Flattenable luminaire

[0002] This patent is a continuation-in-part of my co-pending application Ser. No. 09/444,182, filed Nov. 19, 1999, which is a continuation-in-part of my application Ser. No. 09/410,805, filed Oct. 1, 1999.

[0003] This invention relates to luminaires in general, and to lightweight, field-assembled luminaires for suspended ceilings in particular.

[0004] Current fluorescent luminaires are connected to the utility power line via conduit, BX, or Romex type cable. Since the fluorescent luminaire is connected directly to the utility power line via a 15 or 20-amp branch circuit, the luminaire must be designed to enclose and protect the input leads to the fluorescent lamp ballast, the lamp sockets, and the interconnecting leads between the ballast and the lamp sockets. In order to provide the necessary protection, fluorescent luminaires are made out of relatively heavy gauge steel to meet specific standards set by Underwriters+ Laboratories (UL), such as, UL1570. UL requires that heavy gauge metal be used to insure that the luminaire can withstand a certain degree of abuse without exposing leads, electrical components, the ballast, current carrying parts or devices with exposed metal which could constitute a shock or fire hazard.

[0005] Due to the structural requirement set out in the UL standard a typical 2×4 foot luminaire can weigh over 30 pounds and a 2×2 foot fixture can weigh over 15 pounds. Since current luminaires act as electrical enclosures for the fluorescent ballast and the interconnecting leads, raceway covers (also made out of heavy gauge steel) are provided to contain the potentially hazardous wiring. Luminaires, currently on the market, often contain 25 to 30 stamped metal parts plus the fasteners to hold them all together.

[0006] Because these luminaires contain such a large number of parts, they are assembled in factories, where they are packaged in individual boxes. Then they are loaded onto trucks, shipped to and stored in warehouses. They are then loaded onto different trucks and delivered to lighting wholesalers and retailers or job sites where they are stored until they are installed. In each case, the luminaires occupy a significant amount of floor space and volume.

[0007] Once at the job site the luminaires are lifted overhead into position within the ceiling grid. This is no easy task since each 2×4 luminaire can weigh 30 pounds or more. The grid system and the supporting wires are required to be sufficiently strong to accommodate this extra weight.

[0008] Fluorescent lamp ballasts currently in production are designed to operate from 15 or 20 amp branch circuits, which are typically 120, 240, or 277 volts; 60 Hertz. Due to the high energy levels available from these branch circuits, the lines connecting the input to the ballast to the branch circuit is required by the local electrical code to be run in conduit, BX, or Romex. The output leads connect the ballast to the lamp sockets and supply voltages and currents, which do not meet the limits of the National Electrical Code requirements for either Class II or Class III wiring. Therefore, this wiring too must be provided with special protective encasement by the luminaire. This is generally accomplished by designing wire raceways in the luminaire to meet special requirements established by Underwriters Laboratories.

[0009] The ballasts currently in production are either magnetic ballasts or electronic ballasts. The input power is provided from 50 or 60 Hertz line voltage and the output of the ballast is connected to a lamp socket or sockets via interconnect wiring. The magnetic ballast generally consists of a transformer with a current limited output and a power-factor correction capacitor connected across the input. Since the magnetic ballast is operating at 60 Hertz, the size of the metal can of a ballast capable of handling 60 watts of output power is 2.25″ wide by 1.5″ high by 8″ long and weighs about 3 pounds. Electronic ballasts are generally manufactured in the same size package but weigh 1.25 to 2.5 pounds.

[0010] Accordingly, several objects and advantages of my invention are a lighter weight, lower cost luminaire with fewer parts, requiring significantly reduced storage and shipping volume, while still maintaining an attractive appearance and providing easy assembly. This is achieved by incorporating the lamp socket into the insulated enclosure of the ballast, thus enclosing any leads or terminals that exceed class II or class III limits within the insulated ballast enclosure. This allows the luminaire to be manufactured out of lighter weight less costly material and in most cases made as a single piece with no factory assembly of the luminaire. Due to the field assembly and the unique design of the reflector portion of the luminaire, the luminaires can be nested one within another or, in another embodiment, shipped in a flattened condition. This greatly reduces the shipping and storage volume. In certain embodiments, the luminaire is capable of being assembled and installed by someone requiring no training as an electrician.

[0011] Still further objects and advantages will become apparent from a consideration of the ensuing description and accompanying drawings.

[0012] FIG. 1 shows a ballasted-socket assembly;

[0013] FIG. 2 shows schematically a typical ballasted-socket circuit;

[0014] FIG. 3 is an exploded view of one embodiment of the Nestable Luminaire for single-ended lamps;

[0015] FIG. 4 shows how an overall system is installed in a suspended ceiling;

[0016] FIG. 5 shows how multiple luminaires can be nested together for shipping and storage;

[0017] FIG. 6 shows how the same invention can be applied to 2′ by 4′ luminaires;

[0018] FIG. 7 shows a variation of the ballasted-socket, which allows lamps to be replaced from the rear of the luminaire;

[0019] FIG. 8 shows how the invention can be applied to luminaires using one or more compact fluorescent lamps;

[0020] FIG. 9 shows how a circular lamp can be used with a ballasted-socket in a nestable luminaire;

[0021] FIG. 10 shows how linear lamps can be used with a ballasted-socket in a nestable luminaire;

[0022] FIG. 11 shows how U-lamps can be used with a ballasted-socket in a nestable luminaire;

[0023] FIG. 12 shows how long-twin-tube lamps can be used with a ballasted-socket in a nestable luminaire;

[0024] FIG. 13 shows how long-twin-tube lamps can be used with a ballasted-socket in a sealable-nestable luminaire;

[0025] FIG. 14 shows a top view of the reflector of a flattenable luminaire in its flattened condition.

