U.S. patent number RE38,767 [Application Number 10/621,198] was granted by the patent office on 2005-08-02 for roadway luminaire.
This patent grant is currently assigned to Acuity Brands, Inc.. Invention is credited to Edward Bernard Bilson, Glenn A. Ellis, III, Rick W. Kauffman, Mark Taylor Wedell, Thomas A. Zimmerman.
United States Patent |
RE38,767 |
Wedell , et al. |
August 2, 2005 |
Roadway luminaire
Abstract
A roadway luminaire is provided which includes a mast mount
docking station securable to an end of a pole mast. The mast mount
docking station includes a power plug electrically coupled to the
power conductors. The luminaire includes a corresponding power plug
which is electrically and mechanically coupled to the mast mount
docking station via a twist-lock feature including mating keys and
keyways in the docking station and luminaire, respectively. The
luminaire includes several plug-in components such as a plug-in
photoelectric cell, a plug-in starter and a capacitor press-fit
into a molded cavity in the luminaire. The power plug of the
luminaire is adaptable to be used with all international voltages.
The twist-lock feature provides for a fool-proof mechanical and
electrical connection to ensure that the correctly rated luminaire
is connected to the supply voltage.
Inventors: |
Wedell; Mark Taylor
(Wrightsville Beach, NC), Bilson; Edward Bernard
(Germantown, TN), Zimmerman; Thomas A. (Southaven, MS),
Ellis, III; Glenn A. (Memphis, TN), Kauffman; Rick W.
(Memphis, TN) |
Assignee: |
Acuity Brands, Inc. (Atlanta,
GA)
|
Family
ID: |
24445577 |
Appl.
No.: |
10/621,198 |
Filed: |
July 16, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
Reissue of: |
610575 |
Mar 8, 1996 |
05803590 |
Sep 8, 1998 |
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Current U.S.
Class: |
362/652; 362/263;
362/370; 362/371; 362/396; 362/431 |
Current CPC
Class: |
F21V
7/048 (20130101); F21V 17/18 (20130101); F21V
7/24 (20180201); F21V 17/20 (20130101); F21V
23/04 (20130101); F21V 23/06 (20130101); F21V
21/116 (20130101); F21V 17/107 (20130101); H01R
29/00 (20130101); F21S 8/086 (20130101); F21V
31/005 (20130101); F21V 7/09 (20130101); F21V
7/10 (20130101); F21V 7/28 (20180201); F21W
2131/103 (20130101); Y10S 362/802 (20130101); F21W
2131/10 (20130101); H01R 13/64 (20130101); H01R
13/625 (20130101) |
Current International
Class: |
F21S 001/10 () |
Field of
Search: |
;362/368,370,371,414,431,263,226,265,430,276,802,418,287,432 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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973165 |
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1142963 |
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1489490 |
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Apr 1969 |
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DE |
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2215888 |
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Mar 1972 |
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DE |
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3539389 |
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May 1987 |
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DE |
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9015538 |
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Mar 1991 |
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DE |
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94111264 |
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Jul 1992 |
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DE |
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0059892 |
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Sep 1982 |
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EP |
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0370825 |
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May 1990 |
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EP |
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938008 |
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Sep 1948 |
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FR |
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2495279 |
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Jun 1982 |
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FR |
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862292 |
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Mar 1961 |
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GB |
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6106854 |
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Apr 1986 |
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JP |
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6111605 |
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Apr 1994 |
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JP |
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6203616 |
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Jul 1994 |
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JP |
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Other References
Product Brochure on Hubbell Lighting's Intelligent Ignitor System
dated Sep. 1999..
|
Primary Examiner: Sember; Thomas M.
Attorney, Agent or Firm: Kilpatrick Stockton, LLP
Claims
What is claimed is:
1. A luminaire for mounting to a pole which comprises: a mast mount
docking station including a clamp for attaching to the pole at one
end of the docking station and a keyed coupling means at an
opposite end of the docking station; an electrical plug connector
disposed in the coupling means end of the docking station; a
luminaire including a mating electrical plug connector for
electrically connecting the mast mount docking station to the
luminaire, the luminaire further including a connection end having
keyways therein such that the luminaire is removably mechanically
and electrically coupled to the mast mount docking station by a
twist-lock mating between the mating electrical plug connectors and
keyed coupling means of the mast mount docking station and the
keyways in the connection end of the luminaire.
