EP3301346A1

EP3301346A1 - Clamping system for luminaire electronic drivers

Info

Publication number: EP3301346A1
Application number: EP17193986.1A
Authority: EP
Inventors: Balazs SZIRMAI; Balazs Meszaros; Imre PAYER; Andras Sinka
Original assignee: GE Lighting Solutions LLC
Current assignee: Current Lighting Solutions LLC
Priority date: 2016-09-30
Filing date: 2017-09-29
Publication date: 2018-04-04

Abstract

A tool-less clamping fixture 20 that provides mechanical fixation and improved heat removal from electronic drivers 24a,24b in luminaires 70. In some embodiments, the clamping fixture 20 includes at least one geartray plate 10, 30a, 30b with an opening 10a sized for inserting one or more electronic drivers 24a, 24b. The geartray plate 10, 30a, 30b may also include a pattern of predefined cutouts 11a-11e, 32a, 32b, 33a, 33b, 34a, 34b on opposite sides of the opening 10a. One or more flexible strips 12a, 12b, 40, 42 are then used to grip the electronic drivers 24a, 24b by forming a grip-connection with corresponding cutouts in the geartray plate 10, 30a, 30b to fix the position of the electronic drivers 24a, 24b (having the same or different shapes and sizes) and to provide a continuous force biasing the drivers 24a, 24b towards a heat sink 22. The result is improved heat removal from the luminaire 70 of heat generated by the electronic drivers 24a, 24b, and the tool-less clamping fixture 20 also significantly reduces assembly time and thus reduces costs as compared to conventional fixtures.

Description

TECHNICAL FIELD

The invention generally relates to lighting systems. More particularly, but not exclusively, the invention relates to a flexible tool-less fixture for fixing of and improving heat removal from electronic drivers in luminaires.

BACKGROUND OF THE INVENTION

There is a high demand and an emerging need for luminaires such as LED (light emitting diode) fixtures to be able to operate at high temperatures, for example at ambient temperatures of about fifty degrees centigrade (50°C) to about sixty degrees centigrade (60°C) or greater. The electronic drivers can generate a lot of heat during operation of the luminaire which must be dissipated before the temperature within the LED lighting fixture (or luminaire) exceeds a critical temperature that forces the electronic drivers to shut down to protect itself from overheating. Effective cooling of the electronic driver has proven to be a challenging problem, and thus more effective approaches for cooling electronic drivers in luminaires are desired.
Another important feature in the design of a luminaires is to provide easy, fast and tool-less (i.e., without using any tools) fixation or attachment of one or more electronic drivers during assembly of the luminaire. Conventional methods, such as using fasteners (such as screws, rivets, and the like) tend to be slow, inefficient and sometimes require extra effort to replace and/or repair electronic drivers. For example, pop-rivets may be used to affix an electronic driver to a luminaire. But the use of pop-rivets requires using a riveting machine, an alignment procedure, and the use of additional fasteners and/or rivets. To affix one electronic driver may require a few rivets, and may require at least two people to properly position and/or align the driver during assembly. In addition, riveting machine maintenance may be required along with initial preparations involving pre-cutting spots on the housing of the luminaire to accept rivets. In addition, in some cases the riveting process may fail, for example, if the paint used on the housing is too thick because a typical riveting pistol is set to a certain air pressure which may not be sufficient in such cases. Thus, if the pop-rivets are improperly installed, their holding force could be insufficient resulting in the electronic driver falling off the housing of the luminaire. Thus, more reliable, easier and less costly approaches for attaching the electronic driver during assembly of a luminaire would be desirable.

