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Title:
LUMINAIRE JOINING SYSTEM
Document Type and Number:
WIPO Patent Application WO/2022/235922
Kind Code:
A1
Abstract:
A luminaire joining system includes an end bracket, nut joining ring, and fastener. The end bracket includes an end face, semi-frustoconical protrusion, passage, and nut cavity. The semi -frustoconi cal protrusion laterally abuts the end face. The passage is defined in the semi-frustoconical protrusion. The passage opens laterally at the end face. The nut cavity is defined in the end bracket. The nut cavity is in communication with the passage. The nut cavity opens laterally at the end face. The nut is positioned in the nut cavity of the end bracket. A portion of the nut extends away from the end bracket beyond the end face. The joining ring is positioned over the semi-frustoconical protrusion. A portion of the joining ring extends away from the end bracket beyond the end face. The fastener extends through the joining ring and the passage of the semi-frustoconical protrusion. The fastener threads into the nut.

Inventors:
CONROY MICHAEL (US)
Application Number:
PCT/US2022/027856
Publication Date:
November 10, 2022
Filing Date:
May 05, 2022
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
HLI SOLUTIONS INC (US)
International Classes:
F21V15/015; F21S8/06; F21V21/008
Foreign References:
US20190264882A12019-08-29
US20160076743A12016-03-17
US20170030564A12017-02-02
US20060138921A12006-06-29
JP2016502255A2016-01-21
Attorney, Agent or Firm:
HAUSMAN, Garrett, M. (US)
Download PDF:
Claims:
CLAIMS

What is claimed is:

1. A luminaire joining system comprising: an end bracket including an end face, a semi-frustoconical protrusion laterally abutting the end face, a passage defined in the semi-frustoconical protrusion, the passage open laterally at the end face, and a nut cavity defined in the end bracket, the nut cavity in communication with the passage, the nut cavity open laterally at the end face; a nut positioned in the nut cavity of the end bracket, a portion of the nut extending away from the end bracket beyond the end face; a joining ring positioned over the semi-frustoconical protrusion, a portion of the joining ring extending away from the end bracket beyond the end face; and a fastener extending through the joining ring and the passage of the semi-frustoconical protrusion, the fastener threaded into the nut.

2. The luminaire joining system of claim 1, wherein the end bracket is a first end bracket, the luminaire joining system further includes a second end bracket abutting the first end bracket, and the nut, the joining ring, and the fastener cooperate to hold the first end bracket and the second end bracket together.

3. The luminaire joining system of claim 2, wherein the second end bracket is identical to the first end bracket.

4. The luminaire joining system of claim 2, wherein the first end bracket further includes a male section, and the second end bracket includes a female section receiving the male section of the first end bracket.

5. The luminaire joining system of claim 4, wherein the male section of the first end bracket is a first male section, the female section of the second end bracket is a second female section, the first end bracket further includes a first female section, the second end bracket further includes a second male section, and the first female section receives the second male section.

6. The luminaire joining system of claim 2, wherein the end face is a first end face, the semi-frustoconical protrusion is a first semi-frustoconical protrusion, the passage is a first passage, the nut cavity is a first nut cavity, and the second end bracket further includes a second end face, a second semi-frustoconical protrusion laterally abutting the second end face, a second passage defined in the second semi-frustoconical protrusion, the second passage open laterally at the second end face, and the second nut cavity defined in the second end bracket, the second nut cavity in communication with the second passage, the second nut cavity open laterally at the second end face.

7. The luminaire joining system of claim 6, wherein the nut occupies at least a portion of each of the first nut cavity and the second nut cavity.

8. The luminaire joining system of claim 7, wherein the joining ring is positioned over both he first semi-frustoconical protrusion and the second semi-frustoconical protrusion.

9. The luminaire joining system of claim 8, wherein each of the first passage and the second passage has a cross-sectional shape of half of a circle, such that the first passage and the second passage cooperate to form a passage having a circular cross-section.

10. The luminaire joining system of claim 6, wherein the first end face and the second end face contact each other with the nut, the joining ring, and the fastener holding the first end bracket and the second end bracket together.

