GB2574138A

GB2574138A - High bay Luminaire

Info

Publication number: GB2574138A
Application number: GB1911604.5A
Authority: GB
Inventors: Sall Sanjit; Pasavadia Sachin
Original assignee: Holophane Europe Ltd
Current assignee: Holophane Europe Ltd
Priority date: 2019-08-14
Filing date: 2019-08-14
Publication date: 2019-11-27
Anticipated expiration: 2039-08-14
Also published as: GB201911604D0; GB2574138B; GB2574138A8

Abstract

A luminaire includes an electrical housing assembly 102 and a light module assembly 104. The light module assembly 104 is connected to the electrical housing assembly 102 such that an air gap 166 is defined between the light module assembly and the electrical housing assembly. In some examples, the electrical housing assembly has a variable length such that the length of the electrical housing is proportional to the number of light module assemblies connected to the electrical housing assembly. The light module assembly 104 and the electrical housing assembly 102 are connected by at least one module attachment arm 164.

Description

[0001] Embodiments of the invention relate to an improved luminaire that can be, but that does not have to be, supported at elevated heights.

BACKGROUND [0002] Luminaires may be used in various indoor or outdoor applications to emit light into an environment. Some luminaires, such as those for high bay applications, may be designed for locations high above a floor or work space. For example, high bay luminaires may be used in warehouses and manufacturing plants to illuminate work spaces below. Many high bay luminaires are high-powered so that the luminaires can provide sufficient lighting from the elevated heights. However, the high-powered nature of the luminaires produces a large amount of heat that may damage sensitive electrical components of the luminaire and cause the luminaire to become inoperable. Accessing high bay luminaires for maintenance and replacement is expensive as well as time-consuming, dangerous, and labor intensive due to the luminaires’ location high above the floor.

SUMMARY [0003] The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0004] According to certain embodiments of the present disclosure, a luminaire includes an electrical housing assembly and a light module assembly. The electrical housing assembly includes a housing defining a housing compartment. The light module assembly includes a module base and at least one light source. The module base includes a mounting surface and at least one module attachment arm extending in a direction opposite from the mounting surface. The at least one light source may be supported on the mounting surface of the module base. In certain aspects, the at least one module attachment arm is removably connected to the electrical housing assembly such that an air gap is defined between the light module assembly and the electrical housing assembly.

[0005] In some examples, the at least one module attachment arm includes a first module attachment arm and a second module attachment arm. In various examples, the housing includes a base, a first side wall, and a second side wall. The first side wall may include an outer surface defining a first mounting channel, and the second side wall may include an outer surface defining a second mounting channel. In certain aspects, the base, the first side wall, and the second side wall together define the housing compartment. The first module attachment arm may be connected to the first mounting channel and the second module attachment arm may be connected to the second mounting channel.

[0006] In various embodiments, the first mounting channel is a first lower mounting channel and the second mounting channel is a second lower mounting channel, and the outer surface of the first side wall further defines a first upper mounting channel and the outer surface of the second side wall further defines a second upper mounting channel. In some aspects, the at least one module attachment arm may be removably connected to the first lower mounting channel or the second lower mounting channel, and the luminaire may further include a hanging bracket connected to the housing via the first upper mounting channel and the second upper mounting channel. In certain embodiments, the first lower mounting channel includes a vertical axis extending in a direction perpendicular to the longitudinal axis defined along the length of the first lower mounting channel, the first upper mounting channel includes a vertical axis extending in a direction perpendicular to the longitudinal axis defined along the length of the first upper mounting channel, and the vertical axis of the first lower mounting channel is non-parallel to the vertical axis of the first upper mounting channel.

[0007] In some aspects, the at least one light source includes a plurality of light sources, and the light module assembly further includes a reflector assembly and a lens. The reflector assembly may include a holder defining at plurality of apertures and a plurality of reflectors, where each reflector is removably positioned in a corresponding one of the plurality of apertures and proximate to a corresponding one of the plurality of light sources. The lens may be supported on the module base such that the reflector assembly is between the lens and the module base. In some examples, the lens is a light transmissive covering lens. In various examples, the lens is a prismatic lens including one or more side walls and a bottom wall, and the bottom wall includes at least one prism. In various embodiments, the luminaire includes a gasket supported on the module base between the lens and the module base, where the gasket is configured to form a seal between the module base and the lens.

[0008] In certain embodiments, the base of the housing of the electrical housing assembly includes an inner surface that at least partially defines the housing compartment, and the inner surface of the base defines at least one base mounting feature within the housing compartment.

[0009] In some examples, the electrical housing assembly includes a cover having a first attachment arm and a second attachment arm, and the housing includes a base, a first side wall, and a second side wall. The first side wall may include an outer surface defining a first attachment channel, and the second side wall may include an outer surface defining a second attachment channel. The first attachment arm may be removably engaged with the first attachment channel and the second attachment arm may be removably engaged with the second attachment channel.

[0010] In various aspects, the at least one light source includes a plurality of light sources, the module base includes a sensor connector on the mounting surface, and the plurality of light sources are positioned on the mounting surface around the sensor connector. In certain embodiments, the module base defines at least one cooling aperture.

[0011] In some embodiments, the electrical housing assembly includes a gasket and a cover and the housing defines a gasket channel. In some aspects, the housing includes a base, a first side wall defining a first portion of the gasket channel, a second side wall defining a second portion of the gasket channel. The cover may be removably attached to the first side wall and the second side wall, and the gasket may be positioned within the gasket channel and be configured to form a seal between the cover and the housing. In certain examples, the electrical housing assembly includes a first end cap and a second end cap, and the housing includes a first end extending between the first side and the second side and a second end opposite from the first end. The first end cap may be removably coupled to the first end of the housing and may define a third portion of the gasket channel. The second end cap may be removably coupled to the second end of the housing and may define a fourth portion of the gasket channel.

[0012] In certain embodiments, the electrical housing assembly includes a first end cap gasket between the first end cap and the first end of the housing and a second end cap gasket between the second end cap and the second end of the housing.

[0013] Various implementations described in the present disclosure can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS [0014] The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures can be designated by matching reference characters for the sake of consistency and clarity.

