HK1114153A - Highly reflective lighting fixture visor that doubles as glare shield - Google Patents

Description

High-reflectivity lighting appliance protective cover also used as light shield

Cross Reference to Related Applications

This application claims priority from U.S. provisional application serial No. 60/644,517, filed on 2005, month 1, 18, in accordance with 35u.s.c. § 119, which is incorporated herein by reference in its entirety. This application is also a non-provisional application of the following provisional U.S. applications, all of which were filed on 18/1/2005: u.s. serial No. 60/644,639; u.s. serial No. 60/644,536; u.s. serial No. 60/644,747; u.s. serial No. 60/644,534; u.s. serial No. 60/644,720; u.s. serial No. 60/644,688; u.s. serial No. 60/644,636; u.s. serial No. 60/644,609; u.s. serial No. 60/644,516; u.s. serial No. 60/644,546; u.s. serial No. 60/644,547; u.s. serial No. 60/644,638; u.s. serial No. 60/644,537; u.s. serial No. 60/644,637; u.s. serial No. 60/644,719; u.s. serial No. 60/644,784; U.S. serial No. 60/644,687, each of which is incorporated herein by reference in its entirety.

Incorporation by reference

The contents of the following U.S. patents are incorporated by reference in their entirety: 4,816,974, respectively; 4,947,303, respectively; 5,161,883, respectively; 5,600,537, respectively; 5,816,691, respectively; 5,856,721, respectively; 6,036,338.

Background

Technical Field

The present invention relates to lighting fixtures that produce a high brightness, controlled, focused beam of light for relatively distant targets. In particular, the present invention relates to such lighting fixtures, methods of their use, and their use in systems where a plurality of such fixtures are used in combination, typically elevated on poles, in combination efficiently illuminating a target area, with reduced glare and spill (spill) light, and capable of reducing capital and/or operating costs. One main example is the illumination of stadiums.

Background

This general configuration of the sports lighting fixture 2 has remained relatively unchanged for many years because it is a relatively economical and durable design. Recently, sports lighting has also had to deal with the problem of glare and leakage of light. For example, if light is transmitted outside the area of a stadium, it may miss residential houses near the stadium. Moreover, high brightness lights can cause glare to the occupants of these premises or create safety issues for drivers on nearby roads. Some communities have legislated to control how much glare or leakage light can be generated by sports lighting or other large areas of outdoor lighting. There are also a number of attempted remedial measures that result in blocking, absorbing, or otherwise reducing the amount of light entering the field. This not only increases the cost of the lighting system due to glare or leakage light control measures, but also in some cases requires additional fixtures to meet minimum light quantity and uniformity specifications. And therefore incur more expense to compensate for the loss of light in terms of glare and leakage light control measures. In some cases, it may even require more expense and/or additional posts to support the additional appliance.

Thus, competing interests and issues present challenges to sports lighting designers. Some of these benefits and problems may be inconsistent with one another. For example, the need for more economical sports lighting always exists. On the other hand, glare and leakage light control actually increase cost and/or reduce the amount of light that can be used to illuminate the field. The designer has to balance a number of factors such as cost, durability, size, weight, wind load, life, and maintenance issues, to name a few. Attempts to improve the prior art have focused primarily on various discrete aspects of sports lighting. For example, computerized design of lighting systems attempts to minimize hardware costs and system installation costs, but using conventional luminaire technology, there are their drawbacks. Also, lamps with larger lumen output produce more light using only conventional fixture technology. Accordingly, there remains a need for improvements in sports lighting in the prior art.

Disclosure of Invention

One problem solved by the present invention is the efficient generation of light. This has several implications. One is to reduce the amount of energy required to achieve a certain light level and uniformity at the target. Yet another is the ability to increase the amount of useful light for a target from a given energy.

