AU2010101532A4 - Underwater lamp - Google Patents

Abstract

An underwater light assembly 16 including a multi-chromatic light 5 within a sealed submersible housing 26. At least three conductors 88 are electrically connected to the light and extend to an exterior of the housing. A plug 22 including conductors 80 is 5 releasably connectable to the exterior of the housing. The conductors of the plug are respectively electrically connected to the conductors of the housing when the plug is so connected. A sealing arrangement prevents the ingress of water to said electrical connections. A lead 24 is sealingly engaged with the plug. The conductors of the housing, conductors of the plug and lead together define conduction paths, including a 0 respective conduction path for each colour of the light, for connecting the light to a controller 12. The light is configured to receive from the controller, and respond to, signals indicative of desired intensity for each colour of the light via the respective conduction paths. A pool lighting system 10 is also provided.

Description

P/00/01 1 Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Underwater pool light The following statement is a full description of this invention, including the best method of performing it known to us: 2 Underwater Pool Light Field of the invention The invention relates to submersible lights, e.g. submersible lights for illuminating swimming pools. 5 Throughout this specification, the term "pool" includes in its ambit any kind of confined water body in which humans can be immersed, including spas, swim spas and Japanese-style immersion tubs. Background of the invention 10 Swimming pools are from time to time provided with submersible lights to create aesthetically pleasing lighting effects. Conventional lights include a luminaire such as an incandescent bulb, or more recently one or more light emitting diodes (LEDs), within a sealed compartment. A cable extends from the compartment to a power supply to power the luminaire. The cable is typically 15 sealed into the wall of the compartment with the aid of a cable gland or over moulding. Some lights are mounted against the wall of the pool. These lights are referred to as wall mounted lights. Other lights are mounted within a small cavity in the wall of the pool. These lights are referred to as niche mounted lights. Such lights are typically installed during the construction of the pool by forming a 20 conduit from the desired location on the wall, or in the niche, towards a power supply. The cable is typically threaded through the conduit and the light fully installed well in advance of the completion of the pool. This approach has some drawbacks. Lights in situ during pool construction are prone to damage. Moreover as lights are typically relatively valuable items, lights installed on 25 unattended building sites are sometimes stolen.

3 Another approach involves installing the conduit from the light location towards the power supply at an early stage then, when the pool is close to completion, threading a separate line through the conduit, attaching an end of the line to the cable and drawing the cable through the conduit. This approach is time consuming and troublesome. 5 The cable typically carries two separate conductors, eg 2 multi-strand wires, to and from the light to power the light. In the past coloured lighting effects were created using different colour lenses over the luminair. More recently LED technology has allowed a single light to create a range of user selectable colours. According to known approaches luminaires within the sealed 10 compartment include simple logic circuits. The luminaires are configured to produce a small number of pre-selected colours, say ten or so different colours. The logic circuits store the pre-selected colours in a series and are configured to index to the next colour in the series each time the light is activated. As such the power supply provides to the light a simple single 1 bit binary signal. A user may select one of the pre-selected 15 colours by toggling the power supply on and off to activate and deactivate the light thus stepping through the series of colours until the desired colour is reached. Whilst an advance over coloured lenses, this approach has drawbacks in that the range of colours is necessarily rather limited and that each and every time one wishes use the lights they must toggle the power on and off several times in order to find the desired 20 colour. Synchronising multiple such lights so that they all present the same colour is problematic. Certain known lighting systems include a central power supply including a single switch for all of the lights, in addition to a respective switch for each light. When an individual light gets out of sequence, eg because of interference or a loose connection between it and the power supply, it is necessary to access the power supply 25 and identify the correct switch and toggle it on and off until the problematic light is again in sync with the other lights. Objects of the invention include to provide an improved underwater light assembly and an improved pool lighting system, or at least to provide alternatives for those concerned with lighting.