[0026] 10 2′ by 2′ luminaire reflector

[0027] 12 edge A

[0028] 14 edge B

[0029] 16 edge C

[0030] 18 edge D

[0031] 20 ceiling grid opening

[0032] 22 lip

[0033] 24 top plane

[0034] 26 2D lamp

[0035] 28 aperture

[0036] 30 ballasted-socket assembly

[0037] 32 notches

[0038] 34 clip

[0039] 36 fluorescent tube

[0040] 38 plastic support structure

[0041] 40 lamp support clips

[0042] 42 2′ by 2′ lens

[0043] 44 enclosure

[0044] 46 grid system

[0045] 48 T-bars

[0046] 50 permanent ceiling

[0047] 52 support wires

[0048] 54 ceiling panels

[0049] 56 four-port energy-limited power source

[0050] 58 luminaire assemblies

[0051] 60 conduit, BX, or Romex

[0052] 62 cable assembly

[0053] 66 output terminals

[0054] 68 four-pin lamp socket

[0055] 70 transformer

[0056] 72 filament windings

[0057] 74 ballasting capacitor

[0058] 76 tank capacitor

[0059] 78 tank inductor

[0060] 80 four-pin recessed plug

[0061] 82 depressions

[0062] 84 power receptacle

[0063] 86 power plug

[0064] 88 2′ by 4′ reflector

[0065] 90 2′ by 4′ lens

[0066] 92 2′ by 4′ ceiling grid opening

[0067] 94 compact fluorescent lamp socket

[0068] 96 cover plate

[0069] 98 mounting tab

[0070] 100 shaft

[0071] 102 ballast circuit housing

[0072] 104 ballasted-cover-plate

[0073] 106 compact fluorescent lamp

[0074] 108 power cable

[0075] 110 keyhole slots

[0076] 112 circular aperture

[0077] 114 sealable reflector

[0078] 116 double-sided tape

[0079] 118 adjacent grid opening

[0080] 120 ballasted-socket for circular lamps

[0081] 122 circular lamp socket

[0082] 124 steep-sided reflector

[0083] 126 oval aperture

[0084] 128 lamp retaining clip

[0085] 130 lamp retaining clip slot

[0086] 132 circular lamp

[0087] 134 circular lamp plug

[0088] 136 ballast clip slots

[0089] 138 ballasted-socket for linear lamps

[0090] 140 reflector for linear lamps

[0091] 142 remote bi-pin lamp holder

[0092] 144 remote bi-pin lamp holder cable

[0093] 146 lamp support mounting holes

[0094] 148 linear lamp

[0095] 150 ramp

[0096] 152 recess

[0097] 154 relief slot

[0098] 156 reflector for U-lamps

[0099] 158 ballasted-socket for U-lamps

[0100] 160 U-lamp

[0101] 162 ballasted-socket for twin tube lamps

[0102] 164 reflector for twin tube lamps

[0103] 166 lamp support

[0104] 168 twin tube lamp

[0105] 170 aperture A

[0106] 172 aperture pair B

[0107] 174 aperture C

[0108] 176 aperture D

[0109] 178 side mounted ballasted-socket for twin tube lamps

[0110] 180 sealable reflector for twin tube lamps

[0111] 182 lamp cradle

[0112] 184 retaining tab

[0113] 186 retaining slot

[0114] 188 lamp cradle mounting holes

[0115] 190 twin tube lamp socket

[0116] 192 straight-in bi-pin lampholder

[0117] 194 bi-pin lampholder

[0118] 196 tab

[0119] 198 side panel

[0120] 200 continuous hinge

[0121] 202 interlocking tab

[0122] 204 interlocking notch

[0123] 206 outside edge

[0124] 208 adjoining edges

[0125] 210 flattenable reflector

[0126] This invention is directed to a design of field assembled luminaires, primarily for suspended ceilings, which permits one luminaire reflector to be nested within one or more identical luminaire reflectors to minimize shipping and warehouse space. The lamp socket is manufactured as an integral part of the ballast, and clips into and is supported by the reflector. If a lens is desired to block direct view of the lamp, it is not necessary to provide the lens as part of a hinged door. The fact that the reflector can be made from much lighter material (plastic, metal, etc.) permits the lamps to be replaced by removing an adjacent ceiling tile and sliding the reflector over the open space in the grid to access the lamp or, in the case of compact fluorescent lamps, to replace the lamp from the rear.

[0127] FIG. 1 shows a pictorial drawing of a ballasted-socket assembly 30. The enclosure 44 of the ballasted-socket assembly 30 is made of electrically insulating material and encases the electronic circuitry used to provide the necessary interface between a power source and a gas discharge lamp. The back of four-pin lamp socket 68 is encased by the enclosure 44. The four-pin lamp socket 68 is provided with four output terminals 66 and with lamp support clips 40 to support the weight of a lamp when it is mounted in the four-pin lamp socket 68. Clips 34 are provided on alternate sides of the enclosure 44 to hold the ballasted-socket assembly 30 in position when mounted on a luminaire reflector. The cable assembly 62 is used to connect the ballasted-socket assembly 30 to a power source via the power plug 86. An optional power receptacle 84 can be provided as part of the ballasted-socket assembly 30. This permits another ballasted-socket to be plugged into it.

[0128] FIG. 2 is a schematic of a typical ballasted-socket circuit. The power plug 86 is provided for connection to a power source. The output terminals 66 are part of the four-pin lamp socket 68 and provide voltage to heat lamp filaments and current-limited voltage to provide lamp current. Transformer 70 is used to step-up or step-down the lamp starting voltage as required by the particular lamp to be used and to supply filament voltage from the filament windings 72. Ballasting capacitor 74 limits the current supplied to the lamp after lamp ignition. Tank capacitor 76 and tank inductor 78, in concert with the reflected load and ballasting capacitor 74, form a parallel resonant tuned circuit. The optional power receptacle 84 is connected in parallel with the leads to power plug 86.