The present invention also solves other environmental problems. Many lighting applications require not only a certain amount and brightness of light in and above a target space, but also a degree of uniformity through the target space. In the examples discussed above, some lighting fixtures are elevated around the perimeter of a target space and their beams are directed at different locations in an attempt to obtain the desired brightness and uniformity across the target space. It is difficult to achieve that no light falls outside the target space, especially at the edges of the target space. Such leakage light and glare may have environmental impact. This can lead to "light pollution" of neighboring assets (neishmounting property). This can create safety issues, for example, by obscuring the view of the driver or pedestrian on the road or passageway around the light. The invention thus solves the problem of leakage light and glare.

The present invention also provides the ability to select different configurations to meet different needs of lighting applications. For example, the characteristics of the lighting system may be selected to achieve a lower capital cost for the lighting system. Some features may be selected to reduce operating costs. Some characteristics may be selected to reduce glare and leakage of light. Some characteristics may be selected to increase the amount of light or mass in and above the target space and/or the performance of the system. The invention allows focusing on only one of the above listed characteristics or a combination thereof.

Objects, features, or advantages of the invention

It is therefore a primary object, feature, or advantage of the present invention to provide a high brightness lighting fixture, method of use thereof, and incorporation thereof into a lighting system that ameliorates or solves some of the problems and deficiencies of the art.

Other objects, features, or advantages of the present invention include an apparatus, method, or system that can achieve one or more of the following:

a) the energy consumption is reduced;

b) for a fixed energy, increasing the amount of light available at each appliance;

c) more efficient use of light generated at each fixture relative to the target area;

d) glare and leakage light with respect to a target space or area can be reduced;

e) the Effective Projected Area (EPA) of windage or individual appliances or groups of appliances can be reduced, which can allow for smaller and/or less expensive overhead structures (e.g., poles), which in turn can substantially reduce the capital cost of the lighting system.

Examples of the invention

In another aspect of the invention, the additional reflective surface extends forward from the rotating general surface of the main reflective surface and is also made of a high reflectivity material. In contrast to conventional protective covers (visors), which are used primarily for blocking light, the reflective surface not only serves to block light that may be glare or leakage light, but also redirects light that would otherwise be wasted to the target area efficiently and in a highly controllable manner. The frame supporting the additional reflective surface can be connected to the frame of the main reflective surface in an integrated manner that also reduces the wind resistance of the entire device.

In yet another aspect of the present invention, an apparatus, method, and system are provided that substantially reduce glare or leakage light from one or more apparatus for a given application or target space.

These and other objects, features, advantages and aspects of the present invention will become more apparent with reference to the appended description and claims.

Drawings

Fig. 1A-F show a typical sports lighting system.

Fig. 2A-E illustrate one type of arc tube that can be used with the present invention.

Fig. 3A and B illustrate one type of arc lamp that can be used with the arc tube of fig. 2A-E.

Fig. 4 is an exploded perspective view of an exemplary embodiment according to the present invention.

Fig. 5A and 5B are different views of the device of fig. 4 with a first exemplary embodiment of a protective cover (sometimes referred to as a short protective cover) according to the present invention.

Fig. 6A and 6B are similar to fig. 5A and 5B, but for a second exemplary embodiment of a protective cap (sometimes referred to as a long protective cap) according to the present invention.

Fig. 7A is a side-by-side perspective view of the two protective covers of fig. 5A and 6A attached to the reflector frame, and also shows some examples of high reflectivity reflective strips mounted on the underside of the protective covers.

Fig. 7B is a partial perspective view showing the leftmost protective cover of fig. 7A connected to the reflector frame.

Fig. 8A and 8B are additional perspective views of the leftmost reflector of fig. 7A.

Fig. 9A and 9B are additional perspective views of the rightmost reflector of fig. 7A.

Fig. 10A and 11A-D are views of protective cover reflective insert upper and lower rails, respectively, mountable on the inside of a protective cover, capable of attaching high reflectance reflective insert strips such as shown in fig. 7A-9A.

Fig. 12A-D show a protective cover conversion clip secured to the inside of the protective cover for conversion between different sets of reflective inserts at different levels.

