MODULE HIGH-BAY LIGHTING SYSTEMS AND METHODS OF PROVIDING LIGHTING

[0001] This application claims priority pursuant to 35 U.S.C. 119(e) to co-pending U.S. Provisional Patent Application Ser. Nos. 62/063,563, filed Oct. 14, 2014, and 62/067,175, filed Oct. 22, 2014, the entire disclosures of which are incorporated herein by reference.

[0002] The present invention relates generally to high-bay lighting systems. More specifically, the present invention is concerned with unique high-bay light fixtures that are capable of being joined together to provide evenly dispersed lighting over a large area.

[0003] Existing high-bay lighting systems employ a plurality of large light fixtures spaced across a large area. Each light fixture includes a large light source that draws a significant amount of power and generates a significant amount of heat. Because the light source draws so much power, the light fixture must go through a rigorous certification process. In addition, because the light source generates so much heat, most light fixtures include a cumbersome heat sink. Both of these requirements increase the cost of a high-bay lighting system. Moreover, high-bay light fixtures of the prior art generally are constructed to output a predetermined amount of power. If a higher or lower power output is desired, a new design is required. Consequently, it would be beneficial to decrease the cost of high-bay lighting systems by utilizing smaller light sources so that a less rigorous certification process is required and so that a less cumbersome heat sink can be used. In addition, it would be beneficial to provide a high-bay lighting system that is capable of utilizing multiple power output amounts without requiring a newly designed fixture.

[0004] Furthermore, to maximize light being received at a target area from prior art high-bay lighting systems, each light fixture typically includes a reflector surrounding the light source and directing light downwards and outwards such that light from adjacent light fixtures mixes together as it travels away from the light sources. In this way, lighting systems of the prior art attempt to minimize bright spots and dark spots at the target area. Unfortunately, this process provides mixed results at best. For instance, decreasing dark spots in one area may increase bright spots in another area. Alternatively, or additionally, decreasing dark spots in one area using high-bay lighting systems of the prior art may require adding a light fixture to an area where much of the light being emitted from the light source shines on an area that is not required or desired to be lighted. Such situations are not only an annoyance, they also waste energy. Consequently, it would be beneficial to have a high-bay lighting system that is capable of quickly and easily being used to provide relatively even lighting to a target area without wasting energy by providing excess lighting to other areas.

[0005] The present invention comprises a system and method for lighting a target area using one or more unique, modular, high-bay light fixtures. An embodiment of the modular lighting system of the present invention includes a plurality of modular light fixtures. An embodiment of the method of lighting a target area using the system of the present invention includes coupling a plurality of modular light fixtures together, until the desired power, size and/or shape is achieved, and positioning the lighting system such that light emitting from the modular lighting system is directed towards the target area. In many cases, this involves positioning the lighting system above the target area.

[0006] The foregoing and other objects are intended to be illustrative of the invention and are not meant in a limiting sense. Many possible embodiments of the invention may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of invention may be employed without reference to other features and subcombinations. Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention and various features thereof.

[0021] As required, a detailed embodiment of the present invention is disclosed herein; however, it is to be understood that the disclosed embodiment is merely exemplary of the principles of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

[0022] Referring to FIG. 1, some embodiments of each light fixture 10 includes opposed first 12 and second 14 ends and opposed third 16 and fourth 18 ends extending between opposed first 12 and second 14 ends. The first end 12 of each modular light fixture 10 is configured to selectively couple to the second end 14 of every other modular light fixture 10. Similarly, in some embodiments, the third 16 end of each modular light fixture 10 is configured to selectively couple to the fourth end 18 of every other modular light fixture 10. In some embodiments, a separate connecting member (not shown) is attached between the third end 16 of one fixture and the fourth end 18 of the other fixture to enable coupling. In other embodiments, the third end 16 of one fixture is positioned adjacent to the fourth end 18 of another fixture without being coupled. In some such embodiments, the adjacent fixtures are held in position adjacent to one another by an external framework (not shown) in which the modules are positioned.