[0015] FIG. 1 is a perspective view of a luminaire including an electrical housing assembly and a light module assembly according to aspects of the current disclosure.

[0016] FIG. 2 is a side view of the luminaire of FIG. 1.

[0017] FIG. 3 is a front view of the luminaire of FIG. 1.

[0018] FIG. 4 is a top view of the luminaire of FIG. 1.

[0019] FIG. 5 is a bottom view of the luminaire of FIG. 1.

[0020] FIG. 6 is an exploded assembly view of the luminaire of FIG. 1.

[0021] FIG. 7 is a sectional view of the luminaire of FIG. 1.

[0022] FIG. 8 is a sectional view of the luminaire of FIG. 1 taken from box 8 in FIG. 7.

[0023] FIG. 9 is a sectional view of the electrical housing assembly of the luminaire of FIG. 1.

[0024] FIG. 10 is a perspective view of a portion of the luminaire of FIG. 1.

[0025] FIG. 11 is a sectional view of a portion of the electrical housing assembly and the light module assembly of the luminaire of FIG. 1.

[0026] FIG. 12 is a sectional view of another portion of the electrical housing assembly and the light module assembly of the luminaire of FIG. 1.

[0027] FIG. 13 illustrates a temperature gradient on the luminaire of FIG. 1.

[0028] FIG. 14 is a perspective view of the luminaire of FIG. 1 with the electrical housing assembly assembled with the light module assembly.

[0029] FIG. 15 is a perspective view of the luminaire of FIG. 1 with the electrical housing assembly assembled with additional light module assemblies.

[0030] FIG. 16A is a perspective view of a configuration of a luminaire according to aspects of the current disclosure.

[0031] FIG. 16B is a perspective view of another configuration of a luminaire according to aspects of the current disclosure.

[0032] FIG. 16C is a perspective view of another configuration of a luminaire according to aspects of the current disclosure.

[0033] FIG. 16D is a perspective view of another configuration of a luminaire according to aspects of the current disclosure.

[0034] FIG. 17 is an exploded assembly view of a light module assembly of a luminaire according to aspects of the current disclosure.

[0035] FIG. 18 is a bottom view of the light module assembly of FIG. 17.

[0036] FIG. 19 is a perspective view of a luminaire according to aspects of the current disclosure.

[0037] FIG. 20 is an exploded assembly view of a luminaire according to aspects of the current disclosure.

[0038] FIG. 21 is a perspective view of a reflector assembly of the luminaire of FIG. 20.

[0039] FIG. 22 is a bottom perspective view of the luminaire of FIG. 20.

[0040] FIG. 23 is an enlarged view of a portion of the reflector assembly and luminaire of

FIG. 20.

[0041] FIG. 24 is a sectional view of the luminaire of FIG. 20.

[0042] FIG. 25 is an exploded assembly view of a luminaire according to aspects of the current disclosure.

[0043] FIG. 26 is a side view of the luminaire of FIG. 25 [0044] FIG. 27 is a bottom perspective view of a light transmissive covering lens of the luminaire of FIG. 25.

[0045] FIG. 28 is a top perspective view of the light transmissive covering lens of the luminaire of FIG. 25.

[0046] FIG. 29 is a top perspective view of a configuration of a luminaire with a bridging bracket according to aspects of the current disclosure.

[0047] FIG. 30 is a bottom perspective view of the configuration of FIG. 29.

DETAILED DESCRIPTION [0048] The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “top,” “bottom,” “up,” “down,” “left,” “right,” “front,” and “back,” among others are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.

[0049] Embodiments of the present invention are directed to luminaires that generally include an electronic housing assembly and a light module assembly. The luminaire may be a high bay luminaire that is suspended or mounted at a height above a work space. As one non-limiting example, the luminaire may be suspended or mounted at a height from about 12 meters to about 20 meters above a work space; however, in other examples, the luminaire may be suspended or mounted at a height that is less than 12 meters or greater than 20 meters. While embodiments of the luminaire are disclosed for mounting or suspending at an elevated height, such embodiments are not limited to such use, and the luminaire can be installed in different environments (e.g., indoor, outdoor, etc.) and in different manners. Moreover, while light emitting diodes (“LEDs”) are described, it will be recognized that the invention may be embodiments in luminaires using other kinds of light sources such as fluorescent, incandescent, halogen, etc.

[0050] FIGs. 1-15 illustrate an example of a luminaire 100. The luminaire 100 generally includes an electrical housing assembly 102 and a light module assembly 104. The electrical housing assembly 102 may house electrical components (e.g., LED driver, communication modules, power supply units, etc.), and the light module assembly 104 may house one or more light sources such as LEDs. In some examples, the luminaire 100 may include support brackets 106 to support or mount the luminaire 100 in an environment, although various other suitable support mechanisms or devices may be utilized with the luminaire 100 to support or mount the luminaire 100 in an environment. Light emitted by the light sources within the light module assembly 104 may be emitted into the environment.

[0051] The luminaire 100 with the electrical housing assembly 102 and the light module assembly 104 may provide a number of advantages, some of which are discussed in more detail below. In some examples, the luminaire 100 provides improved thermal management that increases the service life of the luminaire 100 and reduces the risk of premature electronics failure. In some cases, the improved thermal management includes minimizing contact between the electrical housing assembly 102 and the light module assembly 104 by providing an air gap between the electrical housing assembly 102 and the light module assembly 104. In such examples, the heat generated by light sources on the light module assembly 104 may be dissipated via convection by the air flowing through the air gap and entirely around the light module assembly 104, thereby minimizing or reducing the heat conducted into the electrical housing assembly 102 and to heatsensitive electrical components housed within the electrical housing assembly 102. The air gap may also promote airflow through and around the electrical housing assembly 102 and the light module assembly 104 individually. The improved thermal management may also include providing a light source distribution that minimizes thermal gradients within the light module assembly 104. In various examples, the luminaire 100 may operate at much higher ambient temperatures (and optionally at a higher lumen output) compared to traditional high bay luminaires. As one non-limiting example, the luminaire 100 may operate at up to 60k lumens in an ambient temperature of up to 70°C.