[0129] FIG. 3 is an exploded view of the instant invention showing the major components. The 2′ by 2′ luminaire reflector 10 in this embodiment is shown as a truncated pyramid. Edge A 12, edge B 14, edge C 16, and edge D 18 are each slightly less than two feet in length to permit the 2′ by 2′ luminaire reflector 10 to be placed into a 2 foot by 2 foot ceiling grid opening 20. A one-half inch lip 22 is provided around the circumference of the lower portion of the 2′ by 2′ luminaire reflector 10 to added rigidity to the reflector and to center the reflector within the 2 foot by 2 foot ceiling grid opening 20. The material used, in this embodiment for the 2′ by 2′ luminaire reflector 10, is a 0.060 inch thick, UV stabilized, white plastic with a HB flame rating. It should be noted that if the luminaire is intended to be used in a ceiling requiring a fire rating, it may be necessary to use metal in place of plastic to achieve the desired fire rating. Using plastic permits a wide variety of shapes to easily be manufactured by vacuum forming or injection molding. The top plane 24 measures approximately 12 inches by 12 inches. A typical height for the luminaire is 3 and ¾ inches. The angle of inclination of each of the sides is slightly greater than 30 degrees. The 12-inch by 12-inch dimension of the top plane 24 is determined by the lamp chosen for the luminaire. For this embodiment a General Electric F55 2D lamp 26, which is approximately 8 inches by 8 inches, is used. An aperture 28 is provided centered in the top plane of the 2′ by 2′ luminaire reflector 10 to receive ballasted-socket assembly 30. The aperture 28 has notches 32 on alternate sides to receive mating clips 34 located on the ballasted-socket assembly 30 to insure that the ballasted-socket assembly 30 is rigidly held in place once installed.

[0130] FIG. 3 also shows how the ballasted-socket assembly 30 is positioned relative to the 2′ by 2′ luminaire reflector 10. The clips 34 are to insure adequate lateral force is available to maintain the ballasted-socket assembly 30 in position when the clips 34 are inserted into the notches 32 of aperture 28.

[0131] The 2D lamp 26 shown in FIG. 3 is a General Electric 2D lamp or similar type. The 2D lamp 26 consists of a single fluorescent tube 36 that is bent to resemble two capital “Ds” back to back. The two ends of the fluorescent tube 36 each terminating at a plastic support structure 38. A four-pin recessed plug 80 is provided in the approximate center of the plastic support structure 38. The lamp also being provided with depressions 82 on alternate sides of the recessed plug 80 to receive the lamp support clips 40 shown in FIG. 1.

[0132] The optional 2′ by 2′ lens 42 can be a simple plastic diffuser, parabolic louver, baffle or any of the standard lens materials used with conventional luminaires. The dimension of each edge of the optional 2′ by 2′ lens 42 is slightly less than two feet in length to permit the optional 2′ by 2′ lens 42 to be placed into the 2 foot by 2 foot ceiling grid opening 20. Adjacent grid opening 118 is one of the four possible grid openings that share a common side with the grid opening containing the luminaire.

[0133] FIG. 4 shows how the overall system is installed in a suspended ceiling. A grid system 46 made up of T-bars 48 is suspended from a permanent ceiling 50 using support wires 52. The T-bars 48 are installed to provide either a 2′ by 2′ or a 2′ by 4′ grid. Luminaire assemblies 58 are placed into the grid as required to provide the desired level of lighting. In FIG. 4, the luminaire assemblies 58 are shown in every other opening of every other row. The remaining openings are filled with ceiling panels 54. Mounted onto the permanent ceiling 50 are a series of four-port energy-limited power sources 56, one four-port energy-limited power sources 56 for every four luminaires assemblies 58. The four-port energy-limited power sources 56 are connected to the utility power line using conduit, BX, or Romex 60 as required by the local electrical code. The four-port energy-limited power source 56 is connected to the ballasted-socket assembly 30 using a lightweight cable assembly 62. The ballasted-socket assembly 30 is affixed to the top of the 2′ by 2′ luminaire reflector 10. An optional 2′ by 2′ lens 42 may be inserted in the grid system 46 ahead of the 2′ by 2′ luminaire reflector 10.

[0134] FIG. 5 is an exploded view showing how multiple luminaires can be nested together for shipping and storage. This figure shows six reflectors 10 nested one within another. Six ballasted-sockets 30 can be placed within the center cavity of the top reflector. Six 2′ by 2′ lenses 42 are then stacked on top of the top reflector 10.

[0135] FIG. 6 shows an exploded view of a 2′ by 4′ luminaire. The 2′ by 4′ reflector 88 contains three apertures 28 to receive three ballasted-socket assemblies 30 each of which is provided with cable assembly 62 and power receptacle 84. Three 2D lamps 26 are inserted into the ballasted-sockets from the bottom side of the 2′ by 4′ reflector 88. The 2′ by 4′ lens 90 is shown located above 2′ by 4′ grid opening 92.

[0136] FIG. 7 shows a ballasted-cover-plate 104 for compact fluorescent lamps. Compact fluorescent lamp socket 94 projects through the center of the cover plate 96. Mounting tabs 98 are round discs approximately 0.3 inches in diameter located in a plane parallel to the cover plate 96 and 0.060 inches above it. The mounting tabs are held in place by a shaft 100, which is affixed into the cover plate 96. The ballast circuit housing 102 encloses all circuitry, the back of compact fluorescent lamp socket 94 and two power receptacles 84. Also shown is power cable 108 with power plug 86 attached to each end.

[0137] FIG. 8 shows how the invention can be applied to luminaires, which use one or more compact fluorescent lamps. The sealable reflector 114 is provided with one or more circular apertures 112 with keyhole slots 110 on opposite sides of the aperture. The ballasted-cover-plate 104 is provided with a socket to receive compact fluorescent lamp 106. The ballasted-cover-plate is also provided with two power receptacles, either of which can receive power cable 108. Power cable 108 is provided with power plugs 86 at each end. An optional strip of double-sided tape 116 can be supplied with the sealable reflector 114. Beneath the sealable reflector is lens 42 that is positioned above a 2′ by 2′ ceiling grid opening 20.

