LUMINAIRE WITH PRE-ASSEMBLED LIGHT ENGINE AND LENS

• US 20160327237A1
• Filed: 05/03/2016
• Published: 11/10/2016
• Est. Priority Date: 05/07/2015
• Status: Active Grant

• Current Assignee: ABL IP Holding LLC (Acuity Brands, Inc.)
• Original Assignee: ABL IP Holding LLC (Acuity Brands, Inc.)
• Inventors: Hoch, Matthew Scott, Miller, Michael Ray, Logan, Mark C.
• Granted Patent: US 10,344,945 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: F21S 8/00 Lighting devices intended for fixed installation F21S9/00, F21S10/00 take precedence; using a string or strip of light sources F21S4/00
• CPC Class Codes: F21S 8/061 with a non-rigid pendant, i.e. a cable, wire or chain
• CPC Class Codes: F21V 15/01 Housings, e.g. material or assembling of housing parts F21V15/02 takes precedence housings forming signs or letters G09F13/04
• CPC Class Codes: F21V 17/101 permanently, e.g. welding, gluing or riveting
• CPC Class Codes: F21V 17/164 the parts being subjected to bending, e.g. snap joints
• CPC Class Codes: F21V 23/009 the casing being inside the housing of the lighting device
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2113/00 Combination of light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A luminaire includes a housing and a light engine. The light engine is detachably secured to the housing and includes a lens and an optical tray. The lens has a top surface, a bottom surface, and a peripheral edge. The top surface of the lens define a lens cavity. The optical tray is supported by the lens within the lens cavity.

Claims

1. A luminaire comprising:

a housing; and

a light engine detachably secured to the housing, the light engine comprising

a lens having an outer surface and an inner surface, the inner surface defining a lens cavity, and

an optical tray supported by the lens within the lens cavity.

2. The luminaire of claim 1, further comprising LEDs provided on a bottom surface of the optical tray.

3. The luminaire of claim 1, wherein the optical tray comprises a mounting support having:

a top surface;

a bottom surface; and

a peripheral edge,

wherein the mounting support comprises an upstanding flange along a first portion of the peripheral edge, and wherein the upstanding flange extends in an upward direction relative to the top surface of the mounting support.

4. The luminaire of claim 3, wherein the upstanding flange comprises at least one slot and wherein the housing comprising at least one fastener that engages the at least one slot.

5. The luminaire of claim 3, wherein the upstanding flange is a first upstanding flange, wherein the optical tray further comprises a second upstanding flange along a second portion of the peripheral edge, wherein the second upstanding flange extends in the upward direction relative to the top surface of the mounting support.

6. The luminaire of claim 5, wherein the mounting support further comprises a downwardly extending flange at the peripheral edge of the mounting support at a location between the first upstanding flange and the second upstanding flange, and wherein the downwardly extending flange extends in a downward direction relative to the bottom surface of the mounting support.

7. The luminaire of claim 6, wherein the downwardly extending flange comprises a lip defining a notch, wherein the inner surface of the lens defines a ledge having a ledge surface and a tab, and wherein the optical tray is positioned within the lens cavity such that the tab is engaged with the notch.

8. The luminaire of claim 7, wherein the lip is positioned on the ledge surface.

9. The luminaire of claim 1, wherein the inner surface of the lens defines a ledge having a ledge surface within the lens cavity, and wherein at least a portion of the optical tray rests on the ledge surface such that the optical tray is supported by the ledge.

10. The luminaire of claim 9, further comprising an adhesive interposed between at least a portion of the ledge surface and the at least portion of the optical tray to secure the lens and optical tray together.

11. The luminaire of claim 1, wherein the housing comprises:

an inner surface; and

an outer surface,

wherein the inner surface defines a housing cavity, and

wherein the light engine is positioned at least partially within the housing cavity.

12. The luminaire of claim 11, further comprising a gasket positioned between the light engine and the housing.

13. A light engine comprising:

a lens having an outer surface and an inner surface, the inner surface of the lens defining a lens cavity and a ledge within the lens cavity; and

an optical tray positioned at least partially on the ledge of the lens within the lens cavity.

14. The light engine of claim 13, wherein the optical tray comprises a mounting support comprising

a downwardly extending flange extending along a portion of the peripheral edge, wherein the downwardly extending flange extends in a downward direction relative to the bottom surface of the mounting support and comprises a lip,

wherein the lip is positioned on the ledge of the lens.

15. The light engine of claim 14, wherein a notch is provided in the lip and a rib is provided on the lens and wherein the rib engages the notch when the lip is positioned on the ledge of the lens.

16. The light engine of claim 13, further comprising an adhesive interposed between at least a portion of the ledge and a portion of the optical tray to secure the lens and optical tray together.

17. A method of assembling a luminaire comprising:

pre-assembling a light engine by securing an optical tray to a lens such that the optical tray is supported by the lens at least partially within a lens cavity; and

detachably securing the light engine to a housing by engagement between the lens and the housing.

18. The method of claim 17, wherein securing the optical tray to the lens comprises at least partially positioning at least a portion of a flange extending from the optical tray on a ledge defined within the lens cavity.

19. The method of claim 17, wherein detachably securing the light engine to the housing comprises:

at least partially positioning the light engine within a housing cavity defined by the housing; and

detachably engaging first fasteners positioned within the housing cavity with a slot defined in a side flange of the optical tray.

20. The method of claim 19, wherein detachably securing the light engine to the housing further comprises securing second fasteners located on one of the housing or the lens with recesses located on the other of the housing or the lens, wherein the second fasteners are positioned on the exterior of the luminaire.