[0052] In certain aspects, the electrical housing assembly 102 can be provided in a length that is proportional to the number of light module assemblies 104 to be supported on the electrical housing assembly 102. Provision of the electrical housing assembly 102 in different lengths may minimize material waste and maximize the usage of the materials by proportionally maintaining the amount of surface area needed for effective heat dissipation. The modular configuration of the luminaire 100 may further reduce waste because individual components may be accessed for maintenance, repair, or replacement without requiring replacement of the complete luminaire structure. In some cases, the luminaire 100 is compliant with the rating IP65 of the International Electrotechnical Commission (IEC) standard 60529 titled “Degrees of Protection Provided by Enclosures (IP Code)” (2001) (hereinafter ‘ΊΡ65 Rating”).

[0053] In some optional examples, up to 80% of the materials used in the luminaire 100 (e.g., aluminum, steel, glass, plastic, electronics, etc.) may be recyclable. As a non-limiting example, a module base 160 of the light module assembly 104, a housing 108 of the electrical housing assembly 102, a cover 110 of the electrical housing assembly 102, and end caps 112A-B of the electrical housing assembly 102 may be formed from recyclable aluminum. Suspension brackets and various fasteners or clips of the luminaire 100 may be formed from recycled metals (e.g., aluminum, steel, etc.) and the light transmissive covering lens may be formed from recycled materials such as glass or plastic. Reflectors and gaskets of the luminaire 100 may be formed from recycled plastic, recycled rubber, etc., and printed circuit boards, light drivers, and various wires and cables may be formed from recycled electronics. Various other suitable materials may be used to form the various components of the luminaire 100, and the above-listed materials should not be considered limiting on the current disclosure.

Electrical Housing Assembly [0054] The electrical housing assembly 102 includes the housing 108 and the cover 110. The electrical housing assembly 102 may also include end caps 112A-B. As mentioned previously, the electrical housing assembly 102 may house electrical components of the luminaire 100 other than the light sources of the luminaire 100.

[0055] The housing 108 includes a base 114 and side walls 116A-B extending along opposing sides of the base 114. The base 114 and side walls 116A-B define a first end 138 and a second end 140 of the housing, and a distance from the first end 138 to the second end 140 is a length of the housing 108. The base 114 and side walls 116A-B each include a portion of an outer surface 118 and a portion of an inner surface 120 of the housing 108. As best illustrated in FIGs. 6-8, the base 114 and side walls 116A-B together define a housing compartment 122.

[0056] As best illustrated in FIGs. 8 and 9, the inner surface 120 of the base 114 may include inner supports 124 within the housing compartment 122. The inner supports 124 may support and/or allow attachment of various electrical or non-electrical components within the housing compartment 122. For example, electrical components such as an LED driver 150, a power source 152, a wireless communication module, and/or various other components may be housed within the housing compartment 122. The outer surface 118 of the base 114 may similarly include outer supports 126 that allow for attachment of components to the base 114.

[0057] In some examples, the outer surface 118 of the side walls 116A-B may define lower mounting channels 128A-B. Optionally, the outer surface 118 of the side walls 116A-B may also define upper mounting channels 130A-B. The lower mounting channels 128A-B and/or the upper mounting channels 130A-B may extend along the entire length of the housing 108, although they need not in other examples. The lower mounting channels 128A-B and the upper mounting channels 130A-B may allow for attachment of various components and accessories to the housing 108. In some examples, attachment mechanisms 132 such as bolts, pins, hooks, rods, screws, or other suitable attachment mechanisms may be used to attach the accessories to the upper mounting channels 130A-B and the lower mounting channels 128A-B.

[0058] In the example of FIGs. 1-15, bolts (attachment mechanisms 132) are used to attach the support brackets 106 to the upper mounting channels 130A-B and the light module assembly 104 to the lower mounting channels 128A-B. This configuration enables the quick and easy replacement of light module assemblies 104 on the electrical housing assembly 102. The location of the support brackets 106 within the upper mounting channels 13 0Α-Β should not be considered limiting on the current disclosure, and the support brackets 106 may be attached at various locations along the length of the electrical housing assembly 102 as desired.

[0059] In some examples, the lower mounting channels 128A-B are tilted relative to the upper mounting channels 130A-B. For example, as illustrated in FIG. 12, each lower mounting channel 128A-B optionally has a vertical axis 134 that extends in a direction perpendicular to the longitudinal axis defined along the length of the lower mounting channel 128A-B. Similarly, each upper mounting channel 130A-B has a vertical axis 136 that extends in a direction perpendicular to the longitudinal axis defined along the length of the upper mounting channel 130A-B. In some embodiments, the vertical axis 134 is not parallel to the vertical axis 136. In some embodiments, the vertical axis 134 extends at an oblique angle relative to vertical axis 136. In certain cases, the vertical axis 134 extends at an acute angle relative to the vertical axis 136, although it need not be. In some aspects, the vertical axis 134 extends at an oblique angle such that the vertical axis 134 is substantially parallel to a mating surface of the light module assembly 104, which may facilitate attachment of the light module assembly 104 to the housing 108. As illustrated in FIG. 12, when bolts (attachment mechanisms 132) are positioned in the upper mounting channel 130A (and likewise the upper mounting channel 13 0B) and the lower mounting channel 128A (and likewise the lower mounting channel 128B), respectively, because the vertical axis 134 is tilted, a lateral axis 137 of the attachment mechanism 132A in the lower mounting channel 128A is not parallel to a lateral axis 135 of the attachment mechanism 132B in the upper mounting channel 130A. Similarly, the lateral axis of the attachment mechanism in the lower mounting channel 128B is not parallel to the lateral axis of the attachment mechanism in the upper mounting channel 13 0B.

