[0001] The present disclosure relates generally to LED luminaires and particularly to recessed
or suspended ceiling and wall mounted LED luminaires. More particularly, the present
disclosure relates to a system and method for replacing the power supply unit (PSU)
and other internal components of a recessed or suspended ceiling or wall mounted LED
luminaire.
[0002] LED luminaires that are recessed in a drop ceiling include a housing that can be
fitted into common ceiling grid systems. The housing is commonly an extruded aluminum
outer shell that is able to lay on the edge of the ceiling grids. The housing encloses
the PSU and the LED module, which is generally attached to a heat sink. The housing
also encloses any reflectors that are used in the luminaire as well as a diffuser
which generally forms the floor of the housing.
[0003] Figure 1 is an example of a prior art luminaire 10 recessed in a ceiling 12. The
luminaire includes an elongated housing 14 having a top wall (not shown), two side
walls (only one partially shown), and two end walls (one shown). The bottom of the
housing is enclosed by a diffuser 16. Diffuser 16 is held in place by retaining lips
17, 18 which run along length "1" of the lower edge of the housing 14.
[0004] A prior art LED luminaire 20 is shown in Figure 2 in cross-section. The luminaire
20 includes a housing having two regions, top region 22 and bottom region 24. Power
supply unit 26 is mounted to the inside surface of the top housing region 22. LED
module 28 is mounted to the underside of heat sink 30 which in turn is mounted with
two rows of screws 32, 34 so that it is between the top housing region 22 and bottom
housing region 24. A diffuser 36 sits in the opening of bottom housing region 24 and
reflectors 38 fit within bottom housing region 24 between the LED module 28 and the
diffuser 36.
[0005] In order to access and replace the PSU 26 of the prior art luminaire 20, the diffuser
36, reflectors 38, and heat sink 30 must first be removed. The diffuser 36 and reflectors
38 are lightweight and relatively simple elements to remove. However the heat sink
30 is heavy and it is awkward to unfasten screws 32, 34 and lower the heat sink from
the luminaire. Moreover, heat sink 30 has mounted thereto the LED module 28 which
is quite fragile and must be carefully handled to avoid damage. Furthermore, any wiring
between the LED module 28 and the PSU 26 must be disconnected in order to remove and
replace the PSU 26.
[0006] In other words, to remove the heat sink 30 from the prior art luminaire 20, the two
rows of screws 32, 34 are removed to release the heat sink 30. The heat sink 30, along
with any wiring connecting the heat sink 30, LED module 28, and the PSU 26, is then
carefully removed. The PSU 26 is then exposed and can be removed and replaced.
[0007] Issues with the prior art assembly are evident. The LED module can be damaged during
the removal and temporary storage of the heat sink. The heat sink is heavy and awkward
and its removal from the housing can be dangerous.
[0008] The above-described shortcomings significantly limit the usefulness of field-serviceable
LED luminaires (i.e. luminaires having a replaceable PSU). Therefore, there remains
a need for an LED luminaire assembly which allows for the easy and safe removal and
replacement of the PSU and other internal components.
[0009] In at least one aspect, the present disclosure provides a field serviceable solid
state lighting device luminaire assembly which allows for the easy and safe removal
and replacement of the power supply unit and other internal components.
[0010] In at least another aspect, the present disclosure provides a solid state lighting
device luminaire assembly wherein the heat sink can be folded aside to allow access
to and removal of the PSU.
[0011] The present disclosure describes a solid state lighting device luminaire assembly
having a housing with a first side wall, a second side wall, a first end wall, and
a second end wall and a power supply unit located within the housing. The solid state
lighting device module is connected to a heat sink which blocks access to the power
supply unit. The heat sink folds or pivots to allow access to the power supply unit.
[0012] In one aspect the heat sink extends across the housing and is attached to the first
side wall of the housing with a fixed attachment and to the second side wall of the
housing with a pivot attachment so that when the fixed attachment is disconnected
the heat sink stays attached to the housing at the pivot attachment and pivots towards
the second side wall. When the heat sink is pivoted the power supply unit is exposed.