FIG. 13 is a plan view of a bottom protective cover attachable to the lens frame of FIG. 23A;

FIG. 14 is a plan view of a protective cap extension that may be connected to the bottom protective cap of FIG. 13 to form the short protective cap of FIG. 7A;

FIG. 15 is a plan view of a protective cap extension that may be connected to the bottom protective cap of FIG. 13 to form the elongated protective cap of FIG. 9A;

FIGS. 16A-C illustrate an example of a longer protective cover insert;

FIGS. 17A-C are various views of a specially configured end reflective protective cover insert that may be positioned on opposite sides of a protective cover;

FIGS. 18A and 18B are alternative embodiments of a reflective protective cover insert;

19A-C are alternative embodiments of opposing end reflective protective cover inserts that may be used with the reflective insert of FIG. 18A;

FIGS. 20A-C are views of a protective cap insert holder for the protective cap insert of FIGS. 16A and 17A;

FIGS. 21A-C are views of a protective cover insert holder that may be used with the reflective insert of FIGS. 18A and 19A;

FIGS. 22A-C are views of the protective cover insert assembly alignment bracket;

FIGS. 23A-F are lens frames for use with the above devices;

fig. 24A-E, 25A and 26A-C show components of a lens frame clamp.

Detailed Description

Exemplary apparatus

Fig. 4A shows some of the basic components of the sports light fixture 10 in an exploded form. Fig. 5A and B show their perspective form after assembly. The appliance 10 has some general components similar to state of the art sports lighting appliances, but introduces some different structural components and concepts.

The reflector frame 30 (cast aluminum type 413) is bolted to the lamp cone 40. The frame for the glass lens 32 (fig. 23A) is removably latched to the front of the reflector frame 30. A protective cover 70 may be mounted to the lens frame and extend from above and forward of the reflector frame 30 when in place. Which includes some high reflectivity strips on the interior 72 thereof.

As can be seen by comparing FIG. 5A to FIG. 6A, the protective cap 70 can take on different shapes and forms. The first version of protector cap 70A (FIG. 5A) is shorter and does not extend as far forward and downward as the second version of protector cap 70B (FIG. 6A). Both have the same base which extends from the reflector frame 30 initially at a small convergent angle. The distal extension is connected to the base and angles back inwardly toward the central axis of the reflector frame 30. The shorter protective cover 70A employs a shorter extension than the longer protective cover 70B. For example, protective cover 70B is useful when implement 10 is aligned at an angle close to horizontal. It blocks and redirects more light than protective cover 70A, which would otherwise be deflected away from the target area.

As shown in fig. 4, a protective cap 70 may be attached to the appliance 10. A high total reflectivity material is mounted on the interior or downwardly facing side 72 thereof. Substantially outside the protective cover 70 is a protective covering layer of high reflectivity material that it supports. Fig. 5A, 6A, and 7-9 illustrate two general forms of protective caps 70 that may be employed.

Each form of protective cover 70 is substantially larger in size than many existing protective covers, increasing the overall size of the appliance 10. However, their shape and configuration have been designed to actually reduce wind loads of the order of 40% over conventional appliances. The length, shape and edges of protective cover 70 are designed to enhance the EPA of the entire appliance 10. They are cost-effective and have excellent reflection efficiency.

Two general forms of protective cap 70 are shown (see, for example, short protective cap 70A of fig. 5A and long protective cap 70B of fig. 6A). Both begin with a bottom protective cover portion 240 (fig. 13) that is riveted, bolted, or otherwise attached to the lens frame 230. The second or outer protective cover portion, either the short protective cover portion 250 (FIG. 14) or the long protective cover portion 260 (FIG. 15), is riveted, bolted, or otherwise attached to the bottom protective cover 240.