[0060] The outer surface 118 of the side walls 116A-B may also include attachment features 142A-B that allow for selective engagement of the cover 110 with the housing 108. In the example of FIGs. 1-15 (and as best illustrated in FIG. 9), the attachment features 142A-B are attachment channels that allow for a snap-fit engagement of the cover 110 with the housing 108 via attachment features 143A-B on the cover 110. The attachment features 143A-B may be ribs or other suitable attachment features as desired. Optionally, the cover 110 includes a pair of opposing attachment arms 145 A-B that extend from a base 147 of the cover 110, and the attachment features 143 A-B are on the attachment arms 145A-B. Snap-fit attachment of the cover 110 to the housing 108 enables quick and easy access to the electrical components housed in the housing compartment 122. In other examples, various other suitable types of attachment features on the housing 108 and cover 110 may be utilized to secure the cover 110 to the housing 108.

[0061] In some examples, the side walls 116A-B may define portions of a gasket channel 144 of the housing 108. As best illustrated in FIGs. 6-8, a gasket 146 may be positioned within the gasket channel 144. When the cover 110 is attached to the housing 108, the gasket 146 may form a seal between the cover 110 and the housing 108 to minimize contaminant entry (e.g., dust, moisture, etc.) into the housing compartment 122. In certain cases, the seal is compliant with the 1P65 Rating. [0062] As mentioned, the electrical housing assembly 102 also includes the end caps 112A-B. In some examples, the end cap 112A is attached to the first end 138 of the housing 108 and the end cap 112B is attached to the second end 140 of the housing 108. Optionally, a first end cap gasket 148A is provided between the end cap 112A and the housing 108 and a second end cap gasket 148B is provided between the end cap 112B and the housing 108. Similar to the gasket 146, the end cap gaskets 148A-B may form a seal between the end caps and the housing. As best illustrated in FIG. 6, each end cap 112A-B may optionally define portions of the gasket channel 144 for receipt of the gasket 146 such that a continuous seal may be created at the interface between the cover 110 and housing 108. Optionally, one or more of the end caps 112A-B may include one or more connectors 147 for electrical connections to the electrical housing assembly 102 (e.g., power, communications, other wiring, etc.).

[0063] The cover 110 includes a first end 154 and a second end 156, and a distance from the first end 154 to the second end 156 is a length of the cover 110. Similar to the housing 108, the length of the cover 110 may be provided in various lengths as desired. As illustrated in the figures, the cover 110 includes the attachment features 143A-B that selectively engage the attachment features 142A-B of the housing 108. In the example of FIGs. 1-15, the attachment features 143A-B are ribs, although other suitable attachment features may be utilized in other examples.

[0064] Referring to FIGs. 14 and 15, the length of the housing 108 (and thus the length of the cover 110) may depend on the number of light module assemblies 104 intended to be supported and powered by the electrical housing assembly 102. Thus, the length of a housing 108 used to support and power a single light module assembly 104 will be less than the length of a housing 108 used to support and power two light module assemblies 104, which in turn will be less than the length of a housing 108 used to support and power a three light module assemblies 104, etc. This can be seen by comparing FIGs. 14-16. In this way, the electrical housing assembly 102 is scalable depending on the lighting needs of an installation. In one non-limiting example, the length of the housing 108 is at least 325 millimeters; however, in other examples, the length of the housing 108 may be less than 325 millimeters or greater than 325 millimeters as desired.

[0065] In various aspects, the length of the housing 108 is controlled such that the length of the housing 108 is proportional to the number of light module assemblies 104 attached to the housing. In certain cases, the length of the housing is controlled to maintain a ratio of the length of the housing 108 (and thus the size of the housing compartment) to the total length of the light module assemblies 104 attached to the housing 108 (which may be the length of a single light module assembly 104 is only one light module assembly 104 is attached, or may be the total length of two or more light module assemblies 104 when more than one light module assembly 104 is attached to the housing 108). In some non-limiting examples, the ratio of the length of the housing 108 to the total length of the light module assemblies 104 attached to the housing is from about 1:1 to about 2:1. As one non-limiting example, if the total length of the light module assemblies 104 is 325 millimeters, the length of the housing could be from about 325 millimeters to about 650 millimeters. It will be appreciated that these lengths are provided for illustrative purposes only and should not be considered limiting on the current disclosure. In one non-limiting example, the ratio of the length of the housing 108 to the total length of the light module assemblies 104 is about 1.2:1. Other ratios may be utilized. Maintaining the ratio of the length of the housing 108 to the total length of the light module assemblies 104 may maintain the proportion of the space available for heat dissipation to the light output and allow for the housing 108 to be more fully utilized, which may improve energy efficiency and environmental efficiency (because material usage is optimized).

Light Module Assembly [0066] The light module assembly 104 is removably connected to the electrical housing assembly 102 and includes a module base 160 with a mounting surface 162 provided on a first side 161 of the module base 160. One or more light sources 170 of the luminaire 100 are supported on the mounting surface 162. The module base 160 thus serves as a heat sink for the light sources 170. In various examples, any desired number of light module assemblies 104 may be mounted to a single electrical housing assembly 102. For example, FIGs. 1-14 illustrate one light module assembly 104 mounted to a single electrical housing assembly 102, FIGs. 16A and 16C illustrate two light module assemblies 104 mounted to a single electrical housing assembly 102, and FIGs. 15, 16B, and 16D illustrate three light module assemblies 104 mounted to a single electrical housing assembly 102.

[0067] In some examples, the module base 160 includes at least attachment arm 164 that extends from a second side 163 of the module base 160 opposite the first side 161 and in a direction away from the mounting surface 162. In the example of FIGs. 1-15, the module base 160 includes two module attachment arms 164A-B. In certain examples, the module attachment arms 164A-B connect the light module assembly 104 to the electrical housing assembly 102 such that an air gap 166 is defined between the module base 160 and the electrical housing assembly 102. The attachment arms 164 may be integrally or monolithically formed with the module base 160 as a single component, or the attachment arms 164 may be separate components joined to the module base 160 through various suitable joining techniques or mechanisms.