2. A luminaire as defined by claim 1, wherein the mast mount
docking station comprises an upper mast assembly and a lower mast
assembly, one of the upper mast assembly and lower mast assembly
including the clamp for attaching the docking station to the pole,
the upper mast assembly being removably secured to the lower mast
assembly to thereby secure the electrical plug connector
therein.
3. A luminaire as defined by claim 1, wherein the mast mount
docking station includes a series of inclined steps at the mast
mounting end to allow angles of tilt for leveling the
luminaire.
4. A luminaire as defined by claim 1, wherein the luminaire is
twist-lock coupled to the mast mount docking station by about a
15.degree. to about a 30.degree. rotational movement of the
luminaire with respect to the docking station.
5. A luminaire as defined by claim 1, wherein the electrical
connector of the docking station receives power conductors which
exit the pole, the electrical connector being provided with a
series of crenulations, such that each crenulation is identified
with a different voltage rating to accommodate all international
voltages.
6. A luminaire for mounting to a pole, comprising: a mast mount
docking station having a pole connection end including means for
attaching the docking station to the pole and a coupling means at
an opposite end of the docking station; and a luminaire including a
connection end having mating coupling means with the docking
station coupling means such that the luminaire is removably coupled
to the mast mount docking station by a twist-lock mating between
the respective coupling means; wherein the pole connection end of
the mast mount docking station includes an opening for receiving
the pole having a plurality of removable knock-outs therearound for
enlarging the opening to accommodate mast diameters of varying
sizes.
7. A luminaire for mounting to a pole, comprising: a mast mount
docking station having a pole connection end including a means for
attaching the docking station to the pole and a coupling means at
an opposite end of the docking station; and a luminaire including a
connection end having mating coupling means with the docking
station coupling means such that the luminaire is removably coupled
to the docking station by a twist-lock mating therebetween, wherein
the luminaire further includes a molded photoelectric control
receptacle extending above a top portion of the luminaire and a
molded electronics compartment extending below a bottom portion of
the luminaire to provide hand holds to perform the twist-lock
mounting of the luminaire to the docking station.
8. A method of installing or removing a roadway luminaire, the
luminaire including a mast mount docking station for attachment to
a pole mast, the luminaire and docking station including mating
twist-lock connectors, the luminaire and mast mount docking station
further including mating power plug connectors, the method
comprising the step of: twisting the luminaire with respect to the
docking station to thereby mechanically and electrically connect
and/or disconnect the mating twist-lock connectors and the mating
power plug connectors.
9. A method as defined by claim 8, wherein the step of twisting the
luminaire is accomplished in less than a quarter-turn.
10. A roadway luminaire comprising: a mast mount docking station
having a pole connection end including means for attaching the
docking station to the pole and a coupling means at an opposite end
thereof; a first plug connector having fixed contacts coupled to a
power supply, the first plug connector being positioned at the
coupling means end of the docking station; a lamp assembly
including a housing having a mating connection end and a central
cavity enclosing an illumination lamp electrically connected to
ballast circuitry, the mating connection end further including a
second plug connector having fixed contacts electrically coupled to
the ballast circuitry, wherein upon twist-locking the mating
connection end of the lamp assembly housing to the docking station,
the lamp assembly is removably mechanically coupled and the fixed
contacts of the first plug connector interengage with the fixed
contacts of the second plug connector to provide power to the
illuminating lamp.
11. A roadway luminaire as defined in claim 10, wherein the fixed
contacts of one of the first and second plug connectors are
blade-type contacts which are received in mating blade receiving
socket contacts.
12. A roadway luminaire as defined in claim 10, wherein the docking
station attaching means is a slip-fitter clamp.
Description
FIELD OF INVENTION
The present invention relates generally to luminaires for outdoor
lighting and more particularly relates to a roadway luminaire which
is easy to mount to a mast arm and easy to maintain due to a
mounting arm assembly, a twist-lock feature, a fool-proof power
plug and a plug-in replacement luminaire.