The bottom protective cover portion 240 is attached to the lens frame 230 (with the glass lens 3 mounted). Fig. 24, 25 and 26 show details of components for some of the lens frame clips 233, which lens frame clips 233 are capable of latching the lens frame 230 to the reflector frame 30. A lens frame 230 (fig. 23A) generally mates the peripheral opening with the reflector frame 30. The bottom protective cover portion 240 is welded or riveted into the slit 232 of the lens frame 230 and is supported by the arm 234. The slit 236 supports the glass lens 3. The slit 238 allows connection to the reflector frame 30. Lens gasket 231 cushions and seals glass lens 3 in slit 236.

A built-in extrusion (extrusion) on the exterior of the lens frame 230 provides a mounting flange for the protective cover 70. When mounted thereon, the bottom protective cover portion 240 is at an angle (20 degrees) to the lens frame 230 and reflector frame 30. Some latches 242 (see fig. 5 and 6 showing the latches 242 in the latched state and some of the components used to make the latches in fig. 24-26) allow the lens 34/protective cover 70 combination to be securely and easily removed and remounted to the reflector frame 30.

As can be seen in fig. 8, a plurality of side-by-side, high reflectivity reflector inserts (e.g., some of the reflective inserts 252 of fig. 16A) are riveted or otherwise secured to the inside of the bottom reflector 240 and to the reflector 250. Alternatively, the upper rail 254 and lower rail 256 may be attached to proximal and distal locations on the inside of the protective cover combination 240/250 with some reflective protective covers fitted into slots 255 and 257, respectively, and then riveted or bolted into place. One or more radial support brackets 258 (see fig. 20A-C) may be attached back to the front of the protective cover combinations 240 and 250 to provide more rigidity to the upper and lower protective cover reflective insert rails 254 and 256.

The reflective insert 252 on the protective cover 70 may be the same material as the reflector insert 120 for the primary reflective surface 32 described above. Alternatively, they may be flat reflector portions with surface variations that produce diffusion of the mixed light. For example, they may have facets or steps (e.g., hammer points or dots). They may also have areas of lower reflectivity or non-reflective areas (e.g., painted light black) that can block or absorb light relatively easily (see muscco u.s. patent 6,036,338 for additional details).

Specially shaped end reflective inserts 253 can be positioned on the side edges of the opposite sides of the protective cover 70 (see fig. 17A-C). End reflective inserts 262 may be placed on the underside of the longer combination of protective covers 240/260 (see fig. 18A-B). End insert 263 is similar to end insert 253, but is configured for a shorter protective cover 250/260 (see fig. 19A-C).

The reflective insert may be attached directly to the underside of the protective cover combination 240/260. Alternatively, they may be connected to appropriately configured upper and lower rails, such as 254 and 256 (FIGS. 20-22), which are connected to the underside of reflector 70. In certain cases, there may be a transition between reflective inserts. Fig. 12 illustrates a conversion fixture 264 and fig. 21A-C illustrate an insert support bracket 268 that would be attached first to the underside of the reflector 70, followed by the reflective insert being mounted to the reflector 70.

The surface characteristics of the reflective inserts 252, 253, or 263 can be selected, mixed, and matched depending on the type of light manipulation required. As can be seen from the figures, the reflective insert strips may have different widths, lengths and surfaces. Some may be smooth, some may be pimpled, as shown, or become less conspicuous or diffuse light. The inserts may also be stepped along their longitudinal axis.

The protective cover 70 serves both to block and redirect light that would otherwise be off target. The high reflectivity material used for the reflective surface of the protective cover reduces light loss and thus provides more light to the target area, even beyond the existing protective covers with a certain reflectivity. It provides significant optical gain compared to conventional protective covers that merely block or absorb most or all of the light impinging thereon.

Further, it should be understood that other variations of the reflector 70 are possible. Some examples are shown in U.S. patent 5,211,473 to muscco. Examples of these types of protective covers are available from Musco Inc. including LEVEL8^TMIncluding various trade names. They provide varying degrees of glare or leakage light control. They can be selectively added to the appliance 10. Some of the variations shown in U.S. patent 5,211,473 are for substantially reducing glare and leakage light. Some include a louver spanning the protective cover. If used with the protective cover 70 of the present embodiment, the appliance 10 will still have good efficiency and not have as much optical loss (e.g., a rotating aluminum reflector) as the type of appliance disclosed in U.S. patent 5,211,473. Other variations are described and illustrated herein.