4 Summary of the invention Accordingly in its various aspects, the invention provides underwater light modules, underwater light assemblies, various components therefor and methods of operating underwater lights. 5 In one aspect the invention provides an underwater light assembly including: a multi-chromatic light within a sealed submersible housing; at least three conductors electrically connected to the light and extending to an exterior of the housing; a plug including conductors and being releasably connectable to the exterior of 0 the housing, the conductors of the plug being respectively electrically connected to the conductors of the housing when the plug is so connected; a sealing arrangement to prevent the ingress of water to said electrical connections; a lead sealingly engaged with the plug; 15 the conductors of the housing, conductors of the plug and lead together defining conduction paths, including a respective conduction path for each colour of the light, for connecting the light to a controller; the light being configured to receive from the controller, and respond to, signals indicative of desired intensity for each colour of the light via the respective conduction 20 paths. The light may be tri-chromatic, e.g. red-green-blue LEDs, and be connected to at least four conductors. Preferably the light is configured to receive and respond to the indicative signals by each colour of the light being powered via its respective conduction path.

5 The sealing arrangement may include one or more compressible sealing members, preferably in the form of O-ring(s). Most preferably a common sealing member is arranged about the electrical connections. Alternatively each electrical connection may have its own respective sealing member. The sealing member(s) are optionally carried 5 in respective grooves formed in the plug or the exterior of the housing. In another aspect the invention provides a pool lighting system including a controller and at least two underwater light assemblies, each underwater light assembly including: a light within a sealed submersible housing; 0 conductors electrically connected to the light and extending to an exterior of the housing; a plug including conductors and being releasably connectable to the exterior of the housing, the conductors of the plug being electrically connected to the conductors of the housing when the plug is so connected; 5 a sealing arrangement to prevent the ingress of water to said electrical connections; a lead sealingly engaged with the plug; the conductors of the housing, conductors of the plug and lead together defining conduction paths for connecting the light to a controller; 20 the controller being configured to send to each light via its conduction paths, and the lights being configured to respond to, one or more signals indicative of colour and/or intensity to vary output light whilst the lights are active. The controller is preferably configured to separately control one or more of the lights. This might involve groups of lights producing like output light wherein the groups are 6 separately controlled. Most preferably each light is separately controlled. Optionally, the controller is configured to coordinate the output light with music. Preferred versions of the system further include an illuminated waterfall controlled by the controller. A user interface might be provided in the form of a waterproof hand held remote control 5 unit by which the underwater light assemblies may be controlled by a user from any desirable location in or about the pool. Brief description of the drawings / figures The Figures illustrate preferred embodiments of the invention. Figure 1 is a schematic view of a pool lighting system. 0 Figure 2 is a rear perspective view of an underwater light assembly. Figure 3 is a rear perspective view of a plug. Figure 4 is a forward perspective view of a plug. Figure 5 is an axial cross section view of a plug. Figure 6 is a close up view of a portion of Figure 5. 15 Figure 7 is a front view of a plug. Figure 8 is a side view of a plug. Figure 9 is a rear view of a plug. Figure 10 is a front perspective view of an underwater light module. Figure 11 is an exploded view of the module of Figure 10 and a portion of the pool wall 20 to which it is in use mounted.

7 Figure 12 is a rear perspective view of the module of Figure 10. Figure 13 is a side view of the module of Figure 10. Figure 14 is a front view of the module of Figure 10. Figure 15 is an axial cross section of the mounting components of the module of Figure 5 10. Figure 16 is a close up view of a portion of Figure 15. Figure 17 illustrates the installation of the module of Figure 10. Figure 18 illustrates the installed appearance of the module of Figure 10. Figure 19 is an axial cross section view of the module of Figure 10. 10 Figure 20 is a side view of the module of Figure 10 when installed. Figure 21 is a front perspective view of an underwater light module in accordance with a second embodiment of the invention. Figure 22 is an exploded view of the module of Figure 21. Figure 23 is a side view of the module of Figure 21. 15 Figure 24 is a front view of the module of Figure 21. Figure 25 is an axial cross section view of the module of Figure 21. Figure 26 is a close up view of a portion of Figure 25. Figure 27 is a close up view of a portion of Figure 25. Figure 28 illustrates the installation of the module of Figure 21.