[0138] Referring to FIG. 1, the ballasted-socket 30 encapsulates the ballast circuitry, all wiring, plus the connections between the ballast circuitry and the four-pin lamp socket 68; therefore, the ballasted-socket 30 is the only part of the luminaire which must meet the stringent requirements regarding the enclosure of fluorescent lighting fixtures established by Underwriters+ Laboratories, Inc. in UL1570. Input power is provided to the ballasted-socket assembly 30 through power plug 86 and cable assembly 62. An alternative connection technique, not shown, is to use insulation displacement connectors built into the ballasted-socket assembly 30 into which a multi-conductor cable is inserted and a cover or cam is slid or rotated into place to make the connection via contact point which pierce the insulation, similar to the plugs that are added to lamp cords.

[0139] FIG. 2 is typical of a circuit, which can be used in a ballasted-socket assembly or ballasted-cover-plate. In a preferred embodiment, the circuit is powered from a class II or class III power-limited supply. As a result, the National Electrical Code does not require the interconnecting wires between the power supply and the ballasted-socket assembly to be run in conduit or BX, but permits much lighter weight non-armored cable to be used. In order to minimize the physical size of the electronic components used for the ballast circuitry (tank capacitor 76, tank inductor 78, ballasting capacitor 74, and transformer 70) an operating frequency in the range of 18 kHz to 100 kHz is preferred. The filament windings 72 provide voltage to heat the lamp filaments for rapid start operation. By increasing the secondary turns and eliminating the filament windings, instant start operation can be achieved.

[0140] Referring to FIG. 3, a complete luminaire consists of a ballasted-socket assembly 30, a lamp 26, an optional lens 42 and the 2′ by 2′ luminaire reflector 10. The reflector merely supports the ballasted-socket assembly 30 and reflects the light down to the room being illuminated, but does not enclose any wires, transformers, capacitors, ballasts, current-carrying parts, devices with exposed metal, leads or terminals for field connection of supply wires. Therefore, the enclosure requirements of UL1570 do not have to be met by the reflector portion of the luminaire. This means that the reflector can be manufactured out of much lighter gauge material than that required for the equivalent conventional luminaire. The luminaires can be shipped to the job site in bulk (i.e. the 2′ by 2′ luminaire reflectors 10 can packed by nesting one reflector within another). As a result, the equivalent of ten conventional 2′ by 2′ troffer type luminaires can be placed in on container measuring 2′ by 2′ by 6″ thick and weigh a total of only 25 pounds including the reflectors, ballasted-sockets, and lenses. Ten conventional 2′ by 2′ troffers would normally be packed in individual boxes measuring 2′ by 2′ by 5″ thick and create a stack over four feet tall weighing 150 pounds. It would take sixty nestable luminaires to add up to 150 pounds and they would only stand 12 inches tall. Each additional reflector increases the height of the stack by only slightly more than the material thickness of the reflector.

[0141] Since the luminaire reflector 10 can be made out of a single sheet of material, this piece can be inexpensively manufactured by being vacuum formed or injection molded in the case of plastic, or either drawn or fabricated out of a single sheet of steel or aluminum. In situations where the luminaire is installed without a diffuser for a lens, it is possible to provide a textured finish on the reflecting side of the reflector to greatly reduce the amount of glare that would otherwise be produced by the glossy painted surface of a conventional luminaire.

[0142] In its basic form, the nestable luminaire can be manufactured with a single piece reflector. This is the only part requiring significant tooling. It does not require the tooling of numerous channels, covers and clips that is required for the equivalent conventional luminaire. Thus, the tooling cost to get into the luminaire business using the nestable luminaire approach is dramatically less than the cost to get into the business of manufacturing conventional luminaire designs. Again, due to the fact that the physical volume required to ship a finished reflector is no more and in some cases actually less than the volume to ship the raw material, the luminaire reflector can be manufactured anywhere in the world and shipped to the job site for 2% of what it would cost to ship conventional luminaires. Therefore, the suppliers of the luminaire reflectors are not limited to domestic vendors. There is no factory wiring; therefore, there is no manufacturing space or labor required for wiring the nestable luminaire.

[0143] As seen in FIG. 3 the entire luminaire can be assembled from three components, the luminaire reflector 10, the ballasted-socket assembly 30 and a lamp 26. An optional lens 42 can be added to reduce glare. As stated previously, one key feature of the nestable luminaire is its dramatic reduction in shipping and warehousing volume. In order to achieve the maximum reduction in volume the luminaire is shipped disassembled. It is therefore necessary that the luminaire is capable of being easily assembled at the job site. As shown in FIG. 3 the ballasted-socket 30 is merely clipped into the luminaire reflector 10 using the clip 34. The lamp 26 is then inserted into the four-pin lamp socket 68 of the ballasted-socket assembly 30. If a lens is used, the lens 42 is placed into the ceiling grid opening 20. The reflector 10, which also has the lamp 36 and ballasted-socket 30 installed, is placed over the lens 42 into the ceiling grid opening 20 from an adjacent grid opening 118. This installation process becomes a much easier task since the weight of a 2′ by 2′ luminaire is less than 3 pounds instead of 15 and in the case of a 2′ by 4′ luminaire the weight is less than 6 pounds instead of nearly 30. It should be noted that a significant portion of the shipping advantage of the nestable luminaire could still be achieved with ballasted-socket installed before shipping.

[0144] Referring to FIG. 4, once the luminaire has been placed into the suspended ceiling grid system 46 the cable assembly 62 is plugged into a four-port energy-limited power source 56 (for an example of an acceptable energy-limited power source see U.S. Pat. No. 5,691,603). Since in the case of an energy-limited system the wiring between the power source and the luminaire is class II or class III, it is only necessary to have an electrician install the four-port energy-limited power sources 56. The wiring between the power source and the luminaire can be installed by unskilled labor, because the wiring merely plugs together. Even where unions may require the luminaires to be installed by electricians, the speed at which the luminaires are installed will be very much increased and installation cost very much reduced.