11. The luminaire joining system of claim 6, wherein a separation gap is present between the first end face and the second end face with the nut, the joining ring, and the fastener holding the first end bracket and the second end bracket together.

12. An end bracket for use with a luminaire joining system, the end bracket comprising: a head section including a semi-frustoconical protrusion, a passage defined in the semi-frustoconical protrusion, and a nut cavity defined in the head section, the nut cavity in communication with the passage; and two legs extending from the head section, each leg including at least one of a rail and a slot for slidably interfacing with a luminaire housing.

13. The end bracket of claim 12, wherein the head section further includes at least one of a rail and a slot for slidably interfacing with the luminaire housing.

14. The end bracket of claim 12, further comprising an end face, the end face defining a side of each of the head section and the two legs.

15. The end bracket of claim 14, wherein an axis of the semi-frustoconical protrusion lies in a plane that is coplanar with the end face.

16. The end bracket of claim 15, wherein the passage has a semi-circular cross-sectional shape, a diameter of the semi-circular cross-sectional shape passing through the axis.

17. The end bracket of claim 12, wherein the semi-frustoconical protrusion includes an angled outer surface, such that the semi-frustoconical protrusion narrows as the semi-frustoconical protrusion extends in a direction away from the head section.

18. The end bracket of claim 17, wherein the semi-frustoconical protrusion narrows as the semi- frustoconical protrusion extends in the direction away from the head section toward a plane passing through both of the two legs.

19. The end bracket of claim 18, wherein the semi-frustoconical protrusion is a first semi-frustoconical protrusion, the direction is a first direction, and the end bracket further includes a second semi-frustoconical protrusion, the second semi- frustoconical protrusion narrowing as the second semi-frustoconical protrusion extends in a second direction, the second direction being opposite the first direction.

20. The end bracket of claim 19, wherein at least a portion of the second semi-frustoconical protrusion is wider than the first semi- frustoconical protrusion.

Description:
LUMINAIRE JOINING SYSTEM

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63/184,874, filed May 6, 2021, the entire contents of which are incorporated herein.

FIELD

[0002] Embodiments described herein relate to a joining system for luminaires.

SUMMARY

[0003] The present disclosure relates, in one aspect, to a luminaire joining system. The luminaire joining system includes an end bracket, a nut, a joining ring, and a fastener. The end bracket includes an end face, a semi-frustoconical protrusion, a passage, and a nut cavity. The semi -frustoconi cal protrusion laterally abuts the end face. The passage is defined in the semi- frustoconical protrusion. The passage opens laterally at the end face. The nut cavity is defined in the end bracket. The nut cavity is in communication with the passage. The nut cavity opens laterally at the end face. The nut is positioned in the nut cavity of the end bracket. A portion of the nut extends away from the end bracket beyond the end face. The joining ring is positioned over the semi-frustoconical protrusion. A portion of the joining ring extends away from the end bracket beyond the end face. The fastener extends through the joining ring and the passage of the semi-frustoconical protrusion. The fastener threads into the nut.

[0004] The present disclosure relates, in another aspect, to an end bracket for use with a luminaire joining system. The end bracket includes a head section and two legs. The head section includes a semi-frustoconical protrusion, a passage, and a nut cavity. The passage is defined in the semi-frustoconical portion. The nut cavity is defined in the head section. The nut cavity is in communication with the passage. The two legs extend from the head section. Each leg includes at least one of a rail and a slot for slidably interfacing with a luminaire housing. [0005] Other aspects of the embodiments will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 illustrates a perspective cross-sectional view of a luminaire joining system installed on a frame of a luminaire, according to embodiments described herein.

[0007] FIG. 2 illustrates an end bracket, or end header, of the luminaire joining system of FIG. 1.

[0008] FIG. 3 illustrates another perspective view of the end bracket of FIG. 2.

[0009] FIG. 4 illustrates a perspective view of another end bracket, or end header, of a luminaire joining system, according to embodiments described herein.

[0010] FIG. 5 illustrates another perspective view of the end bracket of FIG. 4.

[0011] FIG. 6 illustrates a perspective view of a joining ring of the luminaire joining system of FIG. 1.