SUMMARY OF THE INVENTION

Presented is a tool-less clamping fixture for providing mechanical fixation and improved heat removal from electronic drivers in luminaires. In some embodiments, the clamping fixture includes at least one geartray plate having an opening configured for inserting one or more electronic drivers. Some embodiments of the geartray plate also include a pattern of predefined cutouts on opposite sides of the opening. One or more flexible strips are then used to grip the electronic driver(s) by forming a grip-connection across the opening, in some embodiments by using corresponding cutouts in the geartray plate, to fix the position of the electronic drivers (having the same or different shapes and sizes). The flexible strip(s) also provide a continuous force that biases the drivers towards a heat sink. Such an assembly results in improved heat removal of the heat generated by the electronic drivers from the luminaire. In some embodiments, the tool-less clamping fixture decreases the electronic driver temperature by approximately 15-20% while also significantly reducing assembly time and costs in comparison to conventional fixtures.
In some embodiments, when an electronic driver is inserted through the opening in the geartray plate to contact a top portion of the heat-sink in a luminaire, the predefined tool-less procedure includes aligning the first tab of the flexible strip along a first side of the electronic driver near a first side of the geartray plate opposite an outward cutout formed on the other side of the opening, and then inserting the first tab under the geartray plate. Next, the second tab of the geartray plate is inserted into the outward cutout such that the at least one concave portion of the flexible strip contacts a top portion of the electronic driver. An assembler then slides the first and second tabs of the flexible strip along a bottom portion of the geartray plate in a direction towards the first cutout and the second cutout on opposite sides of the opening, and locks the flexible strip in place by aligning the first tab with the first cutout and the second tab with the second cutout to provide a secure connection.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and aspects of the present disclosure will become better understood when the following detailed description is read, with reference to the accompanying drawings, in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 is an example of a geartray plate and two identical flexible strips in accordance with an embodiment of the invention;
FIG. 2 is an exemplary side view of a tool-less clamping fixture having two electronic drivers mounted on a heat sink of a luminaire according to an embodiment of the invention;
FIGS. 3A-3B are exemplary views of two geartray plates having different cutout patterns in accordance with some embodiments of the invention;
FIG. 4 is a perspective view of a flexible strip in accordance with some embodiments of the invention;
FIGS. 5A-5F are perspective views of a clamping fixture to illustrate a step-by-step tool-less assembly procedure according to some embodiments of the invention;
FIG. 6A is a perspective view of a clamping fixture assembly including a geartray plate, two electronic drivers and two flexible strips according to an embodiment of the invention;
FIG. 6B is a perspective view of the clamping fixture assembly of FIG. 6A installed within a luminaire according to an embodiment of the invention;
FIG. 7 is a cross-sectional view of a luminaire having a tool-less clamping fixture installed therein in accordance with an embodiment of the invention; and
FIGS. 8A-8F are top views of various electronic driver and flexible strip configurations (geartray plates not shown) in accordance with some embodiments of the invention.