BACKGROUND OF THE INVENTION
Poles for supporting luminaires for the illumination of roadways,
parking lots and the like differ not only in that they have either
a vertical end with a mast arm or an inclined end, but also in that
the diameters of the poles vary. For example, some poles have
approximately a horizontal end, the end often being at an angle of
5.degree. to about 15.degree. to the horizontal. This variety of
pole constructions results in that luminaires are commonly
manufactured and warehoused in a corresponding variety of
constructions. Accordingly, it would be advantageous to have a
universal mounting device for mounting a luminaire to a pole or
mast arm.
Additionally, current maintenance costs associated with roadway
luminaires is extremely high. Particularly, maintenance is usually
performed by licensed electricians to replace capacitors, ballasts,
photoelectric controls, starters and complete luminaires. The
average cost to replace/install a luminaire is approximately three
times the cost of the luminaire itself, e.g. the cost of three men,
two trucks and a trailer. There have been efforts in the past to
overcome some of the maintenance problems associated with roadway
illumination. For example, U.S. Pat. No. 4,937,718 discloses a
roadway luminaire having the electrical components employed in the
lamp ballasting circuitry mounted to a door member by means of a
universal mounting bracket having a deformable planer construction.
In this way, a variety of different sized components can be mounted
using the disclosed bracket. Additionally, U.S. Pat. No. 4,538,217
discloses a flood light luminaire having all the electrical
components mounted on a removable door casting to allow for
servicing and maintenance. U.S. Pat. No. 4,791,539 discloses a
luminaire having quick-disconnect components which one mounted on
an electrical plate detachably secured to a support plate of the
luminaire. The plate includes a quick disconnect for detaching the
electrical plate from the support plate. However, maintenance of
the luminaire is still costly and replacement of components of the
ballasting circuitry is difficult and time consuming.
Another disadvantage of known roadway luminaires includes the
possibility of replacing a luminaire with one of a different
voltage. Currently, roadway lighting may be operated at voltages of
120, 208, 220, 230, 240, 277, 347 and 480 volts throughout the
world. Accordingly, it is quite possible when replacing or
repairing luminaires to use replacement parts rated for a different
voltage. Thus, it would be advantageous to provide a luminaire
which includes a means for keying the luminaire so that it can only
be replaced by a luminaire which operates at the same voltage.
Yet another disadvantage of known roadway luminaires is the "hot
wiring" of the luminaire, thus making replacement difficult and
dangerous. In most cases, rather than shutting off the power to the
roadway lighting, the lighting is repaired with power being
supplied to the luminaire. Accordingly, only licensed electricians
with proper protective gear generally perform replacements of
luminaires. Thus it would be advantageous to have a luminaire which
can be safely and easily replaced even with power being supplied to
the luminaire.
In view of the present disadvantages of currently available roadway
lighting devices, it is desirable to redesign the luminaire to be
easy to install and maintain, provide a fool-proof replacement
system which permits only luminaires of same voltage to replace a
damaged luminaire and to make installation and maintenance most
cost effective.
SUMMARY OF THE INVENTION
It is an object of the present invention to allow safe and easy
installation and maintenance of roadway luminaires.
It is a further object of the present invention to provide an
improved mounting system for a luminaire to a mast arm.
It is yet a further object of the present invention to provide a
keyed power plug receptacle for connecting the luminaire to the
power supply.
It is yet another object of the present invention to provide a
luminaire which can be mounted to a mast arm assembly utilizing a
simple twist-lock feature.
It is still a further object of the present invention to provide a
luminaire having a plug-in starter module located externally on the
luminaire housing for ease of replacement.
It is yet a further object of the present invention to provide a
luminaire including an internal leveling device for proper
positioning of the luminaire.