[0013] In another aspect, the heat sink extends across the housing and is attached to the
first end wall with a fixed attachment and to the second end wall with a removable
attachment and the heat sink includes at least two segments connected by a hinged
connection. The heat sink can be unattached from the second end wall and folded at
the hinged connection to expose the power supply unit.
FIG. 1 illustrates a prior art ceiling mounted luminaire.
FIG. 2 illustrates a schematic view of a prior art LED luminaire.
FIG. 3 illustrates a schematic view of an LED luminaire assembly in accordance with
at least one embodiment of the present disclosure.
FIG. 4 is another schematic view of the LED luminaire assembly with the heat sink
pivoted to allow access to the PSU.
FIG. 5 is an up-close view of the pivot attachment of the heat sink to the housing.
FIG. 6 is a view of another embodiment of a pivot attachment of the heat sink to the
housing using a hook mechanism.
FIG. 7 is a view of another embodiment of a pivot attachment of the heat sink to the
housing wherein the pivot mechanism is not an integral part of the housing.
FIG. 8 is a view of another embodiment of the fixed attachment of the heat sink to
the housing using a snap-fit fastener.
FIG. 9 is a view of another embodiment of the fixed attachment of the heat sink to
the housing using a pin and snap ring.
FIG. 10 illustrates an LED luminaire where the LED module is attached to a heat sink
which is hinged on an alternative axis.
Figure 11 illustrates one embodiment of a hinged connection between permanent and
removable segments of a heat sink.
Figure 12 illustrates the hinged connection of Figure 11 in disengaged status.
[0014] The present disclosure may take form in various components and arrangements of components,
and in various process operations and arrangements of process operations. The present
disclosure is illustrated in the accompanying drawings, throughout which like reference
numerals may indicate corresponding or similar parts in the various figures. The drawings
are only for purposes of illustrating preferred embodiments and are not to be construed
as limiting the disclosure. Given the following enabling description of the drawings,
the novel aspects of the present disclosure should become evident to a person of ordinary
skill in the art.
[0015] The following detailed description is merely exemplary in nature and is not intended
to limit the applications and uses disclosed herein. Further, there is no intention
to be bound by any theory presented in the preceding background or summary or the
following detailed description. While embodiments of the present technology are described
herein primarily in connection with LED luminaires for use in recessed drop ceilings,
the concepts are also applicable to other types of LED luminaires and luminaires having
other light sources. In addition, while the invention is described herein as applicable
to LED luminaires it should be understood that it is applicable to other solid-state
lighting devices as well. For example light-emitting transistors or organic light-emitting
diodes/devices (OLEDs) are applicable alternative SSL devices.
[0016] In at least one aspect, the present disclosure provides an LED luminaire assembly.
As shown in Figure 3, the LED luminaire 50 includes a single piece housing 52 which
is extruded aluminum, another metal, or plastic. The PSU 54 is mounted to the inside
of the housing 52 such as with two rows of bolts 56, 58.
[0017] Diffuser 60 is held by inner pointing retaining lips 62, 64 that run the length of
the lower edge of the housing 52. Similar retaining lips 17, 18 are shown for the
prior art luminaire shown in Figure 1 running along length "1" of the lower edge of
the housing 14.
[0018] LED module 66 is mounted on the underside of heat sink 68 by screws, adhesives, or
other means (not shown). Heat sink 68 is held in place on one side by fixed attachment
to an inwardly directed lip 70 with screws or bolts 72 or temporary or quick release
mechanisms such as magnets, tethers, chains, levers, pins, or clevis fasteners. The
other edge of heat sink 68 is held in place by a pivoting or hinged attachment 74.
[0019] Heat sink 68 is typically aluminum but can be another thermally conductive metal,
thermally conductive plastic, or other plastic. Its thickness generally ranges between
about 0.5 to 20 mm.