DETAILED DESCRIPTION

A new tool-less clamping fixture, for providing mechanical fixation of and improved heat removal from electronic drivers in luminaries, such as LED luminaries and/or outdoor luminaries, is presented. In some embodiments, the clamping fixture includes at least one geartray plate with an opening for inserting electronic drivers, and contains a pattern of predefined cutouts along a perimeter of the opening. Some implementations include specially shaped flexible strips operable to grip electronic drivers by forming a grip-connection with corresponding cutouts in the geartray plate to fix the position of the electronic drivers (having the same or different shapes and sizes). Such a connection may also provide a continuous force necessary for improving the removal of heat generated by the electronic drivers, away from the luminaire. Thus, some embodiments of the devices presented herein provide an approximately 15-20% decrease in the electronic driver temperature as compared to conventional systems, while at the same time significantly reducing assembly time and assembly costs.
According to one embodiment, a geartray plate can have an opening that may have a rectangular shape, or a "T" shape or the like, with a predefined pattern of outward cutouts on at least two opposite sides of the opening. In addition, the geartray plate may include two or more flexible strips, having the same or different dimensions, wherein each may have bended wavy shaped portions. The flexible strips can be utilized to provide a continuous pretension (i.e., a spring-like force effect) for holding the one or more electronic drivers when assembled by forming a grip-connection of two lip-like portions for each of the two or more flexible strips at corresponding outward cutouts of the predefined pattern of outward cutouts. In some embodiments, a tool-less procedure and/or assembly method can be used, wherein no tools are used.
According to some embodiments, one or more electronic drivers can be placed on a top of a heat-sink part (e.g., an external housing) in the luminaire and inserted through an opening and engaged with the geartray plate, such as a rectangular opening in the geartray plate. The one or more electronic drivers can be further assembled using any of the two or more flexible strips placed on the top of the electronic drivers using a tool-less assembly procedure described herein (see FIGS. 5A-5F) to facilitate the grip-connection between the two or more flexible strips and the geartray plate, by leaving an air gap between a bottom of the geartray plate and a top of the heat-sink part. When a corresponding distributed downward force is applied on a top surface of the geartray plate to press the one or more electronic drivers towards the top of the heat sink part, the tool-less clamping fixture can provide both a mechanical fixation of, and an improved heat removal from, the one or more electronic drivers.
According to some embodiments, the predefined pattern of outward cutouts on each of the at least two opposite sides of the opening may include: a) two or more outward cutouts at predetermined distances from each other, each cutout on one of the at least two opposite sides has a symmetrical cutout on another of the at least two opposite sides, and b) one or two further outward cutouts at one or both of at least two opposite sides having a deeper cutout depth by a predefined margin as compared to any of the two or more outward cutouts in a).
According to some embodiments, each of the two or more flexible strips may include: a) a top portion having an overall length substantially equal to a distance between the two opposite sides of the opening in the geartray plate and having one or more bended downward, wavy shaped portions, to provide a continuous pretension on a surface beneath the top portion; b) two side portions bent approximately ninety degrees downward from two ends of the top portion, each of the two side portions having at least one bended inward wavy shaped portion to provide a continuous pretension on a side surface perpendicular to the surface beneath the top portion; and c) two bottom portions comprising the two lip-like portions bent approximately ninety degrees inward from two ends of the two side portions, so that a length of the two lip-like portions is larger than a depth of the two or more outward cutouts to provide the grip-connection, but smaller than the cutout depth of the one or two further outward cutout to provide the tool-less assembly.
According to yet further embodiments, the geartray plate can include a further predefined pattern of outward cutouts on two other opposite sides of the opening (such as a rectangle), so that the further predefined pattern of outward cutouts can be further used to facilitate a further grip-connection when at least one further strip of the two or more flexible strips is placed on the top of the electronic drivers perpendicular to the (already placed) any of the two or more flexible strips using the tool-less assembly to facilitate the further grip-connection between the at least one further strip of the two or more flexible strips and the geartray plate.
In some embodiments, various materials can be used for the aforementioned components. For example, the geartray plate can be made of a metal or a plastic material with a desired strength property, or of a composite material. The flexible strips can be made of a metal material or a plastic material or a composite material with a desired spring property.
The figures described below provide non-limiting examples for practicing various embodiments of the invention. It is noted that identical or similar parts/elements are designated using the same reference numbers in different figures.
FIG. 1 depicts an exemplary view of a geartray plate 10 with a generally rectangular-shaped opening 10a having cutouts 11a, 11b, 11c, 11d and 11e, and two identical flexible strips 12a and 12b. It should be understood that these are examples of components for a tool-less clamping fixture as described herein, in accordance with some embodiments, and are not meant to be limiting.
FIG. 2 is an exemplary view of a tool-less clamping fixture 20 having two electronic drivers 24a and 24b mounted on a heat sink component 22 of a luminaire (not shown), in order to demonstrate a principle of operation according to some embodiments. The heat sink component 22 may be associated with or part of a luminaire housing (not shown), and may be made of a metal and/or an aluminum material having a high thermal conductivity, as the heat sink is designed to remove heat generated by the electronic drivers 24a and 24b. The electronic drivers 24a and 24b may, in general, be of different shapes and/or sizes as will be explained below with references to FIGS. 8A-8F.