[0012] FIG. 7 illustrates a perspective view of the luminaire joining system of FIG. 1 installed on the frames of two adjacent respective luminaires.

[0013] FIG. 8 illustrates a perspective view of the luminaire joining system and two frames of FIG. 7 moved into alignment.

[0014] FIG. 9 illustrates a perspective view of the luminaire joining system and two frames of FIG. 8 with the joining ring and fastener positioned to be installed.

[0015] FIG. 10 illustrates a detailed perspective view of the luminaire joining system, two frames, joining ring, and fastener of FIG. 9 fully joined.

DETAILED DESCRIPTION

[0016] Current designs for joining luminaires require the luminaires to be at least partially disassembled at a job site in order to join the luminaires to each other. Multiple screws or other fasteners are often needed. These fasteners extend through the ends of two adjacent luminaires at parallel to the support surface (such as a ceiling and the fasteners extending horizontally) or some other angle. This requirement for the fasteners can make access to the required locations in the luminaires quite difficult. Also, the luminaires must be reassembled after the joining process is completed. This time-consuming disassemblyjoining, and reassembly often leads to improper or aesthetically undesirable alignment of adjacent luminaires due to the reliance on multiple fasteners extending at multiple locations. Each aperture through which a respective fastener extends has its own tolerance, and these tolerances can add up to affect the overall alignment of the adjacent luminaires.

[0017] With reference to FIG. 1, a luminaire joining system 100 is shown. The luminaire joining system 100 includes an end bracket, or end header, 102, a nut 104, a fastener 106, and a joining ring 108. In some embodiments, the luminaire joining system 100 includes a single fastener 106 (e.g., screw, bolt, or the like), thereby reducing the likelihood of alignment issues between adjacent luminaires.

[0018] As shown in FIG. 1, the end bracket 102 is sized and shaped to slide into an end of a luminaire housing 110 and be trapped therein. In some embodiments, a detent mechanism and/or one or more teeth, stops, surfaces, or the like may trap the end bracket 102 in place upon installation in the end of the luminaire housing 110. In some embodiments, removal of the end bracket 102 may require a tool, key, or the like. The end bracket 102 may include one or more slots 112 that are configured to receive corresponding rails 114 (shown in FIG. 1) of the luminaire housing 110. Similarly, the end bracket 102 may include one or more rails 116 that are configured to be received in corresponding slots 118 of the luminaire housing 110. This interface between the end bracket 102 and the luminaire housing 110 ensures proper positioning of the end bracket 102 relative to the luminaire housing 110, thereby allowing proper alignment of two adjacent luminaires. In the illustrated embodiment, the end bracket 102 further includes a head section 120 and two legs 122 extending therefrom. The head section 120 couples to the luminaire housing 110 adjacent a base side 124 of the luminaire housing 110. The two legs 122 extend away from the head section 120 in a direction toward the light emission side 126 of the luminaire housing 110. In this manner, the illustrated embodiment of the end bracket 102 occupies three sides of the luminaire housing 110 to provide strength at the joint between two adjacent luminaires. The shape of the end bracket 102 allows for access to and use of a majority of the space on the end of the luminaire. As such, internal components of the luminaire need not be rearranged in most embodiments.

[0019] Turning now to FIGS. 2 and 3, the illustrated end bracket 102 further includes a nut cavity 128 for housing the nut 104. The nut cavity 128 may be formed as a slot accessible from a side of the end bracket 102. In this manner, the nut 104 may be removably placed in the nut cavity 128 of the end bracket 102. As shown in FIGS. 1 and 7, the nut 104 may be of a shape that does not allow the nut 104 to rotate in the nut cavity 128 relative to the end bracket 102. This feature allows a user to install the fastener 106 with a single tool such as, for instance, a screwdriver without the need for a wrench to hold the nut 104 in place. A benefit of a removable nut 104 is that the nut 104 may be replaced as needed if, for instance, the threads of the nut 104 were stripped or the nut 104 has been damaged in some other way. Of course, other embodiments may include the nut 104 permanently trapped in the end bracket 102 once the nut 104 has been placed in the nut cavity 128. Still other embodiments may include the nut 104 being welded or otherwise permanently attached to the end bracket 102. Some embodiments may even include a tapped hole defined in the end bracket 102 instead of the inclusion of a separate nut 104 to be connected to or trapped within the end bracket 102.