In accordance with the present invention, a luminaire for mounting
on a pole, and more specifically, a roadway luminaire includes a
mast mount docking station having a clamp for attaching to the pole
at one end of the docking station and a keyed coupling means
provided at an opposite end of the docking station and the
luminaire having a connecting plate provided with keyways such that
the luminaire is removably coupled to the mast mount docking
station by a twist-lock mating between the keys and key-ways of the
coupling means and connector plate. The mast mount docking station
further includes an electrical plug connector located at the
coupling end of the docking station and, the luminaire includes a
mating electrical plug connector for electrically connecting the
mast mount docking station to the luminaire. Specifically, the
supply voltage is coupled to the electrical plug connector in the
mast mount docking station and the mating electrical plug connector
in the luminaire provides the supply voltage to the ballast
circuitry and ultimately the lamp.
For ease of attachment of the mast mount docking station to the
pole, the docking station includes a plurality of knock-outs for
adapting to mast diameters of varying sizes. In this way, the mast
mount docking station can be specifically adapted such that little
space is left between the mast and the docking station to prevent
animals and the like from entering the docking station. The docking
station more specifically includes an upper mast assembly and a
lower mast assembly. The upper mast assembly includes the clamp for
attaching the docking station to the pole. The upper and lower mast
assemblies are secured together by bolts such that the electrical
plug connector mentioned above is secured therebetween.
Additionally, the docking station may include a series of inclined
steps located in the upper mast assembly to permit angles of tilt
for leveling the luminaire.
With respect to the twist-lock feature, the luminaire may be
coupled to the mast mount docking station by a 15.degree. to about
30.degree. rotational movement of the luminaire with respect to the
docking station. This rotational movement provides both electrical
and mechanical connection. More specifically, upon rotation, the
power plugs of the mast mounting docking station and luminaire,
respectively, are electrically connected and the keys of the
docking station are mechanically connected to the connector plate
of the luminaire in the same motion. The luminaire also preferably
includes a molded photoelectric control receptacle extending above
a top portion of the luminaire and a molded capacitor compartment
which extends below a bottom portion of the luminaire to provide
hand holds for performing the twist-lock mounting of the luminaire
to the docking station.
With respect to the electrical connectors, each of the connectors
is provided with a series of crenulations, each crenulation being
identified with a specific voltage rating to cover the spectrum of
all available international voltages. The twist-lock feature for
mating the connectors is provided with keyways which ensure that
only corresponding voltage rated connectors are operatively coupled
together.
The roadway luminaire of the present invention also includes a
lower housing in which the ballast circuitry is mounted to a
surface thereof such that the starter receptacle opens externally
to an assembled upper and lower housing assembly and the starter
module includes a plug-in connector to electrically couple the
starter to the receptacle without the use of tools. Likewise, the
upper housing is provided with a photoelectric control cell
receptacle integrally molded to a top surface thereof. The
luminaire includes a plug-in photoelectric cell which can be
selectively inserted into the receptacle and replaceable without
the use of tools. Lastly, the lower housing includes a cavity for
receiving a capacitor of the ballast circuitry. The capacitor is
press-fit into the cavity for insertion and/or removal without the
use of tools. Accordingly, maintenance of the luminaire is simple
and fast.
Also disclosed is a method of installing or removing a roadway
luminaire, the luminaire including a mast mount docking station for
attachment to a pole mast. The luminaire and docking station having
mating twist-lock connectors, the method comprising the step of
twisting the luminaire with respect to the docking station to
thereby mechanically couple and/or release the mating twist-lock
connectors. The method is further defined such that the luminaire
and mast mount docking station include mating power plug connectors
and wherein the step of twisting the luminaire also electrically
connects and/or disconnects the mating power plug connectors.
Lastly, a method of manufacturing a housing for a luminaire is
disclosed. Specifically, the method includes the steps of molding a
composite to form the housing including a dome section surrounding
an area of the lamp; coating an inner surface of the dome section
with urethane; vacuum metalizing the inner surface of the dome
section with aluminum; and coating the inner surface of the dome
section with acrylic to form a reflective surface.
A preferred form of the luminaire, as well as other embodiments,
objects, features and advantages of this invention, will be
apparent from the following detailed description of illustrative
embodiments thereof which is to be read in connection with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the luminaire assembly including
the mast mounting assembly with the lower door of the luminaire in
an open position formed in accordance with the present
invention.
FIG. 2 is an exploded perspective view of the luminaire assembly
formed in accordance with the present invention.