[0023] Referring to FIGS. 1B-1E, coupling a plurality of modular light fixtures together enables a user to create a variety of lighting systems to meet a variety of lighting needs. For instance, referring to FIG. 1B, coupling a second end of a first light fixture 110 to a first end of a second light fixture 120 enables a user to quickly and easily create a first run 100 of light fixtures having a first edge 102, a second edge 104, a third edge 106, and a fourth edge 108. The first 102 and second 104 edges of the first run 100, being the first end of the first light fixture 110 and the second end of the second light fixture 120, respectively. Referring to FIG. 1C, coupling another light fixture 130 to either the first 102 or second 104 edge of the first run 100, increases the length and power output of the first run. Referring to FIG. 1D, coupling yet another light fixture 140 to the first run 100 further increases the length and power output of the first run 100. In this way, a user can create an ideal high-bay lighting system over a long distance, such as over an aisle, or of a desired power value, by coupling a plurality of light fixtures together to increase the length and power output of the first run 100 of light fixtures to a desired length or power output.

[0024] In some embodiments, the third 106 and fourth 108 edges of the first run 100 of light fixtures are defined by the third and fourth ends, respectively, of each light fixture 110, 120 in the first run 100 of light fixtures. Consequently, in some such embodiments, and as shown in FIG. 1E, the third edge 106 of the first run 100 of light fixtures is configured to couple to a fourth edge 208 of a second run 200 of light fixtures. In this way, a user can couple the first 100 and second 200 runs of light fixtures together so as to create an ideal high-bay lighting system over a large area, such as over a work area. In other embodiments, a separate connecting member (not shown) is attached between the third end of one fixture and the fourth end of the other fixture to enable coupling. In other embodiments, the third end of one fixture is positioned adjacent to the fourth end of another fixture without being coupled. In some such embodiments, the adjacent fixtures are held in position adjacent to one another by an external framework (not shown) in which the modules are positioned. In some embodiments, instead of adjoining first 100 and second 200 runs of light fixtures together, a first run of fixtures is designed to be the same size as the combined first and second runs.

[0025] In some embodiments, the first 102 and second 104 edges of the first run 100 of light fixtures are even with respective first 202 and second 204 edges of the second run 200 of light fixtures such that the entire system defines a quadrilateral shape so as to accommodate providing relatively even lighting throughout a standard room. In other embodiments, the first 102 and/or second 104 edge of the first run 100 of light fixtures is offset from its respective first 202 or second 204 edge of the second run 200 of light fixtures so as to accommodate additional and/or different lighting requirements. In still other embodiments, one or more lighting fixture and/or one or more run of lighting fixtures is coupled to the fourth edge 108 of the first run 100 of light fixtures and/or to a third edge 206 of the second run 200 of lighting fixtures so as to further accommodate additional and/or different lighting requirements.

[0026] It will be appreciated that the lighting fixtures in some embodiments are capable of being combined in a variety of other configurations beyond those described herein or shown in the drawings. Consequently, the versatility of the modular light fixtures of the present invention allows a user to quickly and easily provide relatively even lighting to a target area without wasting energy by providing excess lighting to other areas.

[0027] Some embodiments of the module lighting system of the present invention include end caps 50 coupled to one or more ends of each lighting fixture. For instance, in a single-run lighting system, an end cap 50 is coupled to a third and fourth end of each light fixture in the lighting system. As another example, in a double-run lighting system, an end cap 50 is coupled to a fourth end of each light fixture in a first run 100 and to a third end of each light fixture in a second run 200. In some such embodiments, the end caps 50 prevent additional light fixtures from being coupled to the third edge 206 of the second run 200 and/or the fourth edge 108 of the first run 100 of the lighting system.

[0028] In some embodiments, each end cap 50 defines an interior area 56. In some such embodiments each end cap 50 also defines a front aperture 52 and a rear aperture 54 such that when two or more end caps are positioned in line with each other, the plurality of end cap interior areas 56 define a raceway that is configured to receive electrical wires. In this way, power can be supplied from a central power source directly to each individual lighting fixture. In some such embodiments, an end cap cover 60 is coupled to each end cap 50 so as to cover the individual interior areas 56 of each end cap 50, thereby concealing the raceway from view.

[0029] In some embodiments, power from a central power source (not shown) is received by a power converter 70 coupled to each light fixture 10. The power converter converts the central power supply into a power supply that is appropriate for the individual light fixture. In some embodiments, the power converter 70 is positioned within an interior area 56 of an end cap 50. In some such embodiments, an end cap cover 60 is coupled to each end cap 50 so as to cover the interior area 56 of the end cap 50, thereby concealing the power converter 70 from view.