8 Figure 29 is a schematic view of a pool lighting system. Detailed description of the embodiments Figure 1 schematically illustrates a pool lighting system 10 in accordance with a preferred embodiment of the invention. The system 10 includes a controller 12 arranged 5 to control and power four underwater light modules 14 via respective leads 24. The system 10 includes a user interface 11 by which a user may input variables ('user variables') indicative of the desired lighting conditions. As will be described, the controller 12 directly controls the colour and intensity of the lighting modules 14 via the leads 24 and releasable sealed plug arrangements. This 10 approach produces a lighting system which is convenient to install and use. The underwater light module 14 is shown in cross section in Figure 19. It includes an underwater light assembly 16 and mounting components 32. The light assembly 16 and its plug 22 are illustrated in Figures 2 to 9. Note: the connection between the lead 24 and the to be described connector 76, internal to the plug 22, is not shown in figure 5. 15 The underwater light assembly 16 includes two principal components: a housing 26 and the plug 22. The housing 26 includes an annular body 18 formed from injection moulded plastic. The annular body defines a circular opening at each end and includes a radial flange about its forward end. A circular metallic heat sink 20 spans and sealingly connects to the rearward opening of body 18 to close the rearward opening. 20 A plurality of recesses 38 are formed about the periphery of the heat sink 20. The body 18 includes complementary alignment tabs 36 which project rearwardly to engage the recesses 38 to aid in assembly. Axial internally threaded bosses 34 are spaced around the periphery of the body 18. A complementary array of holes extends through the heat sink 20. Screws are passed through these holes to engage the bosses 34 to retain the 25 heat sink 20. An O-ring 21 is captured between opposing faces of the annular body 18 and the heat sink 20 and clamped in place to form an effective watertight seal. The 0 ring 21 (see figure 19) is concentrically aligned with the body 18 and sits radially inward from the screws retaining the heat sink 20.

9 The opening at the forward end of body 18 is closed by a lens 42. The lens 42 has an outwardly domed form. As best illustrated in figure 19 the lens 42 has rearwardly projecting annular skirt about its periphery. The skirt is received and bonded within a complementary annular groove formed in a forward face of the annular body 18. 5 The heat sink 20, annular body 18 and lens 42 together define a sealed watertight compartment 4. A light 5 is mounted within the compartment 4 on an internal surface of the heat sink 20. In this embodiment the light 5 takes the form of red green blue (RGB) LEDs and associated electronics. RGB LEDs are a form of tri-chromatic light. Tri-chromatic lights 0 have 3 colours which combine to form a desired shade, referred to herein as 'output light'. Of course it is contemplated that other forms of light might be employed. Whilst this embodiment employs RGB LEDs other tri-chromatic, as well as various dichromatic and tetra chromatic arrangements might be employed. As illustrated in figures 2 and 19 a boss 40 projects rearwardly from the heat sink 20. 5 The plug 22 is mounted to a rearward face of the boss 40. The plug 22 includes an over moulded body 82 carrying a connector 76 and the lead 24. The body 82 is preferably a hard PVC of about 70 duro. The connector 76 is set back within a forwardly opening cavity 78 and includes 4 pins 80 which project forwardly into the cavity 78. The cavity 78 is broadly cylindrical and coaxially aligned with the plug. 0 20 ring groove 72 is formed in a forward face 79 of the plug 22 and is arranged concentrically with the cavity 78. The groove 72 carries an 0-ring 74. The groove 72 is dimensioned so that 0-ring 74 in its free condition projects slightly beyond the face 79. When the plug 22 is mounted on the rearward face of the boss 40 the O-ring 74 bears against the rearward face and is compressed into the groove 72 to form an effective 25 circular seal against the rearward face of boss 40. Figure 26 illustrates the connection of the plug 22 to the boss 40 in the context of a second embodiment of underwater light module 14'. The described module embodiments share a common underwater light assembly 16.