FIG. 3 is an exploded perspective view of the mast mounting
assembly including the female power plug of the luminaire formed in
accordance with the present invention.
FIG. 4 is an end view of the female power plug formed in accordance
with the present invention.
FIG. 5 is an end view of the male power plug formed in accordance
with the present invention.
FIG. 6A is a perspective view of an alternative lock-plate.
FIG. 6B is a side view of the lock-plate of FIG. 6A.
FIG. 7 is a partial cross-sectional view of the lower housing
wherein the lens is trapped under the gasket.
FIG. 8 is a longitudinal cross-sectional view of the upper
housing.
FIG. 9A is a front view of a toggle-type latch.
FIG. 9B is a side view of the latch of FIG. 9A.
FIG. 10 is a bottom view of the upper housing illustrating the
geometry of the reflective surface.
FIG. 11 is a cross-sectional view of the upper housing taken along
lines A--A of FIG. 10.
FIG. 12 is an exploded view of section B of FIG. 11.
DETAILED DESCRIPTION OF THE
PREFERRED EMBODIMENTS FIG. 1 illustrates a roadway illumination
luminaire 10 which includes an upper housing 2, a lower housing 4
and a mast mounting docking station 6. The upper housing 2 includes
two sections. The first section is the dome section 8 which
includes a lamp 12, lamp socket 14 and a reflective inner surface
16. The second section is the protective housing 18 for the
electronic circuitry and electrical components of the
luminaire.
Preferably, the upper housing 2 is formed of long-life, weather and
corrosion resistant fiber reinforced polymer construction. Known
luminaires usually include separate reflectors that are typically
stamped of aluminum and are supported in the dome portion of the
luminaire housing. In the present invention, the reflector 16 is
integrated into the upper housing 2. More specifically, the upper
housing is preferably a compression molded composite with the
reflective surface geometry 51 being formed during the molding
process.
The preferred embodiments of the upper housing 2 and reflective
surface include either a natural housing finish or a simulated
metal finish. In a preferred embodiment of the upper housing 2, the
interior reflective surface 16 is base coated with a urethane, then
vacuum metalized with aluminum and top coated with an acrylic.
Thus, a reflective surface is provided on the interior of the dome
portion only and all other surfaces are unfinished. Furthermore,
the upper housing may be pigmented grey during the molding process
to achieve to simulated metal finish discussed above.
The upper housing 2 also includes a photoelectric control cell
socket for receiving a plug-in photoelectric controller 24. The
photoelectric control cell socket is integrally formed during the
molding process in a top section of the upper housing to provide
for an unobstructed line-of-sight for the photoelectric control
cell 24. The socket is preferably a standard three terminal,
polarized, locking-type socket.
As shown in FIG. 1, the luminaire also includes a lower housing or
door assembly 4 which is removably coupled the upper housing 2 via
hooks 26 (FIG. 2) and detents 28 of the lower housing 4 which
allows the lower housing or door to circuitry of the luminaire. A
common failure mode among luminaires using the circuitry of the
present invention is starter failure. In known luminaires, the
starter is generally bolted to the inside of the luminaire
requiring the luminaire to be disassembled to replace the starter.
In order to make maintenance of the luminaire of the present
invention simple and fast, the starter 63 plugs into the starter
receptacle 61 from outside the luminaire housing. The starter 63
includes male terminals 65, preferably three 1/4" faston terminals,
which are received in the mating female starter receptacle 61. In
order to further protect the starter 63 from the elements, the
starter 63 is positioned within a molded starter case 67. The
starter case and receptacle 61 preferably also include a snap-lock
feature to ensure good mating contact between the male terminals on
the starter 63 and female receptacle. The snap-lock feature is
achieved by molding snap-locks into the lower housing during
manufacture and molding corresponding mating connectors 69 onto the
starter case 67. In the preferred embodiment of FIG. 2, the starter
63, located within the starter case 67, extends downward from the
bottom of the lower housing 4 when the lower housing is in a closed
position with respect to the upper housing 2. Accordingly, the
starter 63 is protected by the luminaire from direct contact with
the elements, yet is easily and readily accessible for maintenance
purposes. Additionally, no tools are necessary when changing the
starter due to the snap-lock feature which eliminates any hardware.