[0020] Returning to FIGS. 2 and 3, the illustrated end bracket 102 further includes a semi- frustoconical protrusion 130, that is, half of a truncated cone, with a corresponding passage 132 defined axially therethrough. An end face 134 of the end bracket 102 lies in a plane that is incident with an axis A1 of the semi-frustoconical protrusion 130 and of the passage 132. A diameter of the base of the semi-frustoconical protrusion 130 is also coplanar with the end face 134. This arrangement allows the end faces 134 of two adjacent end brackets 102 to mate up to each other (as shown in FIG. 8) for joining two adjacent luminaires. Note that, while the end faces 134 of adjacent end brackets 102 may contact each other once the luminaire joining system 100 is fully installed, some embodiments do not require the end faces 134 contact each other. Instead, some embodiments may provide a separation gap between the adjacent end faces 134. In such embodiments, the end faces 134 may represent a plane that truncates the semi-frustoconical protrusion 130 slightly short of the half-way point of the geometry of the frustocone (such as by 1 millimeter, for instance). This separation gap can be advantageous in that it allows for less precise tolerances during manufacturing. While the protrusion 130 is illustrated as a semi- frustoconical protrusion, other embodiments may include a protrusion of a different geometric shape such as, for instance, a semi-frustopyramidal protrusion. In such embodiments, the semi- frustopyramidal protrusion is formed as a pyramid that is truncated such that the tip is omitted and also truncated such that the pyramid shape is cut in half along an axis of the pyramid. The frustopyramidal shape formed by two mating end brackets may be a triangular pyramid, rectangular pyramid, pentagonal pyramid, hexagonal pyramid, or the like.

[0021] With reference to FIG. 7, each end bracket 102 may further include a male section 136 and a female section 138. The male section 136 and the female section 138 are arranged such that two end brackets 102 may mate together and touch each other at the end faces 134 of the end brackets 102. The interface of male section 136 and female section 138 between end brackets 102 may further align the end brackets 102 with each other, thereby further ensuring proper alignment of two adjacent luminaires. The male and female sections 136, 138 may be located anywhere along the end bracket 102 adjacent the end face 134, but the illustrated embodiment includes the male and female sections 136, 138 located on respective legs 122 of the end bracket 102. This arrangement is advantageous because the semi-frustoconical protrusion 130 will serve as an anchor location that holds two end brackets 102 together (discussed further below), so the added interconnection between the legs 122 of adjacent end brackets 102 offers further stability to the joining system 100. Also, the illustrated embodiment further has the benefit of utilizing identical end brackets 102 in the joining system 100. As such, the joining system 100 may be mass produced more easily and at a lower cost than if the joining system 100 required two end brackets 102 that are different in shape from one another.

[0022] Before discussing the installation of the luminaire joining system 100 and the subsequent joining of two luminaires in detail, it should be understood that the present disclosure does not contemplate only the end brackets 102 shown in FIGS. 1-3 and 7-10.

[0023] With reference to FIGS. 4 and 5, another embodiment of an end bracket 202 is shown. Many features of the end bracket 202 are similar to those discussed above with regard to the first embodiment of an end bracket 102. As such, these similar features may not be explicitly discussed, with their reference numerals being a value of one hundred higher than the corresponding feature of the end bracket 102 discussed above.

[0024] As shown in FIG. 4, the end bracket 202 may include a head section 220 that does not project in a direction away from the legs 222 beyond the semi-frustoconical protrusion 230. Instead, the semi-frustoconical protrusion 230 is the highest point of that side of the end bracket 202. Further, the end bracket 202 may have a different overall geometry than the end bracket 102 above. This different overall geometry is because the end bracket 202 is configured to join luminaires of a different type, model, brand, etc. than those which the end bracket 102 is configured to join. Lastly, the end bracket 202 further illustrates that the overall end bracket 202 may have a greater depth dimension than is shown with regard to the end bracket 102. This greater depth dimension is measured in a direction that is perpendicular to the end face 234, and it may offer greater strength in the joint between two luminaires. This greater strength may be advantageous with regard to larger sized luminaires, heavier luminaires, luminaires in windy conditions, or the like.