[0030] In some embodiments, each high-bay light fixture 10 includes a plurality of light sources 22. As shown in FIGS. 3A and 3B, some embodiments of a light fixture include a reflector panel 30 that includes thirty-six (36) discrete reflectors 32 positioned in a six by six pattern. In other embodiments, the reflector panel 30 includes forty-nine (49) discrete reflectors 32 positioned in a seven by seven pattern. It will be appreciated that in still other embodiments, the reflector panel 30 includes still other quantities and/or configurations of discrete reflectors 32.

[0031] Each discrete reflector 32 defines a top aperture 34 and a bottom aperture 36 and includes a reflective surface 38 extending between the top 34 and bottom 36 apertures. The top aperture 34 is configured to receive a discrete light source 22, such as a light emitting diode, while the bottom aperture 36 is configured to allow light from the light source 22 to travel away from the light source 22. In some embodiments, the reflective surface 38 defines a frustoconical shape extending from the bottom aperture 36 towards the light source 22. In some such embodiments, the frustoconical shape defines a 130 degree vertex angle. It will be appreciated that in other embodiments, the reflective surface 38 defines other shapes and/or defines different vertex angles.

[0032] In some embodiments, each light source 22 is coupled to a light panel 20 and the light panel 20 is coupled to the reflective panel 30. In this way, each light source 22 is capable of being positioned relative to a respective reflector 32 without requiring each light source 22 to be coupled directly to its respective reflector 32. In some such embodiments, the light panel 20 is a circuit board connecting each light source to a power source. In other such embodiments, the light fixture 10 includes wiring electrically connecting each light source 22 to a power source, such as a power converter 70.

[0033] A heat sink 40 is coupled to a back side of each light fixture 10. In some embodiments, the heat sink 40 includes a first piece 42 and a second piece 44. The first piece 42 includes a tongue on a second edge while the second piece 44 includes a groove on a first edge. The tongue of the first piece 42 is configured to slide into the groove of the second piece 44 so as to secure the first 42 and second 44 pieces together. In this way, each piece has a lower profile than would a one-piece heat sink, thereby saving tooling costs so as to reduce the overall cost of the light fixture.

[0034] In some embodiments of a heat sink 40, the first piece 42 also includes a groove on a first edge and the second piece 44 also includes a tongue on the second edge. In this way, a heat sink from a first light fixture can be coupled to a heat sink from a second light fixture in much the same way as the first piece of the heat sink is coupled to the second piece of the heat sink.

[0035] In some embodiments, a lens 28 is coupled to a front side of each light fixture. The lens is at least partially translucent and/or transparent such that at least some of the light emitted from the light sources 22 is visible through the lens 28.

[0036] In some embodiments, each light fixture provides 6,000 lumen of light while requiring less than ninety (90) watts of electricity. By coupling two light fixtures together, the module lighting system provides 12,000 lumen of light. Similarly, by coupling six light fixtures together, the module lighting system provides 36,000 lumen of light. As will be appreciated, virtually any number of light fixtures are capable of being coupled together to provide an ever-increasing amount of light. In some such embodiments, each light fixture includes its own independent power source, such as a power converter. Consequently, no matter how many light fixtures are coupled together, none of the light fixtures require the more rigorous certification process required of other high-bay lighting fixtures of the prior art because each of the light fixtures of the present invention require less than ninety (90) watts of electricity.

[0037] In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the inventions is by way of example, and the scope of the inventions is not limited to the exact details shown or described.

[0038] Although the foregoing detailed description of the present invention has been described by reference to an exemplary embodiment, and the best mode contemplated for carrying out the present invention has been shown and described, it will be understood that certain changes, modification or variations may be made in embodying the above invention, and in the construction thereof, other than those specifically set forth herein, may be achieved by those skilled in the art without departing from the spirit and scope of the invention, and that such changes, modification or variations are to be considered as being within the overall scope of the present invention. Therefore, it is contemplated to cover the present invention and any and all changes, modifications, variations, or equivalents that fall within the true spirit and scope of the underlying principles disclosed and claimed herein. Consequently, the scope of the present invention is intended to be limited only by the attached claims, all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

[0039] Having now described the features, discoveries and principles of the invention, the manner in which the invention is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.

[0040] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.