[0145] FIG. 5 shows how the reflectors 10 can be nested one within another and one possible way of packaging the luminaires as do-it-yourself (DIY) kits. In this case, six reflectors 10 are packed with six ballasted-sockets 30 packed in the center of the top reflector. The lenses 42 are then packed on top of the upper reflector. This kit of six luminaires will fit in roughly the same size container that is currently used for a single equivalent conventional luminaire. Another alternative for both the DIY market and the commercial market is to ship the reflectors 10, ballasted-sockets 30, lenses 42 and lamps 26 separately in bulk, perhaps 50 to 100 per container. This way the do-it-yourselfer or commercial user can mix and match reflectors, ballasted-sockets, lenses and lamps. Also, if the aperture 28 of the reflector 10 (see FIG. 3) and the mounting technique of the ballasted-socket 30 were standardized, then the end user can choose a ballasted-socket from one of a number of ballast manufacturers on a reflector assembly from one of several luminaire manufacturers. The shelf space savings generated by the reduced volume of the nestable luminaire is especially important to the lighting retailer and home improvement center, where the shelf space is particularly valuable, since the merchandise is often warehoused on the store shelves.

[0146] FIG. 6 shows how the same invention can be applied to a 2′ by 4′ luminaire. The 2′ by 4′ reflector 88 contains one or more apertures 28. The ballasted-sockets 30 are clipped into the 2′ by 4′ reflector 88. The lamps 26 are inserted into the ballasted-sockets 30. The luminaires are then installed into the ceiling grid as previously discussed. To minimize the wiring above the suspended ceiling, each ballasted-socket 30 can be provided with a power receptacle 84 allowing one ballasted-socket 30 to be plugged into the preceding one with only one cord assembly 62 run back to the power source. All comments regarding the nesting, shipping, and warehousing previously discussed also apply to this type of luminaire.

[0147] The ballasted-cover-plate 104 in FIG. 7 is similar to the ballasted-socket assembly 30 except the ballast circuitry is mounted on a cover plate 96. A compact fluorescent lamp socket 94 is mounted on the cover plate 94 also. In the configuration shown, access to the compact fluorescent lamp socket 94 is through the cover plate. In other configurations, the lamp socket 94 may be mounted on the cover plate 96 without requiring that the base of a lamp extend through the cover plate 96. The diameter of the cover plate 96 is made slightly larger than the base of a compact fluorescent lamp As an alternative to having a cable assembly as part of the ballasted-socket, the ballasted-cover-plate 104 is shown with two parallel connected power receptacles 84. A separate power cable assembly 108 is provided with power plugs 86 at each end to interconnect the ballasted-cover-plate 104 to a power source.

[0148] Using a ballasted-cover-plate 104 permits relamping from the rear of the fixture as is shown in FIG. 8. A compact fluorescent lamp 106 is inserted into the compact fluorescent lamp socket of the ballasted-cover-plate 104. The compact fluorescent lamp is inserted through the circular aperture 112. The two mounting tabs 98 (shown in FIG. 7) are placed through the large ends of the two keyhole slots 110 located on both sides of circular aperture 112. The ballasted-cover-plate 104 is then rotated to lock it in place. If more than one lamp is used, the same procedure is followed for the remaining lamps. If a diffuser is used for the lens 42, the luminaire can be sealed by removing the paper backing from one side of the double-sided tape 116 and attach it to the bottom side of lip 22 around the perimeter of the luminaire. The lens 42 is then placed into the ceiling grid opening 20. The backing is removed from the double-sided tape 116. The sealable reflector 114 is then inserted through an adjacent grid opening and placed over the lens 42. Once in place, the double-sided tape adheres to the lens 42 and forms a sealed unit minimizing the infiltration of dirt. When a lamp reaches its end of life, the ballasted-cover-plate 104 is removed from the rear of the sealable reflector 114, the lamp is replaced with a new one and the ballasted-cover-plate 104 is reinstalled. It may be more cost effective in some cases to have the double-sided tape 116 preinstalled on the lens or the reflector by the manufacturer.

[0149] It should be noted that the sides of the reflector can be designed to be much steeper. As the sides of the reflector get steeper the improvement in packing density is somewhat decreased and is a function of the angle of the sides plus the thickness of the material used to manufacture the reflector, but significant improvement in the packing density compared to individually boxed luminaires is still achieved. For instance, if the reflector is designed such that a second reflector nested over it creates a gap of 1 inch between the top planes 24 of the two reflectors and the height of each reflector is approximately 4 inches, when ten reflectors are shipped nested, they will still only occupy roughly one-third of the volume of individually boxed conventional luminaires. With a design that creates a gap between top planes, the option exists to supply the ballasted-socket assemblies preinstalled either on the backside as has been shown, or with minor modifications to the mounting arrangements and power input connection it can be preinstalled on the inside of the reflector.

[0150] The First Related Family of Embodiments demonstrates how the nestable luminaire is used with 2D lamps and compact fluorescent lamps. The second related family of embodiments applies the same concept to circular lamps, linear lamps, U-lamps and long-twin-tube type lamps. To accommodate these lamps, the sides of the reflector of the luminaire are made steeper to make the larger top plane required by these lamps. The concept is still the same in that the luminaire is comprised of the same three or four basic parts: a ballasted-socket, a reflector, a lamp or lamps, and an optional lens. The reflectors are capable of being nested one within another to minimize shipping volume. The ballasted-sockets can be shipped either packaged within the top reflector or shipped separately in bulk. The luminaires are then easily assembled at the time of installation.