10 As illustrated in Figure 26 the boss 40 carries a connector 86 which projects rearwardly. The connector 86 defines 4 sockets complementary to the pins 80. When the plug 22 and boss 40 are mated the pins 80 engage the sockets 88. As such respective electrical connections are formed between the pins 80 and sockets 88. In this embodiment the 0 5 ring 74 constitutes a common compressible sealing member encircling all 4 electrical connections. It is also contemplated that rather than a common, single, 0-ring a separate sealing member may be provided about each connection. Returning to figures 5 to 9, a forward end of the plug 22 terminates in a radial flange 23. An array of 6 axially extending through holes 84 is formed about the flange 23. The 0 flange 23 has a contoured outer profile. The boss 40 of the heat sink 20 has a complementary contoured out profile. A metallic retaining plate 28 overlies a rearward face of the flange 23. The plate 28 has an outer profile corresponding to the contoured shape of the flange 23. A centre portion of the plate 28 is cut out whereby the plate embraces the body 82 of the plug 22. The plate 28 includes an array of holes 5 complementary to the holes 84. Screws 30 pass through the holes of plate 28, through the holes 84 and engage respective blind threaded bores in the boss 40. Thus the flange 23 is clamped in place and the plug 22 is thus retained. As best illustrated in figure 7 the array of holes 84 is non circular and asymmetric to prevent the plug being assembled at an incorrect orientation. 20 Grooves 88 are formed along side portions of the body 82 of the plug 22 giving it a degree of flexibility to reduce strain on cable 24 as it exits the body 82. Blind cut outs 86 in face 79 reduce the material bulk of the flange 23. Figures 13 to 20 illustrate the underwater light module 14 and its installation. This particular embodiment is intended for use in a fibreglass pool. Fibreglass pools are 25 relevantly characterised by their relatively thin wall structure. As previously mentioned the module 14 includes the underwater light assembly 16 and mounting components 32. The mounting components 32 include an outer lens 46, dress ring 48, outer housing 54, O-ring 58 and collar 60. Figure 11 also shows dress ring 11 components 50 and 52 which together form a two part dress ring. This two part dress ring is a cosmetic alternative to the dress ring 48. The outer housing 54 has a broadly tubular form and is open only at its forward end. A cable gland 44 extends in a radial direction from a rear end of the outer housing 54. As 5 will be described the light assembly 16 is received within the forward end of the outer housing 54 and its cable 24 leaves outer housing 54 via the gland 44. Figures 15 and 16 illustrate the installation of the mounting components 32 in the wall of a pool. The outer housing 54 includes a radial flange about its forward end and an external thread about its body. Initially an appropriately sized hole is cut in the pool wall 0 56. The outer housing 54 is then passed in a rearward direction through the hole. An 0 ring 58 is passed over the rearward end of the outer housing 54 followed by the collar 60. The collar 60 includes an internal thread complementary to the external thread of the outer housing 54. Circumferential beads of silicon adhesive 64 are applied about the outer housing 54 immediately fore and aft the wall 56. The collar 60 is then engaged 5 with the external thread about the body 54 and tightened to advance the collar 60 towards the wall 56. A forward extent of the collar 60 includes an annular groove for receiving the O-ring 58. As the collar 60 is further tightened the O-ring 58, beads of silicon 64 and wall 56 are compressed between the radial flange 68 and the collar 60. At this point the plug 22 and lead 24 may be installed through the gland 44. Turning to 20 figure 17, sometime later the housing 26 can be installed. The plug 22 is fastened to the heat sink as previously described and the outer periphery of the housing 26 (defined by the annular body 18) is seated within the forward end of the outer housing 54. The dress ring 48 carrying the outer lens 46 is then placed over the housing 26 and outer housing 54. 25 The dress ring 48 includes three counterbored screw holes. Screws are passed through these holes, through complementary holes in the annular body 18, and into additional complementary holes in the outer housing 54. By tightening these screws the underwater light assembly 16 is retained within the underwater light module 14, and the module 14 presents an attractive outward appearance as illustrated in figure 18.

