of the hinged panels being connected to a different edge of a common rectangular panel via a hinge;

said reflector having a certain height immediately prior to installation into the ceiling grid system;

said reflector having a height during shipment substantially less than said certain height;

said reflector capable of receiving said ballasted-socket assembly;

a gas-discharge lamp; and

said enclosure included in the ballasted-socket assembly not enclosing the gas-discharge lamp.

97. The luminaire recited in claim 96, wherein said hinged panels are substantially rectangular in shape.

98. The luminaire recited in claim 96, wherein two of the hinged panels are rectangular and two of the hinged panels are trapezoidal.

99. The luminaire recited in claim 96, wherein height reduction during shipment is greater than 50%.

100. A ceiling including:

a plurality of openings;

a plurality of luminaires;

said luminaires suitable for placement into the openings of said ceiling;

said luminaire having a reflector;

said reflector having four hinged panels;

each of the hinged panels being connected to a different edge of a common rectangular panel via a hinge;

said reflector having a certain height immediately prior to installation into the rectangular grid opening; and

said reflector having a height during shipment substantially less than said certain height.