[0151] FIG. 9 is an exploded view of a nestable luminaire for a circular lamp. Steep-sided reflector 124 contains three sets of apertures and slots in its top plane 24. Oval aperture 126 is designed to receive circular lamp socket 122 of ballasted-socket for circular lamps 120. Ballast clip slot 136 is for engagement of clip 34. The ballasted-socket for circular lamps 120 includes two power receptacles 84. Lamp retaining clip slots 130 are designed to receive lamp retaining clip 128. Circular lamp 132 is provided with circular lamp plug 134. An optional 2′ by 2′ lens 42 may be a diffuser or parabolic lens.

[0152] FIG. 10 is an exploded view of a nestable luminaire for long-twin-tube lamps. The top plane 24 of reflector for twin tube lamps 164 contains lamp support mounting holes 146 and aperture C 174 with relief slots 154 on alternate sides. Ballasted-socket for twin tube lamps 162 is provided with ramp 150 and recess 152 plus a power receptacle 84 on each end and twin tube lamp socket 190. Lamp support 166 is spring loaded to clamp around the parallel tubes of the twin tube lamp 168. The optional lens 42 can be a diffuser or a parabolic lens.

[0153] FIG. 11 is an exploded view of a nestable luminaire for long-twin-tube lamps used as a sealable luminaire. The top plane 24 of sealable reflector for twin tube lamps 180 contains the lamp cradle mounting holes 188 and retaining slot 186. The side of the sealable reflector for twin tube lamps 180 contains the aperture D 176, which receives side mounted ballasted-socket for twin tube lamps 178. The side-mounted ballasted-socket for twin tube lamps 178 has two power receptacles 84 a twin tube lamp socket 190 and a retaining tab 184. Lamp cradle 182 is a narrow plastic or metal U-shaped bracket designed to be inserted into and held by lamp cradle mounting holes 188. The lamp cradle 188 supports the twin tube lamp 168 in a plane parallel to the top plane 24. Double-sided tape 116 is used to adhesively seal lens 42 to lip 22.

[0154] FIG. 12 is an exploded view of a nestable luminaire for U-lamps. The reflector for U-lamps 156 contains aperture pair B 172 to receive ballasted-socket for U-lamps 158. Each aperture pair 172 having relief slots 154 on each side of each aperture. The ballasted-socket for U-lamps 158 having a power receptacle 84 at each end as well as a straight-in bi-pin lampholder 192 at each end. The two straight-in bi-pin lampholders 192 facing the same direction with the opening capable of receiving the lamp bi-pins located 90 degrees to the axis of the longest dimension of the ballasted-socket for U-lamps 158. A typical center-to-center distance between the two lamp holders is six inches. Each of the straight-in bi-pin lampholders 192 having a ramp 150 and recess 152. The top plane 24 also contains lamp retaining clip slot 130 for the insertion of lamp retaining clip 128. A typical U-lamp 160 is a 1-inch diameter lamp bent in the shape of a U with a center-to-center leg spacing of six inches and nominal length of 22 inches. Optional lens 42 can be either a diffuser or a parabolic lens.

[0155] FIG. 13 is an exploded view of a nestable luminaire for linear lamps. Reflector for linear lamps 140 contains at least one pair of apertures A 170 to receive the main body of ballasted-socket for linear lamps 138 and remote lamp socket 142. The main body of ballasted-socket for linear lamps 138 contains one or more power receptacles 84. Tab 196 allows the width of the aperture to increase to permit insertion of a lampholder. The main body of the ballasted-socket for linear lamps 138 and the remote lamp socket 142 are provided with a ramp 150 and a recess 152. The main body of the ballasted-socket for linear lamps is connected to the remote bi-pin lampholder 142 by remote bi-pin lampholder cable 144. This cable can be a single conductor for instant start lamps, a pair of insulated conductors or a pair of insulated conductors within a cable for rapid start lamps. For rapid start lamps, when the ballasted-socket is powered from a Class II or Class III circuit, the conductors in the remote bi-pin lampholder cable 144 become a Class II circuit since the voltage between the conductors is nominally only 3.6 volts and if the input to the ballasted-socket is power limited, the output between these conductors is also power limited to the same power level. Therefore, no special enclosure requirements apply regarding UL 1570. If the ballasted-socket for linear lamps is powering rapid start lamps and is powered from a non-class II or III circuit, the remote lamp socket cable 144 needs to be enclosed appropriately to meet the requirements of UL1570 or a circuit component, such as, a capacitor can be added within the ballasted-socket enclosure in series with one of the conductors to limit the current available between the two conductors to a level within the Class II limits. The length of the remote bi-pin lampholder cable 144 is determined by the length of the linear lamps used in the luminaire. In some cases, it may be desirable to enclose this cable in a rigid housing to mechanically connect the main body of the ballasted-socket for linear lamps 138 to the remote bi-pin lampholder 142. Linear lamps 148 are shown above lens 42.

[0156] The reflector for linear lamps is shown without a lip around the perimeter of the luminaire. For T5 rapid start lamps the reflector can be made with or without a lip since a nominal 2 foot lamp has an overall length of 21.6 inches and a nominal 4 foot lamp has an overall length of 45.2 inches. T8 and T12 lamps are only 0.25 inches shorter than their nominal length. Therefore, there is no room to add the lip to these reflectors. In addition, the lampholders are held in by tab 196. This tab allows the lampholders to be spaced far enough apart to accept T8 and T12 lamps.

[0157] Refer to FIG. 2 for a circuit that is typical of a circuit that might be used in the various ballasted-sockets shown in FIG. 9 through FIG. 13.

[0158] FIG. 9 shows how a nestable figure is adapted to use circular lamps. The ballasted-socket for circular lamps 120 has an integral circular lamp socket 122 mounted at approximately 45 degrees from vertical and toward the center of the ballasted-socket. All the ballast circuitry is contained within the housing of the ballasted-socket; therefore, the ballasted-socket is the only part of the luminaire that needs to meet the structural and electrical requirements of UL1570. At the time of installation, the ballasted-socket for circular lamps 120 is attached to the steep-sided reflector 124 by inserting circular lamp socket 122 through oval aperture 126 and engaging clip 34 into ballast clip slot 136. The lamp retaining clips 128 are each inserted into lamp retaining clip slots 130. The circular lamp 132 is then forced over the lamp retaining clips 128 with the circular lamp plug 134 engaging the circular lamp socket 122. This assembly is then inserted into a ceiling grid opening preceded by an optional lens 42. The power receptacle 84 is then connected to a source of power.