12 Figure 20 illustrates additional plumbing associated with the cabling. A conduit 66 extends upwardly from the gland 44 to a draw box 68. A second conduit 70 extends from the draw box 68 towards the controller 12. The draw box 68 is open to atmosphere above the water level of the pool. This prevents water siphoning from the pool to the 5 controller. Figures 21 to 28 illustrate an alternative form of underwater light module 14'. This module is configured to be mounted within the wall of a concrete pool. The underwater light module 14' includes an underwater light assembly 16 in common with the underwater light module 14, and mounting components 32'. The mounting components 0 32' include a forward outer housing 54A and a rear outer housing 54B which together perform an analogous function to the outer housing 54. Like the outer housing 54, the rear outer housing 54B has a broadly tubular form which is open only at its forward end. With reference to figure 28, the outer housing 54B has a simple tubular wall at its forward end, the extremity of which is flush mounted within the concrete of the wall of 5 the pool. The forward outer housing 54A has a short tubular form and includes an outward radial flange 62' arranged in front of a plurality of outwardly projecting circumferential ribs. After the rear outer housing 54B has been installed the forward outer housing 54A is fitted into the forward end of the rear outer housing 54B. The circumferential ribs of the forward outer housing 54A bear against an interior of the rear .0 outer housing 54B. The radial flange 62' bears against an outer surface of the concrete. The flange 62' is then tiled over with tiles 56B. Once the housing components 54A and 54B are installed, the lead 24 and plug 22, then the housing 26 may be installed and retained by a dress ring 48' carrying an outer lens in a manner analogous to the foredescribed embodiment. 25 When so installed the sockets 88 of the housing 26, the pins 80 of the plug 22 and the lead 24 define 4 conduction paths between the controller 12 and the light 5. According to the described embodiments three of these conduction paths respectively carry signals indicative of a desired intensity of a respective colour. The fourth conduction path defines a common or return path.

13 This four conduction path releasable plug arrangement has substantial advantages in that it allows for the housing 26 to be installed well after the plug 22 and, as will be described, much greater control over the lighting effects produced by the light modules 14'. 5 The controller 12 and the underwater light modules 14 are configured to cooperate via pulse width modulation. The controller 12 sends to the light via each of the three conduction paths an 8 bit signal indicative of the desired intensity of the respective colour. As such 2563 different signal states, each corresponding to a respective different colour/intensity, are available. This correspondence, or 'mapping', between the 0 controller's signals and the colour/intensity of the output light allows the controller to directly control the output light without feedback (e.g. from a user) regarding the colour/intensity of the output light. The pulse width may be varied to dynamically change from one colour to any other colour in contrast to prior art arrangements in which a user must step through the colours sequentially by activating and deactivating the light. 5 This vast array of colours is a substantial improvement over the limited number of colours available to the end user from prior art devices. This arrangement also overcomes the difficulties associated with synchronising lights - because the controller 12 directly controls the colour of each light, rather than simply sending a simple on or off signal, a minor interruption or interference along one of the cables 24 will not result in a 20 light falling out of sync with the other lights. This approach also allows for a vast array of lighting effects whereby the lights are separately controlled, ie wherein each light receives a signal which is optionally independent from the signals received from the other lights. As such the controller may control the lights to have different colours, optionally in some coordinated fashion. This approach also allows the lighting effects to 25 be dynamically varied. The dynamic variation might involve coordinating the lighting with music and/or to produce fade, rainbow and/or disco effects. The user interface 11 might take on a variety of forms. According to preferred forms of the invention the user interface is constituted by a conventional personal computer. Optionally, the user interface 11 may be constituted by, or cooperate with, a remote 14 control. This would conveniently allow for the lighting conditions to be controlled from any convenient location in or about the pool. Figure 29 schematically illustrates a preferred form of pool lighting system 10' including its controller 12'. 5 The controller 12' includes a user panel 17 which includes an LCD display and a key pad by which a user may input user variables indicative of a desired lighting effect. The user panel 17 may co-operate with a personal computer. A control line 19 extends from the user panel 17. The control line 19 connects the user panel 17 to control modules 13A to 13P. Each control module is in turn connected to 0 two underwater light modules via each light module's respective leads 24. The user panel 17 transmits via the control line 19 power and data to the modules 13A to 13P. The data includes an indication of an address and a respective desired output light for each address. In this embodiment the address is a 4 bit signal corresponding to 16 unique addresses each uniquely mapped to a respective control module. 15 Each module 13 includes 4 binary microswitches by which it may be manually assigned its respective address. The modules are configured to receive from the user panel 17, via the control line 19, data indicative of desired output light corresponding to the modules' assigned address. The modules take the data and power from the control line 19 and apply logic to produce the signals to control and power each module 14 via its 20 lead 24. As previously described, it is preferred that each lead includes a respective conduction path for each colour of the light and that the light is controlled via pulse width modulated signals transmitted along these conduction paths, but of course other modes of power and data transmission are possible. Accorded to the illustrated embodiment each module 13 is connected to a pair of 25 underwater light modules 14. The light modules 14 within each pair receive a like signal from their module 13 and as such cannot be controlled independently of each other.