[0025] Both illustrated embodiments allow the installer to access the fastener 106 from a light emission side 126 of the luminaire housing 110. This arrangement is advantageous in that luminaires that are wall mounted or ceiling mounted do not require the installer to access base side 124 of the luminaire housing 110. The end bracket 202 illustrated in FIGS. 4 and 5, however, further includes a second semi-frustoconical protrusion 242 facing a direction opposite the first semi-frustoconical protrusion 230. The two semi-frustoconical protrusions 230, 242 may be the same size and angle, or they may have different sizes and/or angles. The nut 104 can be inserted in the nut cavity 228 regardless of which semi-frustoconical protrusion 230, 242 will receive the joining ring 108. This arrangement allows the installer to choose which way to place the joining ring 108 and the fastener 106, either from the base side 124 of the luminaire housing 110 or from the light emission side 126. Of course, other embodiments may include only a semi- frustoconical protrusion accessible from the base side 124 of the luminaire housing 110. Such embodiments can be useful for, for instance, hanging luminaires.

[0026] With reference to FIG. 6, the joining ring 108 is shown. The joining ring 108 has a passage 140 defined centrally therein and passing through an axis A2 of the joining ring 108. The joining ring has an angled inner surface SI that is configured to engage an angled outer surface S2 of the semi-frustoconical protrusion 130. The angled inner surface SI, particularly in the illustrated embodiment, can draw adjacent end brackets 102 together in both the lateral direction as well as the height direction, effectively aligning the end brackets 102 in multiple directions and, thereby, the luminaire housings 110. The joining ring 108 further includes a flat surface S3 (shown on FIG. 9) that is on an opposite side of the joining ring 108 from the angled inner surface SI. This flat surface S3 acts as a washer to receive force from the fastener 106 once the fastener 106 is tightened down into the nut 104. In some embodiments, however, the joining ring 108 may include protrusions and/or recesses on this side.

[0027] Turning now to FIGS. 7-10, a process of using the luminaire joining system 100 to couple two adjacent luminaires (illustrated as only the luminaire housings 110) will be discussed. With regard to FIG. 7, an end bracket 102 has been slidably placed in the end of each of two respective luminaire housings 110. The nut 104, which is illustrated as being rectangular in outer shape for ease of installation and retention, is placed in the nut cavity 128 of one of the end brackets 102. As shown in FIG. 8, the two luminaire housings 110 and, therefore, the two end brackets 102 are moved toward each other until the end faces 134 of the end brackets 102 are adjacent one another. In the illustrated embodiment, this configuration also includes the female section 138 of each end bracket 102 receiving the corresponding male section 136 of the other end bracket 102. Also in the illustrated embodiment, the remaining half of the nut 104 that is exposed in FIG. 7 is inserted in the nut cavity 128 of the second end bracket 102, such that roughly half of the nut 104 is in each of the two nut cavities 128. In FIG. 9, the joining ring 108 is placed over the two adjacent semi-frustoconical protrusions 130 such that the angled inner surface SI of the joining ring 108 contacts the angled outer surface S2 of each of the two adjacent semi-frustoconical protrusions 130. The fastener 106 is then hand threaded to start the engagement of the fastener 106 and the nut 104. As shown in FIG. 10, the fastener 106 is fully tightened down into the nut 104, thereby forcing the joining ring 108 down onto the two adjacent semi-frustoconical protrusions 130. This action causes the angled inner surface SI of the joining ring 108 to transfer force into the angled outer surface S2 of each of the two adjacent semi- frustoconical protrusions 130, thereby pulling the two semi-frustoconical protrusions 130 closer together. This pulling causes the two adjacent end brackets 102 to move closer together, thereby causing the two adjacent luminaire housings 110 to move closer together. The two adjacent luminaire housings 110 are now joined. Because none of the steps cause a permanent change in any of the components, the steps may be performed in reverse in order to separate the luminaire housings 110 without causing damage.

[0028] Although certain aspects have been described in detail with reference to the above disclosed embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects as described. Various features and advantages are set forth in the following claims.