[0020] To remove the PSU 54, the diffuser 60 and reflector 61 are removed from the luminaire
assembly and placed aside. The screws 72 or other fastening devices are removed, allowing
the heat sink 68 to hinge or pivot within the housing 52.
[0021] Figure 4 illustrates the luminaire assembly with the heat sink 68 pivoted to provide
access to the PSU 54. Screws 56, 58 can be removed, allowing removal of the PSU 54.
The LED module 66 is protected from damage because it is between the heat sink 68
and housing wall 52. Furthermore, heat sink 68 is prevented from pivoting all the
way against the housing wall 52 by the lip 62 which also provides protection to the
LED module 66.
[0022] Pivot attachment 74 is shown in more detail in Figure 5. In this embodiment, the
pivot attachment is a longitudinal extruded center of rotation. A retaining finger
80 is extruded as part of housing wall 52. Heat sink 68 includes a divot 82 in the
surface thereof which matches with retaining ball 84, also extruded as a segment of
housing wall 52. Heat sink 68 rotates around retaining ball 84 on the divot 82 as
indicated by the directional arrow and the end 86 of heat sink 68 is retained by retaining
finger 80. Pivot attachment 74 can be segmental along the inside of housing 52 (one
or more mechanisms 74) or can be a continuous element.
[0023] Pivoting attachments can be used other than the embodiment shown by Figures 3-5.
For example, other solutions can be a classic door hinge, or a hold open hinge.
[0024] Figure 6 illustrates another embodiment of a pivoting attachment that can be used
to provide a pivoting heat sink. The heat sink 90 is fastened on one side to the housing
wall inwardly directed lip 92 that is an integral part of the luminaire housing 94.
This fixed attachment can be the same as described for the above embodiment. The other
side of the heat sink 90 is fastened to the luminaire housing 97 via one or more hooks
96 extending through one or more holes of the heat sink 90. When the heat sink 90
is loosened from the one side it swings or pivots providing access to the PSU.
[0025] Figure 7 illustrates a pivot attachment similar to that shown in Figures 3-5 except
that the mechanism is not an integral part of the housing 98. Instead the retaining
finger 100 and retaining ball 102 are a pivot unit 104 attached to the housing 98
with screws or such 106, 108 or welded to the housing 98.
[0026] Heat sink 68 can be attached to housing 52 on its non-pivoting side in a number of
ways. One embodiment is shown in Figures 3-6. Figure 8 illustrates another embodiment
of a fixed attachment, wherein a snap-fit fastener 110 is used to fasten the heat
sink 112 to the housing retaining lip 114.
[0027] Figure 9 illustrates yet another embodiment of a fastening means 120 having a pin
122 that extends through the retaining lip 124 and the heat sink 126 and is kept in
position by a snap ring 128.
[0028] A number of other fastening devices can be used including screws, bolts, slide bolt
latches, magnets, rivets, cotter pins, leaf springs, or wedges.
[0029] A second embodiment of a field serviceable luminaire assembly 148 is illustrated
in Figure 10. This embodiment includes a heat sink 164 that folds crosswise to provide
access to the power supply unit 162, rather than pivoting lengthwise to provide access
as in the previously described embodiment.
[0030] As shown in Figure 10, this embodiment includes a housing 150 with a top panel 152,
first side panel 154, second side panel (not shown in this view), and end walls 158,
160. Power supply unit (PSU) 162 is mounted to the top panel 152. Heat sink 164 has
a plurality of LED modules 166 mounted thereto. Heat sink 164 has two connected, hinged
segments, a permanent segment 168 and a removable segment 170. Segments 168, 170 appear
to be shown as being of equal length but they can be of unequal length or the heat
sink 164 can be divided into more than two segments. Segment 170 is shown folded in
Figure 10, so that the power supply unit 162 is exposed.
[0031] It should also be noted that the luminaire 148 could have multiple power supplies
or there may be other components, such as controllers, sensors, terminal blocks, etc.
that the service-operator may need to access. Also, the pivoting segment need not
be attached at an end of the housing 150. There may be three (or more) segments with
the pivoting segment in the middle, for example.