The shape of the protective cover 70 is designed to achieve several functions. First, it supports the highly reflective insert in a manner that controls leakage and glare. Second, it supports the reflective insert in a manner that minimizes optical losses and can increase the light reaching the target. Third, its shape generally minimizes the projected area of the protective cover and implement to produce a lower drag coefficient. Fourth, it accomplishes these functions in a relatively low cost but efficient manner.

Even if the overall size of the appliance 10 is larger than some conventional similar appliances, the wind resistance is reduced by 40% or more. Leakage and glare can be controlled not only with the protective cover 70, but also with some other feature disclosed herein, if used (e.g., lower initial output intensity, side shifting, reflective surfaces that highly control the direction of light). This can allow for the use of cheaper rods, which can effectively reduce the overall cost of the lighting system. Less wind resistance means that the strength of the pole that raises these appliances can be less.

Even if glare and leakage are not an issue because of the improved EPA of the appliance, the protective cover 70 can be used, which can reduce the cost of the wand. It has excellent efficiency and relatively low cost. This is particularly beneficial for outdoor sports lighting.

It is understood that the present invention can take many forms and embodiments. Variations that are obvious to those skilled in the art are intended to be included in the present invention. The scope of the invention is to be determined entirely by the claims, rather than by the specific embodiments herein.

These figures illustrate one way of making the protective cap 70. The aluminum sheet bottom reflector is attached to the lens frame (fig. 13). A frame of aluminum or sheet metal is made (fig. 10A-D). Some reflective insert strips and sheets are mounted to the frame (fig. 11A-D). The frame with attached reflective insert is attached to the bottom reflector (fig. 12A-D). The protective cover extension, either a short piece of aluminum or a long piece (fig. 15), is then attached to the subassembly of fig. 12A-D.

Claims (8)

1. A high intensity lighting fixture for increasing useable light to a target area without increasing energy usage, comprising:

a. a reflector frame mountable on the lamp cone and comprising a bowl-shaped outer surface, an inner surface comprising mounting structure for the reflective surface, and a main opening over which the glass lens can be mounted;

b. a protective cover mounted on and extending outwardly from the top of the reflector frame, having an outer side and an inner side;

c. a very high total reflectance reflective surface mountable to the inside of the protective cover and adapted to redirect incident light generally downward when the implement is in an operative position relative to a target area;

d. at least one louver spanning a portion of the reflector frame.

2. The lighting fixture of claim 1, wherein the protective cover inner side is adapted to support a high total reflectance reflective surface extending outwardly from the reflector frame.

3. The lighting fixture of claim 1, wherein the protective cover reflective surface extends forward and above the lamp when the fixture is in an operating position.

4. The lighting fixture of claim 1, wherein the protective cover reflective surface extends about or greater than 180d degrees around a longitudinal axis of the lamp.

5. The lighting fixture of claim 1, wherein the protective cover reflective surface is a different shape than a major portion of the reflective surface.

6. The lighting fixture of claim 1, wherein the protective cover reflective surface redirects light generally downward to a target area when the fixture is in a working position.

7. A method for high intensity illumination of a target area, comprising:

a. adding an extension structure to a lighting fixture, the extension structure having at least a portion that intercepts a portion of the light output of the fixture;

b. the shape, length, and width of the extended structures are designed to (i) intercept light that can cause glare or leakage of light, and (ii) reflect material with a very high total reflection coefficient to redirect at least some of the light to a target area.

8. The method of claim 7, further comprising selecting a shape, configuration, size and reflective properties for the very high total reflectance reflective surface as needed or desired for glare and leakage control without substantially reducing and/or increasing the amount of light to and/or to the target space.