Advantageously, the starter may be potted to reduce the occurrence
of temperature and vibration failure.
The ballast circuitry in the lower housing 4 is electrically
connected to the upper housing 2, i.e. the lamp socket via a
multiple pin connector (not shown). Most known luminaires have the
ballast circuitry mounted in the upper housing whereas the present
invention mounts all the components of the ballast circuit in the
lower housing. This design allows for easy maintenance when the
lower housing is swung open. Furthermore, the entire lower housing
assembly may be replaced simply by unplugging the multiple pin
connector and lifting the lower housing off the upper housing hooks
26. Alternatively, the type of luminaire can be changed by
replacing the lower housing with one having a different ballast
circuit. Accordingly, the maintenance procedure for the luminaire
of the present invention is greatly simplified. To repair a failed
luminaire, the maintenance worker would check the lamp, the
photoelectric control cell and the starter. If none of these appear
to be the problem, the entire lower housing can be replaced.
Alternatively, the entire luminaire can be replaced by twisting the
luminaire 10 off the mast mount docking station 6 and twisting on a
new one. The twist-lock feature of the present invention will be
described in greater detail below.
FIG. 3 illustrates an exploded view of the mast mount docking
station 6 formed in accordance with the present invention. The mast
mount docking station 6 includes an upper mast assembly 64 and a
lower mast assembly 66. The mast mount docking station is
preferably formed of precision die cast aluminum. The upper mast
assembly 64 is secured to the pole mast by a clamp 68 which is
attached to the upper mast assembly by a pair of bolts (not shown).
The mast mount docking station 6 is capable of receiving 11/4"
through 2" pipe without rearrangement of the clamp or bolts. The
upper mast assembly 64 also includes a series of inclined steps 70
for receiving the end of the pole mast. The inclined steps are
provided to allow angles of tilt for leveling the luminaire 10 with
respect to a horizontal plane to produce maximum light to the
surface below.
Furthermore, the upper and lower mast assemblies 64, 66 are
provided at one end with a thin wall section 72 which may be
removed, similar to a "knock-out" in a junction box, thereby
allowing the mast mount docking station to receive mast arms of
different dimensions and to provide a relatively close fit
therewith to prevent animals from entering the mast mount docking
station. The upper and lower mast assemblies are provided at the
opposite end with a keyed connector 73, 75 for mating connection
with the twist-lock plate 46 shown in FIGS. 1 and 2.
FIG. 3 also illustrates a power plug connector 74 for receiving the
electrical power conductors to operate the luminaire. The power
plug connector 74 is a female connector and includes three snap-in
receptacle terminals which receive the power conductors and are
secured thereto by a screw on the side of the terminal. FIG. 4 is
an end view of the female power plug connector 74. The plug serves
as a receptacle for the male plug connector 36 of the luminaire
(FIGS. 1 and 2). The outer circumferential edge of the female power
plug is provided with a series of crenulations 76, each identified
with a different voltage rating. The plug is designed so that the
intended voltage rating of the power supply is oriented in a
vertical position (along center line 75) to thereby identify the
proper voltage for the particular luminaire to be coupled thereto.
The female receptacle includes three receiving slots 78 which are
generally circular in shape and have a radially extending portion
of the slot for receiving the terminals of the corresponding male
plug positioned in the luminaire. The male plug 36, shown in FIG.
5, includes a corresponding set of crenulations 82 and voltages
associated with each. Thus, it will be readily apparent that the
luminaire is for a specific voltage supply and will be connected
only to a corresponding voltage female plug connector.
The twist-lock feature of the present invention is provided by the
interface between the mast mount docking station 6 and the
luminaire 10, such that the male and female plugs 37, 74,
respectively, are electrically connected upon the mechanical
connection of the luminaire 10 to the mast mount docking station 6.