[0032] Heat sink 164 is shown with segment 170 folded downwards. In use, heat sink 164 is
mounted within housing 150 generally from one end wall 158 to the other end wall 160
and from side wall 154 to the opposite side wall (not shown). The permanent segment
is mounted with screws, adhesive, or other attachment means to the housing. The removable
segment 170 is attached to the permanent segment 168 with a hinged connection 172
and is attached to the inside of the end wall 160 with a tab 174 which mates in a
slot (not shown) on the end wall 160. Other methods of removably attaching the removable
segment 170 can be employed.
[0033] It should be noted that the hinged connection 172 should accommodate any electrical
connections between segments 168 and 170. One embodiment of an appropriate hinged
connection 172 is shown in Figures 11 and 12. As shown in Figure 11, the permanent
segment 168 and removable segment 170 are connected with two slotted hinges 180, 182.
Electrical connection between permanent segment 168 and removable segment 170 is made
with a connector 184. To disconnect and fold the removable segment 170 it is first
pulled to disengage the connector 184 (this step is shown in Figure 12) and the slotted
hinges allow movement of the removable segment 170 away from the permanent segment
168. The removable segment 170 can then be folded as shown in Figure 10.
[0034] The electrical connection between heat sink sections could be a pin connector, ribbon
cable, flexible wire, or flexible printed-circuit board. Alternatively, the entire
heat sink could be a flexible circuit board that has enough slack at the hinged joint
that it can pivot without damaging the board. In that embodiment, a slotted hinge
would not be necessary and a standard hinge or other pivoting mechanism would suffice.
[0035] This embodiment will desirably include reflectors and these must be removed to access
the removable segment 170 of the heat sink 164. The removable segment 170 is then
folded down and the power supply unit 162 can be serviced or removed.
[0036] Alternative embodiments, examples, and modifications which would still be encompassed
by the disclosure may be made by those skilled in the art, particularly in light of
the foregoing teachings. Further, it should be understood that the terminology used
to describe the disclosure is intended to be in the nature of words of description
rather than of limitation.
[0037] Those skilled in the art will also appreciate that various adaptations and modifications
of the preferred and alternative embodiments described above can be configured without
departing from the scope and spirit of the disclosure. Therefore, it is to be understood
that, within the scope of the appended claims, the disclosure may be practiced other
than as specifically described herein.
[0038] Various aspects and embodiments of the present invention are defined by the following
numbered clauses:
- 1. A solid state lighting device luminaire assembly comprising:
a housing comprising a first side wall, a second side wall, a first end wall, and
a second end wall;
a power supply unit located within the housing;
a solid state lighting device module connected to a heat sink;
wherein the heat sink blocks access to the power supply unit when in use; and
wherein the heat sink folds or pivots to allow access to the power supply unit.
- 2. The luminaire assembly of clause 1, wherein the heat sink extends across the housing
and is attached to the first side wall of the housing with a fixed attachment and
to the second side wall of the housing with a pivot attachment so that when the fixed
attachment is disconnected the heat sink stays attached to the housing at the pivot
attachment and pivots towards the second side wall.
- 3. The luminaire assembly of any preceding clause, wherein the power supply unit is
inaccessible when the heat sink is attached with the fixed attachment and accessible
when the heat sink pivots towards the second wall.
- 4. The luminaire assembly of any preceding clause, wherein the power supply unit can
be removed from the luminaire when the heat sink is pivoted towards the second side
wall.
- 5. The luminaire assembly of any preceding clause, wherein the pivot attachment comprises
a retaining finger extending from the second housing wall, a retaining ball extending
from the second housing wall, and a divot on the heat sink, wherein the divot mates
with the retaining ball and the retaining finger connects with the end of the heat
sink.
- 6. The luminaire assembly of any preceding clause, wherein the solid state lighting
device module is between the second side wall and the heat sink when the heat sink
is pivoted towards the second side wall.