[0068] As mentioned previously, the air gap 166 may provide improved thermal management to the luminaire 100 and may promote air flow around and between the module base 160 and the electrical housing assembly 102. Moreover, the module attachment arms 164 are designed to minimize direct contact (and thus a direct thermal path) between the light module assembly 104 and the electrical housing assembly 102 by limiting points of contact between the module attachment arms 160 and the housing 108. In some cases, each attachment arm 164 has two attachment points or points of contact, although other suitable attachment points of minimal contact may be provided. The air gap 166 created by the module attachment arms 164A-B and/or the minimal contact between the module attachment arms 164A-B and the housing 108 may minimize or reduce heat transfer from the light sources 170 of the light module assembly 104 to the electrical housing assembly 102, thereby protecting electrical components within the housing compartment 122 that are heat sensitive (e.g., the LED driver 150). Minimizing the heat transfer from the light sources 170 to the electrical housing assembly 102 may enable the electrical components within the housing compartment 122 to have a long service life and reduce the risk of premature failure of the electrical components and subsequent electrical component waste.

[0069] In some examples, the module base 160 includes one or more cooling apertures 168 along at least a portion of the perimeter of the module base 160. The cooling apertures 168 may promote air flow through the module base 160 and provide additional thermal control of the luminaire 100.

The cooling apertures 168 optionally extend completely through the module base 160. Various other thermal control mechanisms (fins, apertures, etc.) or combination of thermal control mechanisms may be utilized. Similar to the electrical housing 102, the light module assembly 104 may include one or more connectors 149 for electrical connections to the light module assembly 104 (e.g., power, communications, other wiring, etc.).

[0070] In some examples, the light sources 170 include LEDs. The LEDs may be various types of LEDs including single-die LEDs, multi-die LEDs, direct current (DC) LEDs, alternating current (AC) LEDs, organic light emitting diodes, and/or various other suitable LEDs. White, color, or multicolor LEDs, or combinations thereof, may be used. Moreover, the LEDs need not all be the same color and/or type; rather, mixtures of different colors and/or types of LEDs may be used. The LEDs may be provided on one or more printed circuit boards (PCBs). However, in other embodiments, no PCB is needed; rather, the LEDs may be chip-on-board LEDs provided directly on the module base 160. In further examples, any number of PCBs may be utilized, including more than one PCB.

[0071] In certain examples, and as best illustrated in FIG. 5, the light sources 170 may optionally be arranged on the mounting surface 162 in a symmetrical, linear arrangement around a center portion 172 of the mounting surface 162 (i.e., the center portion 172 does not include the light sources 170). In various aspects, the symmetrical arrangement around the center portion 172 provides the benefit of linear arrangement on each PCB (e.g., by maintaining a distance between each light source 170 and the cooling apertures 168) while also expanding the output similar to a cluster arrangement of LEDs. In other words, the arrangement may eliminate a central hotspot and minimize a thermal gradient from the light sources 170 while still providing a high lumen output into a particular environment. FIG. 13 illustrates a relatively uniform thermal gradient on the module base 160 due to the symmetrical arrangement of the light sources 170. In other examples, the light sources 170 may be provided in various other arrangements or configurations on the mounting surface 162 as desired such as polygonal, circular, etc.

[0072] In addition to the module base 160 and the light sources 170, the light module assembly 104 may include a reflector 174 and a light transmissive covering lens 176. The light transmissive covering lens 176 is positioned on the module base 160 and over the light sources 170. The light transmissive covering lens 176 can be made of any non-metallic material that permits light to exit through the light transmissive covering lens 176, including, but not limited to, glass, polymeric materials, silicone and various other suitable materials for light distribution. Optionally, a gasket 179 is positioned between the light transmissive covering lens 176 and the module base 160 such that a seal is formed. In various examples, the seal formed by the gasket 179 is compliant with at least the IP65 Rating. The reflector 174 may be provided between the module base 160 and the light transmissive covering lens .176 and proximate to the light sources 170. The reflector 174 may have various suitable shapes or profiles to control the directionality or appearance of light emitted by the luminaire 100. For example, the reflector 174 may be a single wall that extends around the light sources 170, the reflector 174 may have an inner wall and an outer wall with the light sources 170 located in between, or the reflector 174 may have various other configurations. In the example of FIGs. 1-15 and 17-18, the reflector 174 includes an inner wall 181 and an outer wall 183. The reflector 174 may be a single piece or may be a plurality of components jointed together. The reflector 174 includes a reflective surface, which can include reflective materials such as, but not limited to, polished metals, reflective coatings, reflective paints, or other reflective compositions, to render the reflective surface reflective or enhance the reflectivity of the surface.

[0073] Optionally, and as illustrated in FIGs. 17 and 18, the light module assembly 104 includes a sensor 180 that may control at least one characteristic of the luminaire 100. As some non-limiting examples, the sensor 180 may be an occupancy sensor, a daylight sensor, or other suitable sensor that controls light output from the luminaire 100. For example, depending on a detected presence of a person or a detected amount of daylight, the sensor 180 may be used to increase or decrease the light output from the luminaire 100. The sensor 180 may include a controller integrated with the sensor 180, or the controller may be remote from the sensor 180 (e.g., in the housing compartment 122). In some examples where a sensor 180 is provided, a center cover 182 may be provided on the reflector 174, and the sensor 180 is mounted on the center cover. Optionally, an opening 177 is defined in the light transmissive covering lens 176 such that the sensor 180 extends through the light transmissive covering lens 176. In other examples, the sensor 180 may be provided on the light module assembly 104 in other locations or configurations as desired. In other examples, the sensor 180 may be mounted on the mounting surface 162 via a sensor connector 1901, which may be a socket or other suitable connecting mechanism as desired.

[0074] FIGs. 19-24 illustrate another example of a luminaire 1900 that includes a different light module assembly 104 but that is otherwise identical to the luminaire 100. The light module assembly 104 in luminaire 1900 includes a reflector system 1984 designed to reduce the unified glare rating of the luminaire 1900 and thereby improve visual comfort to a viewer. In addition and in contrast to the light module assembly 104 of luminaire 100, the light sources 170 of the luminaire 1900 are provided in clusters of LEDs rather than a linear arrangement. The clusters of LEDs may further eliminate or reduce central hot spots on the luminaire 1900 compared to traditional luminaires.