Preferably, the twist-lock is accomplished by a rotational movement
of the luminaire with respect to the mast mount docking station
ranging from about 15.degree. to about 30.degree.. The twist-lock
feature provides both electrical connection between the male and
female plugs as well as mechanical connection of the luminaire to
the mast mount docking station. Furthermore, the twist-lock feature
provides for fool-proof voltage matching between the power source
and the luminaire attached thereto. Specifically, the key/keyways
of the mast mount docking station and locking plate of the
luminaire are designed so that only corresponding voltage male and
female plugs may be electrically connected. Additionally,
mechanical stops are provided at the key/keyway interface for
providing a stop against over mechanical rotation.
Accordingly, the luminaire of the present invention is simple to
install due to the two piece design, i.e., the mast mount docking
station 6 and the luminaire fixture 10, which are electrically and
mechanically connected via a twist-lock feature. Also, once the
mast mount docking station is installed, repair and/or replacement
of the luminaire is simplified and can be done "hot" since the
power is connected to the luminaire by means of the mating power
plugs. Furthermore, general maintenance of the luminaire has also
been simplified by eliminating all unnecessary hardware, e.g.
providing a plug-in photoelectric control cell, a plug-in starter,
and a lower housing door latch which requires no tools to open.
Additionally, the design of the lower housing which includes the
ballast circuitry can easily be electrically disconnected form the
upper housing by unplugging a swing open exposing the inner portion
of the upper housing and an inner surface of the lower housing. The
lower housing 4 includes mounted thereon the ballast circuitry to
electrically power the luminaire. The lower housing is capable of
swinging to a closed position enclosing the luminaire and is held
closed via a latch 32. Preferably, the latch 32 can be released
without the use of tools to open the luminaire for repair and
maintenance.
Also shown in FIG. 1 is a lock-plate 46 which is fitted into the
upper housing at its mounting end. More specifically, in a first
embodiment, the lock-plate 46 is held by a pair of
triangular-shaped bosses 45 attached to the side walls of the upper
housing to provide a slot between the bosses 45 and a rear wall 47
of the upper housing 2. The lock-plate 46 is then slidingly fitted
in the receiving slot of the upper housing. The lock-plate 46
includes a central opening and a series of keyways associated with
the central opening for receiving the mast mount docking station
herein. The inter-relationship of the lock-plate with the mast
mount docking station will be described later in greater
detail.
In a second embodiment, the lock-plate 46, as shown in FIGS. 6A, 6B
and 8, includes a series of tabs 49 extending perpendicular to a
surface of the lock-plate for mating connection with a power plug
36. In this embodiment, the lock-plate 46 is adhesively bonded to
the upper housing at its mounting end. The lock-plate 46 of the
second embodiment similarly includes a central opening and a series
of keyways associated therewith, the function of which is the same
as the first embodiment, i.e., receiving the mast mount docking
station.
Referring to FIG. 2, the luminaire 10 is illustrated in an exploded
view showing each of the components in the luminaire. Specifically,
FIG. 2 illustrates the upper housing 2 having the integrally formed
photoelectric control cell socket and hooks 26 for engagement with
the detents 28 of the lower housing 4. The upper housing 2 also
includes a flange 35 surrounding the dome section in which an
adhesive-backed felt or Dacron-polyester gasket 34 can be fitted.
The gasket 34 provides a "breathing seal" gasketing between the
lens 35 of the lower housing 4 and the lamp compartment 8 of the
upper housing 4 to allow superior filtration.
In an alternate embodiment, the gasket 34 is fitted to the lower
housing as illustrated in FIG. 7. Specifically, the gasket 34 is
positioned such that the lens and the edge portion of the lower
housing are trapped beneath the gasket.
The upper housing 2 also provides a mounting surface for a power
plug 36. In the embodiment shown in FIG. 2, the power plug 36 is a
male plug which is held in position within the upper housing by
means of a u-shaped clamp 38. Alternatively, the power plug
includes a series of tabs which matingly connect with the series of
tabs provided on the lock-plate 46 illustrated in FIG. 6. Thus, the
clamp 38 can be omitted reducing the number of parts and enhancing
the maintainability of the luminaire. The power plug 36 provides a
connection means from the line voltage to the luminaire ballast
circuitry. The terminals 37 of the male power plug 36 are keyed,
the purpose of which will be described later in greater detail.