[0159] The embodiment shown shows a single lamp, but the same approach can be applied to two or even three concentric circular lamps of different diameters by either providing two or three separate ballasted-sockets at various angles from one another or by using a single ballasted-socket with appropriate circuitry and two or three integral sockets spaced appropriately along the length of the ballasted-socket assembly.

[0160] FIG. 10 shows how a nestable luminaire is adapted to use long-twin-tube type lamps. The ballasted-socket for twin tube lamps 162 has an integral twin tube lamp socket 190 and two power receptacles 84 one on each end. The integral twin tube lamp socket 190 is provided with a ramp 150 and a recess 152. At the time of installation, the ballasted-socket for twin tube lamps 162 is inserted into aperture C 174. Aperture C is provided with relief slots 154 on each end of the aperture to permit the material used for the reflector to flex enough to permit the end of the ramp 150 to pass over it and lock this tab into recess 152, thus capturing the ballasted-socket for twin tube lamps 162 within aperture C 174. Lamp support 166 is inserted into lamp support mounting holes 146 from underneath. Twin tube lamp 168 is then inserted into twin-tube lamp socket 190 and pressed into lamp support 166. This assembly is placed into a ceiling grid preceded by optional lens 42. The power receptacle 84 is then connected to a source of power.

[0161] FIG. 11 shows how a nestable luminaire is adapted to use long-twin-tube type lamps in a sealable nestable luminaire. The side-mounted ballasted-socket for twin tube lamps 178 has an integral twin tube lamp socket 190 and two power receptacles 84. In this embodiment, the lamp cradle 182 is insert into lamp cradle mounting holes 188 from the bottom side of the sealable reflector for twin tube lamps 180. The twin tube lamp 168 is inserted into the twin-tube lamp socket 190 of the side-mounted ballasted-socket for twin tube lamps 178. This assembly is then inserted through aperture D 176, allowing the twin-tube lamp 168 to rest on and be guided by lamp cradle 182. The retaining tab 184 is placed in retaining slot 186. This locks the ballasted-socket in place. The lens 42 is placed into a ceiling grid opening. The backing from one side of the double-sided tape 116 is removed and placed into the grid with the exposed side against the lens. The backing is then removed from the other side of the tape and the assembled reflector is placed into the grid over the lens, sealing the lens to the reflector. Once sealed it is virtually impossible for dust and insects to accumulate within the luminaire. It may be advantageous to provide the tape pre-installed either on the lip 22 or on the lens 42. Alternately instead of using tape, a Velcro type product can be used on the lens 42 or lip 22 and the loops attached to the opposite piece.

[0162] FIG. 12 shows how a nestable luminaire is adapted to use U-lamps. The ballasted-socket for U-lamps 158 has two integral straight-in bi-pin lamp holders 192 and two power receptacles 84 one on each end. The integral straight-in bi-pin lamp holders 192 are each provided with a ramp 150 and a recess 152. At the time of installation, the ballasted-socket for U-lamps 158 is inserted into aperture pair B 172. Aperture pair B is provided with relief slots 154 on each end of each of the apertures to permit the material used for the reflector to flex enough to permit the end of the ramp 150 to pass over it and lock this tab into recess 152, thus capturing the ballasted-socket for U-lamps 158 within aperture pair B 172. Lamp retaining clip 128 is inserted into lamp retaining clip slot 130 from underneath. U-lamp 160 is then inserted into the pair of straight-in bi-pin lamp holders 192 and held in place with lamp retaining clip 128. This assembly is placed into a ceiling grid preceded by optional lens 42. The power receptacle is then connected to a source of power.

[0163] FIG. 13 shows how a nestable luminaire is adapted for use with linear lamps. The ballasted-socket for linear lamps 138 has one integral bi-pin lamp holder 194 and one remote bi-pin lamp holder 142 plus two power receptacles 84. The integral bi-pin lamp holder 194 and the remote bi-pin lamp holder 142 are each provided with a ramp 150 and a recess 152. At the time of installation, the integral bi-pin lampholder 194 is inserted into one of the apertures A 170. Each aperture A 170 has a tab 196 associated with it to permit the material used for the reflector to flex enough to permit the end of the ramp 150 to pass through the aperture and lock the integral bi-pin lamp holder 194 of the ballasted-socket for linear lamps 138 within aperture A 170. In similar fashion, the remote bi-pin lamp holder 142 is inserted into the corresponding aperture A 170 opposite the aperture containing the integral bi-pin lamp holder 194. A linear lamp 148 is inserted into the lamp holders. This assembly is placed into a ceiling grid preceded by optional lens 42. The power receptacle is then connected to a source of power.

[0164] The First and Second Related Family of Embodiments demonstrate how the nestable luminaire is capable of being nested one within another to minimize shipping volume. That approach is particularly desirable when large quantities of luminaries are being shipped and warehoused in bulk. The current embodiment addresses the situation where a single luminaire is packaged separately or a small number of luminaires are packaged together. In this embodiment, the reflector is flattened to minimize shipping and warehousing volume. For luminaires that use the ballasted-socket, the construction requirements in Underwriters' Laboratory standard UL 1570 that apply to conventional luminaires do not apply; therefore, the luminaire can be made of much lighter materials including plastic. In addition, the ballast-to-socket wiring is all contained in the ballasted-socket assembly. Thus, the luminaire merely supports the ballasted-socket and lamps, but does not need to protect any electrical wiring. Thus, the luminaire does not need to be constructed as rigidly as conventional luminaires.