[0075] As best illustrated in FIGs. 20 and 21, the reflector system 1984 includes a holder 1983 and one or more reflectors 1974. The holder 1983 is attached to the module base 160 and defines one or more apertures 1986. Each reflector 1974 is removably positioned in a corresponding one of the apertures 1986 and proximate to a corresponding light source 170. The reflectors 1974 may be retained in the apertures 1986 through various suitable attachment mechanisms such as snap-fit connections, clips, hooks, pins, twist-lock, etc. such that the reflectors 1974 can be selectively removed from the holder 1983. Accordingly, the reflector system 1984 allows for selective interchangeability of reflectors 1974 to achieve a desired optical distribution. In certain aspects, the holder 1983 includes attachment mechanisms that are complimentary to the attachment mechanisms of the reflectors 1974 including, but not limited to, hooks, pins, slots, threads, etc.

[0076] The reflectors 1974 may be formed through various suitable processes. In one nonlimiting example, each reflector 1974 is formed via a molding process (e.g., injection molding), and a mirrored finish (or other suitable reflective or non-reflective finish as desired) is applied. The reflectors 1974 may include optical distribution properties similar to those of the reflector 174, but the optical distribution properties of one of the reflectors 1974 on the holder 1983 need not be the same as the optical distribution properties of another one of the reflectors 1974 on the holder 1983. In some cases, the reflectors 1974 may have a truncated conical shape, although various other shapes may be utilized. While the inner surface of one or more reflectors can be smooth, in some optional examples the inner surface of one or more reflectors has surface enhancements that impact the appearance of the light emitted from the luminaire. By way only of example and as best illustrated in FIG. 23, a surface of each reflector 1974 may have a specular diffusing surface to provide increased specular reflection and prevent clear images of the light sources 170 from forming on the reflector surface. More particularly, the reflector surfaces are prismatic and include a plurality of arcuate-shaped regions (or other suitably shaped regions as desired).

Prismatic Lens [0077] FIGs. 25-28 illustrate another example of a luminaire 2500 that is identical to the luminaire 1900 except that the light module assembly 104 includes a prismatic lens 2576 (as opposed to a light transmissive covering lens 176). Compared to the light transmissive covering lens 176, the prismatic lens 2576 may further control light output emitted from the luminaire 2500 (i.e., by providing a more diffused appearance of light). The prismatic lens 2576 may include prisms 2577, raised flutes 2579, and various other features and surface enhancements in various patterns (e.g., circular, linear, vertical, horizontal, spiral, checkered, etc.) to achieve a desired appearance of light. In the example of FIGs. 25-28, the prismatic lens 2576 includes vertical flutes 2579 on at least one of the inner and outer surfaces of the vertical side walls 2583 of the prismatic lens 2576, circular prisms 2577 on the outer surface of the bottom wall 2585 of the prismatic lens 2576 that are provided in a radial pattern from the center of the lens 2576 (see FIG. 27), and straight prisms 2577 on the inner surface of the bottom wall 2585 of the prismatic lens 2576 that extend radially outwardly from the center of the lens 2576 (see FIG. 28). In FIG. 25, the prisms 2577 have been omitted for clarity.

[0078] Optionally, a portion of the prismatic lens 2576 may have a specular diffusing surface that provides a blurred or distorted view. In the example of FIGs. 25-28, a center portion 2581 of the inner surface of the bottom wall 2585 of the prismatic lens 2576 has a specular diffusing surface providing a blurred or distorted view. In some embodiments, a center portion 2587 of the outer surface of the bottom wall 2585 may include a mounting pad for the sensor 180 and/or sensor connector 1901. In such examples, an opening 2589 may be defined in the bottom wall 2585 such that wiring or other features of the sensor or sensor connector can pass through the prismatic lens 2576. In various aspects, such a configuration sandwiches the prismatic lens 2576 between the sensor 180 and/or sensor connector 1901 on the outer surface of the bottom wall 2585 and the module base 160.

Lighting System [0079] FIGs. 14, 15, and 16A-D illustrate various examples of lighting systems according to aspects of the current disclosure. Based on desired lighting needs, the lighting systems can be controlled by varying the number of light module assemblies 104 attached to a single electrical housing assembly 102 and/or varying the number of electrical housing assemblies 102 with at least one light module assembly 104. For example, FIG. 14 illustrates a lighting system with a single light module assembly 104 connected to a single electrical housing assembly 102, FIG. 16A illustrates a lighting system with two light module assemblies 104 connected to a single electrical housing assembly 102, FIGs. 15 and 16B illustrate a lighting system with three light module assemblies 104 connected to a single electrical housing assembly 102, FIG. 16C illustrates two electrical housings 102, each having two light module assemblies 104, and FIG. 16D illustrates a two electrical housings 102, each having three light module assemblies 104. Various other lighting systems may be provided as desired. It should thus be apparent that installations can be scaled up or down depending on the lighting needs and conditions by adjusting the number of light module assemblies 104 provided on an electrical housing assembly 102 and/or adjusting the number and configuration of electrical housing assemblies 102.

Bridging Bracket [0080] While support brackets 106 are useful to a support single electrical housing assembly 102, a bridging bracket 2901 may be used to support multiple electrical housing assemblies 102. FIGs. 29 and 30 illustrate a configuration 2900 of two luminaires 1900 that are supported together by a pair of bridging brackets 2901. Bridging brackets 2901 could obviously be used with any of the luminaire embodiments disclosed here. Moreover, in some embodiments, a single bridging bracket 2901 could be sufficient to support multiple luminaires (i.e., a pair of bridging brackets 2901 might not be needed).

[0081] Each bridging bracket 2901 may be constructed from various suitable materials as desired, including, but not limited to, metals, composites, plastics, combinations thereof, or other suitable materials. The bridging bracket 2901 includes a top rail 2907, a bottom rail 2905, and side rails 2909A-B that connect the top rail 2907 and the bottom rail 2905. The rails can be formed integrally with each other or can be separately formed and subsequently attached to each other to form a bridging bracket 2901. Two or more locating regions 2903 are formed across the width of the bottom rail 2905. The locating regions 2903 are each shaped and dimensioned to receive a portion of an electrical housing assembly 102.