The upper housing 2 is further provided at its plug connection end
with a groove for receiving an o-ring seal 42. The groove is
designed to include interference flanges 44 so that the o-ring 42
can be fixedly press-fit into the housing without the use of a
bonding agent. The o-ring seal 42 provides for a water-tight seal
between the luminaire and the mast mount docking station 6. The
functional relationship of the locking plate 46 and the mast mount
docking station 6 will be described later in greater detail.
As previously discussed, the lower housing 4 is maintained in a
closed position with respect to the upper housing by means of a
latch 32. As shown in FIG. 2, the latch comprises a latching device
39 at one end and lances 41 at the opposite end. The lances of the
latch allow the latch to be lockingly engaged into a corresponding
integrally molded receptacle (not shown) in the upper housing,
thereby eliminating the need for additional hardware to mount the
latch.
Alternatively, the latch 32 may be an external toggle-type latch,
similar to latches commonly used on a lunch box. Such a latch is
illustrated in FIGS. 9A and 9B. The latch connection boss of the
upper housing is illustrated in FIG. 8. Accordingly, no tools would
be required to open the housing assembly to access the lamp or
ballast circuitry. The toggle-type latch provides for a positive
locking means closing the upper and lower housing interface while
being simple to manufacture and operate.
FIG. 2 also illustrates that the lamp socket 14 is connected to the
upper housing 2 via a socket bracket 18. The electrical wiring from
the socket to the ballast circuitry is trapped between the upper
housing flange 35 and the gasket 34 thereby protecting the wiring
within the luminaire. Alternatively, when the gasket 34 is
positioned on the lower housing as previously described, the upper
housing flange 35 preferably includes interference ribs therein
such that the socket wiring is wedged between the ribs and the
flange walls thereby holding them securely in place. The lamp
socket 14 is preferably positioned at approximately a 15.degree.
degree angle with respect to a horizontal plane taken through the
center-line of the upper housing 2. The angled socket in
combination with the geometric design 51 of the luminaire
reflective surface produces enhanced photometric performance. More
specifically, the luminaire has true horizontal cutoff performance
in photometrics. The geometric design of the reflector 51, as
illustrated in FIGS. 10, 11 and 12, is designed to have more
uniform light distribution over a wider area. The geometric design
includes a series of substantially triangular-shaped sections to
reflect the light in a downward direction producing a wide
distribution of light to the ground. Additionally, unlike known
luminaires which include globe-style lenses, the lens 35 of the
present invention is flat, providing a sleek appearance to the
luminaire, as well as reducing the surface area exposed to the
wind. However, a globe lens may also be used with the same
advantageous results.
The lower housing 4 as shown in FIG. 2 includes molded recesses 57,
58 therein for receiving components of the ballast circuitry,
namely a ballast 52 and a capacitor 54. The ballast 52 is fixedly
attached to the lower housing by means of bolts which are received
in bosses 56 extending upwardly from a base of the lower housing 4.
The recess or cavity 58 for receiving the capacitor is dimensioned
so that the capacitor is press-fit into the cavity thereby
eliminating the need for any hardware. The capacitor cavity may
include molded ribs 62 which deflect to permit insertion and
withdrawal of the capacitor, yet provide a fit snug enough to hold
the capacitor in place. The ballast 52 and capacitor 54 are closely
fitted in the lower housing and, accordingly, the lower housing
preferably includes a heat shield (not shown) between the ballast
and the capacitor. The heat shield allows for reduced internal
distances thereby reducing the size and cost of the fixture.
The lower housing 4 further includes a starter receptacle 61
integrated therein. The starter 63 is part of the ballast connector
and being lifted off the hooks of the upper housing for simple
replacement. In the alternative, the entire luminaire can be
quickly and easily replaced simply by twisting off the old
luminaire and twisting on a new one. The luminaire of the present
invention also provides power plugs capable of being adapted to all
presently available international voltages and a fool-proof keying
system to allow only corresponding voltage luminaires to be coupled
to the mast mount docking station.
Various changes to the foregoing described and shown structures
would now be evident to those skilled in the art. Accordingly, the
particularly disclosed scope of the invention is set forth in the
following claims.
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