Modular light fixture with power pack

• US 7,575,338 B1
• Filed: 10/03/2005
• Issued: 08/18/2009
• Est. Priority Date: 10/03/2005
• Status: Active Grant

• Current Assignee: Orion Energy Systems, Inc.
• Original Assignee: Orion Energy Systems, Inc.
• Inventors: Verfuerth, Neal R.
• Primary Examiner(s): O'Shea; Sandra L
• Assistant Examiner(s): Cranson; James W
• Application Number:
  US11/242,620
• Time in Patent Office: 1,415 Days
• Field of Search: 362/148, 362/220, 362/221, 362/260
• US Class Current: 362/221
• CPC Class Codes: F21S 8/06 by suspension
• CPC Class Codes: F21V 23/026 Fastening of transformers or ballasts
• CPC Class Codes: F21V 23/0442 activated by means of a sensor, e.g. motion or photodetectors
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 25/02 coming into action when lighting device is disturbed, dismounted, or broken
• CPC Class Codes: F21V 29/503 of light sources cooling arrangements structurally associated with gas-discharge or vapour-discharge lamps H01J61/52; cooling arrangements structurally associated with electric incandescent lamps H01K1/58; cooling arrangements structurally associated with light-emitting diodes H01L33/64
• CPC Class Codes: F21Y 2103/00 Elongate light sources, e.g. fluorescent tubes

Abstract

A modular light fixture specially adapted for flexible, cost-effective, and safe retrofit and maintenance, particularly in large commercial lighting applications. The light fixture preferably includes a frame with one or more lampholders and a detachable power pack with a ballast, with modular connectors used to provide an electrical connection between the detachable power pack and the lampholders. Other aspects of the invention relate to methods of redeploying lighting, and a modular light fixture kit, for example to be used in lighting retrofit and maintenance.

Claims

1. A light fixture comprising:

a fixture body comprising a frame having a top side and a bottom side, the top side defining a ballast channel and the bottom side having a reflector formed from a sheet material;

a lampholder mounted to the frame and configured to receive and electrically connect to a fluorescent tube positioned adjacent to the reflector; and

a detachable power pack that is removable from the top side of the frame substantially free from interference, the detachable power pack comprising;

a ballast channel cover configured to detachably engage the ballast channel on the top side of frame;

a ballast mounted to the ballast channel cover, wherein the ballast comprises power input wiring and ballast output wiring, and further wherein the ballast output wiring is configured to be electrically connected to the lampholder such that electrical power is provided to the lampholder; and

a power input connector mounted to the ballast channel cover, wherein the power input connector is electrically connected to the power input wiring of the ballast and configured to receive the electrical power from a power source.

2. The light fixture of claim 1, wherein at least one of the ballast channel and the ballast channel cover is formed of sheet aluminum.

3. The light fixture of claim 1, wherein the ballast channel is provided substantially along a length of the frame and communicates with a raceway disposed substantially orthogonal to the ballast channel;

and wherein the raceway supports the lampholder.

4. The light fixture of claim 1, further comprising a power cord assembly comprising a power supply line having a first end electrically connectable to the power source and a second end electrically connected to a power supply plug, wherein the power supply plug is adapted to engage the power input connector such that the electrical power is provided to the ballast through the power input wiring.

5. The light fixture of claim 4, wherein the power supply plug is polarized and the power input connector is polarized such that the power supply plug is engageable with the power input connector in only one orientation.

6. The light fixture of claim 1, wherein the lampholder comprises a lampholder harness connector and the ballast further comprises a ballast output connector in electrical communication with the ballast output wiring, wherein the ballast output connector is configured to engage the lampholder harness connector such that the electrical power is provided from the ballast to the lampholder.

7. The light fixture of claim 6, wherein the lampholder harness connector is polarized and the ballast output connector is polarized such that the lampholder harness connector is engageable with the ballast output connector in only one orientation.

8. The light fixture of claim 3, wherein the ballast channel extends substantially along a center of the frame and communicates with a pair of raceways disposed substantially orthogonally proximate opposite ends of the ballast channel.

9. The light fixture of claim 1, further comprising a plurality of clips engagable with the ballast channel cover and the ballast channel to detachably engage the ballast channel cover to the ballast channel without the use of tools.

10. A method of redeploying lighting in a building, comprising:

(a) providing a light fixture, wherein the light fixture comprises

a fixture body comprising a frame having a top side and a bottom side, the top side defining a ballast channel;

a lampholder mounted to the frame, wherein the lampholder comprises a lampholder harness connector; and

a detachable power pack comprising;

a ballast channel cover configured to detachably mount to the top side of the frame and over the ballast channel;

a ballast mounted to the ballast channel cover, wherein the ballast comprises power input wiring and ballast output wiring; and

a ballast output connector electrically connected to the ballast output wiring and configured to engage the lampholder harness connector such that electrical power is provided to the lampholder;

(b) disengaging the ballast channel cover from the top side of the frame such that the ballast output connector and the lampholder harness connector are exposed; and

(c) disengaging the ballast output connector from the lampholder harness connector such that the detachable power pack is detached from the fixture body.