15 In this embodiment the modules 13 are packaged in pairs in respective control boxes 15A to 15H. It is also contemplated that control modules could be connected in series to allow more underwater light modules 14 to be controlled. For safety reasons it is desirable that each underwater light module 14 is independently 5 earthed via its module 13. It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.

Claims (12)

1. An underwater light assembly including a multi-chromatic light within a sealed submersible housing; at least three conductors electrically connected to the light and extending to an 5 exterior of the housing; a plug including conductors and being releasably connectable to the exterior of the housing, the conductors of the plug being respectively electrically connected to the conductors of the housing when the plug is so connected; a sealing arrangement to prevent the ingress of water to said electrical 0 connections; a lead sealingly engaged with the plug; the conductors of the housing, conductors of the plug and lead together defining conduction paths, including a respective conduction path for each colour of the light, for connecting the light to a controller; 15 the light being configured to receive from the controller, and respond to, signals indicative of desired intensity for each colour of the light via the respective conduction paths.

2. The underwater light assembly of claim 1 wherein the light is tri-chromatic and there are at least four conductors connected to the light. 20

3. The underwater light assembly of claim 1 or 2 wherein the sealing arrangement includes one or more compressible sealing members.

4. The underwater light assembly of claim 1, 2 or 3 including a common sealing member about the electrical connections. 17

5. The underwater light assembly of claim 3 or 4 wherein the sealing member(s) is an 0-ring.

6. The underwater light assembly of claim 3, 4 or 5 wherein each sealing member(s) is carried in a respective groove formed in the plug. 5

7. A pool lighting system including a controller and at least two underwater light assemblies, each underwater light assembly including: a light within a sealed submersible housing; conductors electrically connected to the light and extending to an exterior 10 of the housing; a plug including conductors and being releasably connectable to the exterior of the housing, the conductors of the plug being electrically connected to the conductors of the housing when the plug is so connected; a sealing arrangement to prevent the ingress of water to said electrical 15 connections; a lead sealingly engaged with the plug; the conductors of the housing, conductors of the plug and lead together defining conduction paths for connecting the light to a controller; the controller being configured to send to each light via its conduction paths, and 20 the lights being configured to respond to, one or more signals indicative of colour and/or intensity to vary output light whilst the lights are active.

8. The system of claim 7 wherein each underwater light assembly is the underwater light assembly of any one of claims 1 to 6. 18

9. The system of claim 7 or 8 wherein the controller is configured to separately control one or more of the lights.

10. The system of claim 7, 8 or 9 wherein the controller is configured to coordinate the output light with music. 5

11. The system of any one of claims 7 to 10 further including an illuminated waterfall controlled by the controller.

12. The system of any one of claims 7 to 11 including a user interface in the form of a waterproof hand held remote control unit by which the underwater light assemblies may be controlled by a user from any desirable location in or about the pool.