- 7. The luminaire assembly of any preceding clause, wherein the second housing side
wall comprises a lip that prevents the heat sink from pivoting all the way against
the second side wall and prevents the solid state lighting device module from contacting
the second side wall.
- 8. The luminaire assembly of any preceding clause, wherein there are multiple pivot
attachments along the second housing side wall.
- 9. The luminaire assembly of any preceding clause, wherein the pivot attachment comprises
one or more hooks attached to the second housing side wall that engage one or more
holes in the heat sink.
- 10. The luminaire assembly of any preceding clause, wherein the heat sink extends
across the housing and is attached at the first end wall with a permanent attachment
and at the second end wall with a removable attachment;
wherein the heat sink comprises at least two segments connected by a hinged connection
and wherein the heat sink can be unattached from the second end wall and can be folded
at the hinged connection.
- 11. The luminaire assembly of any preceding clause, wherein the heat sink comprises
a first segment permanently attached to the first end wall and a second segment removably
attached to the second end wall, and wherein the first and second segments are connected
by the hinged connector.
- 12. The luminaire assembly of any preceding clause, wherein the hinged connector is
one or more slotted hinges that allow movement of the segments longitudinally away
from each other before the removable segment is folded.
- 13. The luminaire assembly of any preceding clause, wherein the heat sink comprises
a first segment permanently attached to the first end wall and a second segment removably
attached to the second end wall, and a third segment that is connected to at least
one of the first segment or second segment with a hinged connector.
- 14. A solid state lighting device luminaire assembly comprising:
a housing comprising a first side wall, a second side wall, a first end wall, and
a second end wall;
a power supply unit located within the housing;
a heat sink extending across the housing and attached to the first side wall and the
second side wall and blocking access to the power supply unit; and
a solid state lighting device module connected to the heat sink;
wherein the heat sink is attached to the first side wall with a fixed attachment and
to the second side wall with a pivot attachment so that when the fixed attachment
is disconnected the heat sink stays attached to the housing at the pivot attachment
and pivots towards the second side wall.
- 15. The luminaire assembly of any preceding clause, wherein the power supply unit
is inaccessible when the heat sink is attached with the fixed attachment and accessible
when the fixed attachment is disconnected and the heat sink pivots towards the second
wall.
- 16. The luminaire assembly of any preceding clause, wherein the power supply unit
can be removed from the luminaire when the heat sink is pivoted towards the second
side wall.
- 17. The luminaire assembly of any preceding clause, wherein the pivot attachment comprises
a retaining finger extending from the second housing wall, a retaining ball extending
from the second housing wall, and a divot on the heat sink, wherein the divot mates
with the retaining ball and the retaining finger connects with the end of the heat
sink.
- 18. The luminaire assembly of any preceding clause, wherein the solid state lighting
device module is between the second side wall and the heat sink when the heat sink
is pivoted towards the second side wall.
- 19. A solid state lighting device luminaire assembly comprising:
a housing comprising a first side wall, a second side wall, a first end wall, and
a second end wall;
a power supply unit located within the housing;
a heat sink extending across the housing and attached to the first end wall and the
second end wall and blocking access to the power supply unit; and
a solid state lighting device module connected to the heat sink;
wherein the heat sink is attached to the first end wall with a fixed attachment and
to the second end wall with a removable attachment and wherein the heat sink comprises
at least two segments connected by a hinged connection; and
wherein the heat sink can be unattached from the second end wall and can be folded
at the hinged connection.
- 20. The luminaire assembly of any preceding clause, wherein the power supply unit
is exposed when the heat sink is unattached from the second end and folded at the
hinged connection.
1. A solid state lighting device luminaire assembly (50) comprising:
a housing (52) comprising a first side wall, a second side wall, a first end wall,
and a second end wall;
a power supply unit (54) located within the housing (52);
a solid state lighting device module (66) connected to a heat sink (68);
wherein the heat sink (68) blocks access to the power supply unit (54) when in use;
and
wherein the heat sink (68) folds or pivots to allow access within the housing (52).