11. The method of claim 10, further comprising disengaging a power supply plug from a power input connector, wherein the power input connector is mounted to the ballast channel cover and electrically connected to the power input wiring of the ballast, and further wherein the power supply plug is configured to engage the power input connector such that the electrical power is provided to the ballast.

12. The method of claim 10, wherein the detachable power pack is a first detachable power pack, and further comprising:

(d) providing a second detachable power pack comprising a second ballast mounted to a second ballast channel cover, wherein the second ballast comprises second power input wiring and second ballast output wiring, wherein the second ballast output wiring is electrically connected to a second ballast output connector;

(e) engaging the second ballast output connector with the lampholder harness connector; and

(f) engaging the second ballast channel cover with the top side of the frame such that the second ballast is mounted to the frame.

13. The method of claim 12, further comprising engaging a power supply plug with a power input connector mounted to the second ballast channel cover such that the electrical power is provided to the second ballast.

14. The method of claim 10, wherein the detachable power pack further comprises a power input connector mounted to the ballast channel cover and electrically connected to the ballast power input wiring such that the electrical power is provided to the ballast.

15. The method of claim 12, further comprising the step of connecting the ballast and the second ballast to a controller, and wherein the ballast comprises a first ballast factor and the second ballast comprises a second ballast factor such that the controller can adjust a power consumption of the ballast and the second ballast, so that light output of the light fixture is adjusted.

16. The method of claim 10, further comprising

removing the ballast from the ballast channel cover;

mounting a second ballast to the ballast channel cover; and

re-engaging the ballast channel cover with the top side of the frame.

17. A light fixture kit comprising:

a frame having a top side and a bottom side;

a first raceway and a second raceway disposed proximate opposite ends of the frame;

a first lampholder mounted to the first raceway and a second lampholder mounted to the second raceway, wherein the lampholders are electrically connected to a lampholder harness connector; and

a plurality of detachable power packs, wherein each detachable power pack comprises;

a ballast channel cover configured to detachably engage the top side of the frame;

a ballast mounted to the ballast channel cover, wherein the ballast comprises power input wiring; and

a power input connector mounted to the ballast channel cover and electrically connected to the ballast input wiring, wherein the power input connector is configured to receive electrical from a power supply line electrically connected to a power source.

18. The kit of claim 17, further comprising a power supply line, wherein the power supply line comprises a first end configured to engage the power source and a second end having a power supply connector configured to engage the power input connector.

19. The kit of claim 18, wherein the first end comprises at least one of a plurality of wires adapted to be hard wired to the power source and the second end comprises a plurality of wires adapted to be wired to a standard electrical plug.

20. The kit of claim 17, wherein the plurality of detachable power packs comprises a first detachable power pack with a first ballast having a first ballast factor, and a second detachable power pack with a second ballast having a second ballast factor, wherein the first ballast factor is greater than the second ballast factor.

21. A method of redeploying lighting in a building using existing light fixtures, comprising:

(a) accessing the existing light fixture, wherein the existing light fixture comprises;

a frame having a top side and a bottom side, the top side defining a power side adapted to receive any one of a plurality of detachable power packs having different ballast factors, the bottom side defining a light-emitting side with lamp holders coupled to the frame and to a fluorescent lamp and a reflector coupled to the frame to reflect light emitted from the fluorescent lamp into a space beneath the existing light fixture; and

a detachable power pack comprising a ballast having a first ballast factor, the ballast detachably mounted to the top side of the frame and directly removable from the top side of the frame substantially free from interference with the existing light fixture;

(b) evaluating a first lighting level within the space provided by the fluorescent lamp and the ballast having the first ballast factor; and

(c) changing the first lighting level within the space to a second lighting level within the space using the existing light fixtures by removing the ballast with the first ballast factor from the top side of the frame of the existing fixture and installing a second ballast with a second ballast factor on the top side of the frame of the existing light fixture.

22. The method of claim 21 wherein the frame comprises a ballast channel and a pair of raceways arranged in an I-shape configuration, the ballast channel configured to receive the detachable power pack on the power side of the frame, and the raceways configured to support the lamp holders on the light-emitting side of the frame.

23. The method of claim 21 further comprising the step of determining a change in power consumption by the existing lighting fixtures resulting from the step of changing the first lighting level within the space to a second lighting level within the space.

24. The method of claim 21 wherein the existing lighting fixture comprises a plurality of existing lighting fixtures and wherein the step of changing the first lighting level within the space to a second lighting level within the space using the existing fixtures further comprises installing a third ballast with a third ballast factor on the top side of the frame of at least a portion of the existing light fixtures.