[0165] Shown in FIG. 14 is a top view of an example of a flattenable luminaire in its flattened state. Top plane 24 being approximately 10 inches by 10 inches. The top plane 24 is connected to four side panels 198 by way of four continuous hinges 200. The top plane 24 is provided with aperture 28. Each side panel 198 having interlocking notches 204 positioned such as to engage interlocking tabs 202 of its adjacent side panels during assembly. The outside edge 206 of the side panel 198 being slightly less than two feet in length. The adjoining edges 208 of the side panels 198 being approximately 11 inches in length.

[0166] This embodiment is particularly well suited for manufacture out of plastic material. The entire reflector can be stamped out of a single sheet of plastic or molded as a single piece. The continuous hinges 200 can be implemented as living hinges by reducing the thickness of the plastic along the outer edges of the top plane 24 along the line of intersection with the side panels 198.

[0167] When the luminaire is installed, the side panels 198 of the flattenable luminaire reflector 210 are bent back inward until their adjoining edges 208 again meet. If the reflector is provided with interlocking tabs 202 and interlocking notches 204, the side panels 198 are snapped together. If the flattenable reflector 210 is not provided with the interlocking feature, the edges of the side panels are held closed using clamps or tape applied over each of the adjacent adjoining edges 208 on the back side of the flattenable reflector 210.

[0168] Once the flattenable reflector 210 is assembled, a ballasted-socket of the type described in previous embodiments is inserted into the flattenable luminaire reflector 210 and a lamp or lamps are plugged into the ballasted-socket. The assembled luminaire is then placed into the grid of a suspended ceiling. If an optional lens is used, it is merely placed into the grid before the reflector assembly.

[0169] The ballasted-sockets, lamps and lens can be shipped either packaged with the reflector or shipped separately in bulk.

[0170] FIG. 14 shows interlocking tabs 202 and interlocking notches 204 on adjoining edges 208. These can be eliminated and the adjoining edges can be sealed with tape or held together with clamps. The truncated pyramid shape of the reflector shown in FIG. 14 is representative of the many shapes that can be implemented with the instant invention. For instance, there is no particular requirement that the side panels 198 be sloped as in the nestable embodiments described in previous embodiments. The side panels can be vertical if necessary and adjacent side panels do not need to be similarly shaped. It is only necessary that the adjoining edges have the same length. Consequently, any basic shape currently used for troffer type luminaires can be accommodated using this invention.

[0171] The aperture 28 shown in FIG. 14 accepts a ballasted-socket, which would be inserted from the rear of the reflector, and a lamp would then be inserted from the front of the luminaire as is shown in FIG. 3. The flattenable luminaire reflector can also accommodate the lamp and ballasted-socket arrangement depicted in FIG. 8 where one or more lamps can be installed and replaced from the rear of the luminaire. Using this configuration of ballasted-socket and lamps further allows the lens or diffuser to be attached to the front of the luminaire reflector to provide a sealed luminaire.

[0172] An example of an alternate way of implementing this embodiment is to slit the four edges that join the four side panels of the truncated pyramid of a reflector from a nestable luminaire, discussed in previous embodiments. The reflector is packaged with the top plane 24 forced down until it is coplanar with the side panels 198. The reflector is then shipped in this flattened condition. Upon removal from the packaging the reflector will naturally try to assume, at least in part, its original shape.

[0173] Accordingly, it can be seen that the invention provides a dramatic reduction in the cost to manufacture, ship and store luminaires. In addition, substantial savings in the cost of installation are achieved since the luminaires can easily be assembled, installed and connected to the power source by non-skilled, non-electrician installers.

[0174] Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Various other embodiments and ramifications are possible within it's scope. For example, although the specification describes the nestable and flattenable luminaire with a ballasted-socket designed for a class II or class III high-frequency power input, the nestable luminaire concept can also be used with non-class II or III, AC and DC circuits. The ballasted-socket in these situations would merely have to enclose all non-class II and III circuits and wiring, while the input connection would have to meet the local codes that may apply.

[0175] The specification shows and describes the ballasted-socket being mounted through an aperture from the rear of the luminaire. This technique generally allows the lamp to be mounted more closely to the top plane of the luminaire, but the ballasted-socket can be designed to be mounted within and from the front of the luminaire as well. The specification also discusses the field assembly of the nestable luminaire and how the ballasted-socket is clipped into the luminaire's reflector, much of the reduction of the in shipping volume can still be achieved with the ballasted socket already mounted in the reflector prior to shipment.

[0176] While the specification discusses the use of plastic for the reflector material, under certain circumstances it will be advantageous to use other materials, such as metal, fiberglass, etc. The figures show the shape of the reflector to be a truncated pyramid, but any structural shape that will function as a reflector and allow one reflector to be nested within another for shipping purposes is suitable for this purpose. The optics may be improved by making the sides curved instead of flat and by using different angles for the slopes of the sides. The specification is presented in terms of 2′×2′ and 2′×4′ luminaires. While these luminaires are currently the most common, the invention works equally well for other sizes as well.

[0177] The various types of lamps require different ballasted-sockets, which in turn require different mounting apertures. In an effort to minimize the number of different reflectors that are needed to accommodate the various lamp types, the same reflector can be manufactured with the material of the reflector made thinner at the outline of the various apertures. In this way, the same reflector can be used for several different lamp types by merely knocking out the material of the appropriate aperture.

[0178] Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.

[0179] Definitions

[0180] luminaire: a complete lighting unit consisting of a lamp or lamps together with the parts designed to distribute the light, to position and protect the lamps, and to connect and interface the lamps to the power source.

[0181] troffer: a recessed lighting unit, installed with the opening flush with the ceiling.

[0182] compact fluorescent lamps: single-ended fluorescent lamps such as, Biax, double Biax, triple Biax, quad Biax, flat, helical, spring, etc.

[0183] high-frequency: frequencies greater than 10 kHz.