2. The luminaire assembly of claim 1, wherein the heat sink (68) extends across the housing
(52) and is attached to the first side wall of the housing with a fixed attachment
(72) and to the second side wall of the housing with a pivot attachment (74) so that
when the fixed attachment is disconnected the heat sink (68) stays attached to the
housing at the pivot attachment and pivots towards the second side wall.
3. The luminaire assembly of claim 2, wherein the power supply unit (54) is inaccessible
when the heat sink (68) is attached with the fixed attachment and accessible when
the heat sink pivots towards the second wall.
4. The luminaire assembly of claim 2 or claim 3, wherein the power supply unit (54) can
be removed from the luminaire when the heat sink (68) is pivoted towards the second
side wall.
5. The luminaire assembly of claim 2, 3 or 4, wherein the pivot attachment comprises
a retaining finger (80) extending from the second housing wall, a retaining ball (84)
extending from the second housing wall, and a divot (82) on the heat sink (68), wherein
the divot (82) mates with the retaining ball (84) and the retaining finger (80) connects
with the end of the heat sink (68).
6. The luminaire assembly of any one of claims 2 to 5, wherein the solid state lighting
device module (66) is between the second side wall and the heat sink (68) when the
heat sink is pivoted towards the second side wall, wherein, preferably, the second
housing side wall comprises a lip that prevents the heat sink (68) from pivoting all
the way against the second side wall and prevents the solid state lighting device
module (66) from contacting the second side wall.
7. The luminaire assembly of any one of claims 2 to 6, wherein:
there are multiple pivot attachments along the second housing side wall, and/or
the pivot attachment comprises one or more hooks attached to the second housing side
wall that engage one or more holes in the heat sink (68).
8. The luminaire assembly of any preceding claim, wherein the heat sink (164) extends
across the housing (150) and is attached at the first end wall (158) with a permanent
attachment and at the second end wall (160) with a removable attachment;
wherein the heat sink (164) comprises at least two segments (168, 170) connected by
a hinged connection and wherein the heat sink (164) can be unattached from the second
end wall and can be folded at the hinged connection.
9. The luminaire assembly of claim 8, wherein the heat sink (154) comprises a first segment
(168) permanently attached to the first end wall and a second segment (170) removably
attached to the second end wall, and wherein the first and second segments (168, 170)
are connected by the hinged connector.
10. The luminaire assembly of claim 8 or claim 9, wherein the hinged connector is one
or more slotted hinges (180, 182) that allow movement of the segments longitudinally
away from each other before the removable segment is folded.
11. The luminaire assembly of claim 8, 9 or 10, wherein the heat sink (154) comprises
a first segment (168) permanently attached to the first end wall and a second segment
(170) removably attached to the second end wall, and a third segment that is connected
to at least one of the first segment or second segment with a hinged connector.
12. The luminaire assembly of any preceding claim, wherein:
the heat sink (68) extends across the housing (52) and is attached to the first side
wall and the second side wall and blocks access to the power supply unit (54); and
the heat sink (68) is attached to the first side wall with a fixed attachment and
to the second side wall with a pivot attachment so that when the fixed attachment
is disconnected the heat sink (68) stays attached to the housing at the pivot attachment
and pivots towards the second side wall.
13. The luminaire assembly of claim 12, wherein the power supply unit (54) is inaccessible
when the heat sink (68) is attached with the fixed attachment and accessible when
the fixed attachment is disconnected and the heat sink (68) pivots towards the second
wall.
14. The luminaire assembly of claim 1, wherein:
the heat sink (68) extending across the housing (52) and attached to the first end
wall and the second end wall and blocking access to the power supply unit (54); and
the heat sink (68) is attached to the first end wall with a fixed attachment and to
the second end wall with a removable attachment and wherein the heat sink comprises
at least two segments connected by a hinged connection; and
heat sink (68) can be unattached from the second end wall and can be folded at the
hinged connection.
15. The luminaire assembly of claim 14, wherein the power supply unit (54) is exposed
when the heat sink (68) is unattached from the second end and folded at the hinged
connection.