[0082] As illustrated in FIGs. 29 and 30, when assembled with one or more luminaires 1900 (or luminaires 100 or other luminaire embodiments), each locating region 2903 at least partially receives and supports an electrical housing assembly 102. In the example of FIGs. 29 and 30, each bridging bracket 2901 has two locating regions 2903 and can support two electrical housing assemblies 102. However, in other examples, each bridging bracket 2901 forms more than two locating regions 2903 (e.g., three locating regions, four locating regions, etc.) such that the bridging bracket may support more than two electrical housing assemblies 102. Each bridging bracket 2901 may be connected to the electrical housing assemblies 102 via the upper mounting channels 130A-B and/or the lower mounting channels 128A-B as desired, although in other examples the bridging brackets 2901 may be connected to various other regions of the electrical housing assemblies 102. In the illustrated embodiment, attachment mechanisms 132 engage the side rails 2909A-B of the bridging bracket 2901 and the upper mounting channels 13 0 A-B defined in the electrical housing assemblies 102. In other examples, a mechanical connection between the bridging bracket 2901 and the electrical housing assemblies 102 may be omitted. The top rail 2907 may be used to install the luminaire as desired.

Examples [0083] A collection of examples, including at least some explicitly enumerated as “Examples” providing additional description of a variety of example types in accordance with the concepts described herein are provided below. These examples are not meant to be mutually exclusive, exhaustive, or restrictive; and the invention is not limited to these example examples but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0084] Example 1. A luminaire comprising: an electrical housing assembly comprising a housing having a base, a first side wall, and a second side wall, wherein the base, the first side wall, and the second side wall together define a housing compartment; and a light module assembly comprising: a module base comprising a mounting surface on a first side of the module base and at least one module attachment arm extending from a second side of the module base opposite the first side and in a direction away from the mounting surface; and at least one light source supported on the mounting surface of the module base, wherein the at least one module attachment arm is removably connected to the electrical housing assembly such that an air gap is defined between the light module assembly and the electrical housing assembly.

[0085] Example 2. The luminaire of any preceding or subsequent example or combinations of examples, wherein the at least one module attachment arm comprises a first module attachment arm and a second module attachment arm, wherein: the first side wall comprises an outer surface defining a first mounting channel; the second side wall comprises an outer surface defining a second mounting channel, and the first module attachment arm is connected to the first mounting channel and the second module attachment arm is connected to the second mounting channel.

[0086] Example 3. The luminaire of any preceding or subsequent example or combinations of examples, wherein: the first mounting channel is a first lower mounting channel and the second mounting channel is a second lower mounting channel; the outer surface of the first side wall further defines a first upper mounting channel; the outer surface of the second side wall further defines a second upper mounting channel; the at least one module attachment arm is removably connected to the first lower mounting channel or the second lower mounting channel; and the luminaire further comprises a hanging bracket connected to the housing via the first upper mounting channel and the second upper mounting channel.

[0087] Example 4. The luminaire of any preceding or subsequent example or combinations of examples, wherein the first lower mounting channel comprises a vertical axis, wherein the first upper mounting channel comprises a vertical axis, and wherein the vertical axis of the first lower mounting channel is non-parallel to the vertical axis of the first upper mounting channel.

[0088] Example 5. The luminaire of any preceding or subsequent example or combinations of examples, wherein the at least one light source comprises a plurality of light sources, and wherein the light module assembly further comprises: a reflector assembly comprising: a holder defining at plurality of apertures; and a plurality of reflectors, wherein each reflector is removably positioned in a corresponding one of the plurality of apertures and proximate to a corresponding one of the plurality of light sources; and a lens supported on the module base such that the reflector assembly is between the lens and the module base.

[0089] Example 6. The luminaire of any preceding or subsequent example or combinations of examples, wherein the lens is a light transmissive covering lens or a prismatic lens.

[0090] Example 7. The luminaire of any preceding or subsequent example or combinations of examples, wherein the at least one light source comprises discrete clusters of light sources and wherein the plurality of reflectors are each provided around a discrete cluster of light sources.

[0091] Example 8. The luminaire of any preceding or subsequent example or combinations of examples, further comprising a gasket supported on the module base between the lens and the module base, wherein the gasket is configured to form a seal between the module base and the lens.

[0092] Example 9. The luminaire of any preceding or subsequent example or combinations of examples, wherein the electrical housing assembly further comprises a cover comprising a first attachment arm and a second attachment arm, wherein: the first side wall comprises an outer surface defining a first attachment channel; the second side wall comprises an outer surface defining a second attachment channel; and the first attachment arm is removably engaged with the first attachment channel and the second attachment arm is removably engaged with the second attachment channel to snap-fit the cover onto the housing.

[0093] Example 10. The luminaire of any preceding or subsequent example or combinations of examples, wherein the at least one light source comprises a plurality of light sources, wherein the module base further comprises a sensor connector on the mounting surface, and wherein the plurality of light sources are positioned on the mounting surface around the sensor connector.

[0094] Example 11. The luminaire of any preceding or subsequent example or combinations of examples, wherein the module base defines at least one cooling aperture that extends entirely through the module base.

[0095] Example 12. The luminaire of any preceding or subsequent example or combinations of examples, wherein the electrical housing assembly further comprises a gasket and a cover, wherein the housing defines a gasket channel and wherein: the first side wall defines a first portion of the gasket channel; the second side wall defines a second portion of the gasket channel; the cover is removably attached to the first side wall and the second side wall; and the gasket is positioned within the gasket channel and is configured to form a seal between the cover and the housing.

[0096] Example 13. The luminaire of any preceding or subsequent example or combinations of examples, wherein the electrical housing assembly further comprises: a first end cap; and a second end cap, wherein the housing further comprises a first end and a second end opposite the first end, wherein the first end cap is removably coupled to the first end of the housing and defines a third portion of the gasket channel, and wherein the second end cap is removably coupled to the second end of the housing and defines a fourth portion of the gasket channel.

[0097] Example 14. The luminaire of any preceding or subsequent example or combinations of examples, wherein the electrical housing assembly further comprises: a first end cap gasket between the first end cap and the first end of the housing; and a second end cap gasket between the second end cap and the second end of the housing.

[0098] Example 15. The luminaire of any preceding or subsequent example or combinations of examples, wherein the base comprises an inner surface that at least partially defines the housing compartment, and wherein the inner surface of the base defines at least one base mounting feature within the housing compartment.

[0099] Example 16. A lighting system comprising: a first luminaire of any preceding or subsequent example combinations wherein the electrical housing assembly is a first electrical housing assembly; a second luminaire comprising a second electrical housing assembly; and a bridging bracket comprising a top rail and a bottom rail, wherein the bottom rail defines a first locating region and a second locating region spaced apart from the first locating region, wherein the first locating region is configured to receive a portion of the first electrical housing assembly and wherein the second locating region is configured to receive a portion of the second electrical housing assembly.

[0100] Example 17. A bridging bracket for a lighting system, the bridging bracket comprising: a top rail, a bottom rail spaced apart from the top rail, a first side rail connecting the top rail and the bottom rail; and a second side rail connecting the top rail and the bottom rail opposite from the first side rail, wherein the bottom rail defines a first locating region and a second locating region spaced apart from the first locating region, wherein the first locating region is configured to receive a portion of a first electrical housing assembly of a first luminaire of the lighting system, and wherein the second locating region is configured to receive a portion of a second electrical housing assembly of a second luminaire of the lighting system.

[0101] Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and subcombinations. Examples of the invention have been described for illustrative and not restrictive purposes, and alternative examples will become apparent to readers of this patent. Accordingly, the present invention is not limited to the examples described above or depicted in the drawings, and various examples and modifications may be made without departing from the scope of the claims below.

Claims

That which is claimed:

1. A luminaire comprising:

an electrical housing assembly comprising a housing having a base, a first side wall, and a second side wall, wherein the base, the first side wall, and the second side wall together define a housing compartment; and a light module assembly comprising:

a module base comprising a mounting surface on a first side of the module base and at least one module attachment arm extending from a second side of the module base opposite the first side and in a direction away from the mounting surface; and at least one light source supported on the mounting surface of the module base, wherein the at least one module attachment arm is removably connected to the electrical housing assembly such that an air gap is defined between the light module assembly and the electrical housing assembly.

2. The luminaire of claim 1, wherein the at least one module attachment arm comprises a first module attachment arm and a second module attachment arm, wherein:

the first side wall comprises an outer surface defining a first mounting channel;

the second side wall comprises an outer surface defining a second mounting channel; and the first module attachment arm is connected to the first mounting channel and the second module attachment arm is connected to the second mounting channel.

3. The luminaire of claim 2, wherein:

the first mounting channel is a first lower mounting channel and the second mounting channel is a second lower mounting channel;

the outer surface of the first side wall further defines a first upper mounting channel;

the outer surface of the second side wall further defines a second upper mounting channel; the at least one module attachment arm is removably connected to the first lower mounting channel or the second lower mounting channel; and the luminaire further comprises a hanging bracket connected to the housing via the first upper mounting channel and the second upper mounting channel.

4. The luminaire of claim 3, wherein the first lower mounting channel comprises a vertical axis, wherein the first upper mounting channel comprises a vertical axis, and wherein the vertical axis of the first lower mounting channel is non-parallel to the vertical axis of the first upper mounting channel.

5. The luminaire of any preceding claim, wherein the at least one light source comprises a plurality of light sources, and wherein the light module assembly further comprises:

a reflector assembly comprising:

a holder defining at plurality of apertures; and a plurality of reflectors, wherein each reflector is removably positioned in a corresponding one of the plurality of apertures and proximate to a corresponding one of the plurality of light sources; and a lens supported on the module base such that the reflector assembly is between the lens and the module base.

6. The luminaire of claim 5, wherein the lens is a light transmissive covering lens or a prismatic lens.

7. The luminaire of claim 5 or 6, wherein the at least one light source comprises discrete clusters of light sources and wherein the plurality of reflectors are each provided around a discrete cluster of light sources.

8. The luminaire of any of claims 5 to 7, further comprising a gasket supported on the module base between the lens and the module base, wherein the gasket is configured to form a seal between the module base and the lens.

9. The luminaire of any preceding claim, wherein the electrical housing assembly further comprises a cover comprising a first attachment arm and a second attachment arm, wherein: the first side wall comprises an outer surface defining a first attachment channel;

the second side wall comprises an outer surface defining a second attachment channel; and the first attachment arm is removably engaged with the first attachment channel and the second attachment arm is removably engaged with the second attachment channel to snap-fit the cover onto the housing.

10. The luminaire of any preceding claim, wherein the at least one light source comprises a plurality of light sources, wherein the module base further comprises a sensor connector on the mounting surface, and wherein the plurality of light sources are positioned on the mounting surface around the sensor connector.

11. The luminaire of any preceding claim, wherein the module base defines at least one cooling aperture that extends entirely through the module base.

12. The luminaire of any preceding claim, wherein the electrical housing assembly further comprises a gasket and a cover, wherein the housing defines a gasket channel and wherein:

the first side wall defines a first portion of the gasket channel;

the second side wall defines a second portion of the gasket channel;

the cover is removably attached to the first side wall and the second side wall; and the gasket is positioned within the gasket channel and is configured to form a seal between the cover and the housing.

13. The luminaire of claim 12, wherein the electrical housing assembly further comprises:

a first end cap; and a second end cap, wherein the housing further comprises a first end and a second end opposite the first end, wherein the first end cap is removably coupled to the first end of the housing and defines a third portion of the gasket channel, and wherein the second end cap is removably coupled to the second end of the housing and defines a fourth portion of the gasket channel.

14. The luminaire of claim 13, wherein the electrical housing assembly further comprises: a first end cap gasket between the first end cap and the first end of the housing; and a second end cap gasket between the second end cap and the second end of the housing.

15. A lighting system comprising:

the luminaire of any preceding claim, wherein the luminaire is a first luminaire and the electrical housing assembly is a first electrical housing assembly;

a second luminaire comprising a second electrical housing assembly; and a bridging bracket comprising a top rail and a bottom rail, wherein the bottom rail defines a first locating region and a second locating region spaced apart from the first locating region, wherein the first locating region is configured to receive a portion of the first electrical housing assembly, and wherein the second locating region is configured to receive a portion of the second electrical housing assembly.