Referring again to FIG. 2, in some embodiments the clamping fixture includes three parts: the geartray plate 10 with a generally rectangular opening 10a and corresponding cutouts 11a-11e, and two flexible strips 12a and 12b (which may or may not be identical in shape and/or size). It should be understood that a different number of cutouts could be used, or no cutouts may be needed in some implementations. In the example shown in FIG. 2, the electronic drivers 24a and 24b are first inserted through the opening 10a of the geartray plate 10 (also see FIG. 1) during assembly such that a bottom portion of each electronic driver contacts a top portion of the heat-sink component 22. In addition, the two flexible strips 12a and 12b are connected to the cutouts of the geartray plate 20 using a tool-less assembly procedure (a specially designed procedure accomplished without using any tools, which will be described below with reference to FIGS. 5A-5F). In some embodiments, the grip-connection between the flexible strips 12a and 12b and the geartray plate 10 provides an air gap 25 between a bottom portion of the geartray plate 10 and a top portion of the heat-sink component 22. In addition, in some embodiments, side and/or lateral spring forces (depicted by arrows 28c and 28d in FIG. 2) are applied by side portions of the flexible strips 12a and 12b to the sides of the electronic drivers 24a and 24b to limit movement and/or lateral positioning of the electronic drivers.
Referring again to FIG. 2, in some embodiments a corresponding distributed downward force (illustrated by arrows 26) is applied on a top surface of the geartray plate 10 such that additional and/or operational (pretension and/or flexible) forces (illustrated by arrows 28a and 28b) are applied by the one or more top portions of the flexible strips 12a to the tops of the electronic drivers 24a and 24b in the direction of the arrows 26 to further limit and/or fix their positions on the heatsink 22. Forces 28a and 28b imposed by the flexible strips 12a, 12b can further cause the electronic drivers 24a and 24b to be pressed in a downward direction (towards the top portion of the heat sink 22), which may improve the effective heat transfer (by improving the contact between the heat sink and driver components and by minimizing contact heat resistance) from the electronic drivers 24a and 24b to the heatsink 22. The excess heat then can be removed from the heatsink 22 by an energy exchange (illustrated by arrow 27) with the outside atmosphere (for example, heat dissipation from the heat sink to ambient air). It is further noted that the efficiency of the heat transfer may be further improved by at least the following factors: a) fine polishing of the bottom surfaces of the electronic drivers 24a and 24b and top surfaces of the heat sink (which may be an internal luminaire housing) to maximize good contact between them, and b) designing the flexible strips 12a and 12b in such a manner so as to maximize the pressing forces (or downward forces) 28a and 28b. Thus, the tool-less clamping fixture 20 shown in FIG. 2 can be used to provide both a good mechanical fixation of, and improved heat removal from, the electronic drivers 24a and 24b.
FIGS. 3A, 3B and 4 illustrate the design of several components in accordance with some embodiments, such as those depicted in FIGS. 1 and 2, in detail. For example, FIG. 3A is a top view of a geartray plate 30a with a generally rectangular opening 31. In this example, the geartray plate 30a contains a total of five cutouts. Four of the cutouts 32a, 32b, 33a and 33b are identical in shape, have a predefined cutout depth, and are configured for the purpose of gripping two flexible strips (which may or may not have identical dimensions), such as the two flexible strips 40 shown in FIG. 4. As shown, the cutouts 32a and 32b, and the cutouts 33a and 33b, are located at a predetermined distance 36 from each other (and thus each cutout on one side has a symmetrical cutout on the opposite side of the rectangular opening 31). Thus, in some embodiments a first flexible strip 40 can be gripped by or connected to the symmetrical cutouts 32a and 32b, while a second flexible strip 40 can be gripped by or connected to the symmetrical cutouts 33a and 33b, respectively.
Referring again to FIG. 3A, a fifth outward cutout 34a has a cutout depth that is deeper (by a predefined margin) than those of the four other cutouts 32a, 32b, 33a and 33b. This outward cutout 34a can be used for the initial connection and/or loading of one or more of the flexible strips (which is explained below with regard to FIGS 5A-5F). For example, flexible strips 40 can be inserted through the outward cutout 34a during assembly of the electronic driver to the geartray plate and then slid along the edges of the opening 31 (in parallel to the gear tray plate surface) until connected to the symmetrical cutouts 32a and 32b or 33a and 33b (as will be further discussed below with reference to FIGS. 5A-5F).
FIG. 3B is a top view of another embodiment of a geartray plate 30b, which is similar to the geartray plate 30a but includes a second outward cutout 34b (a sixth cutout) on the opposite side of the generally rectangular opening 31a from the first outward cutout 34a. In some embodiments, the second outward cutout 34b has the same cutout depth as the first outward cutout 34a, wherein both are deeper cutout depths by a predefined margin than the predefined depth of the four other cutouts 32a, 32b, 33a and 33b. The functionality of the additional outward cutout 34b is similar to the outward cutout 34a (and will be further discussed below with reference to FIGS. 5A-5F). However, it should be understood that geartray plates can be designed and/or used that do not contain any cutouts, as long as one or more flexible strips can be installed to affix one or more electronic drivers to the geartray plate in accordance with the methods and principals disclosed herein.
FIG. 4 is a perspective view of an example flexible strip 40 according to an embodiment. The flexible strip 40 includes a top portion 47 having an overall length that is the sum of lengths 47a and 47b. In some implementations, the overall length of the flexible strip 40 is substantially the same as the distance 36 shown in FIGS. 3A and 3B between the two opposite sides of the opening 31 (or opening 31a) in the geartray plate 30a (or 30b). In some embodiments, the flexible strip 40 includes two concave-shaped (or wavy-shaped) portions 42a and 42b which bend downward as shown. As shown in FIG. 2, when utilized in the tool-less clamping assembly 20 along with a geartray plate, the concave-shaped portions 42a and 42b of the flexible strip 40 are configured to provide a continuous pretension force on the top surfaces of the electronic drivers 24a and 24b in a downward direction (See the pretension forces depicted by arrows 28a and 28b in FIG. 2).
Referring again to FIG. 4, the flexible strip 40 also includes two side portions 44a and 44b (having a height 43) which are bent approximately ninety degrees in a downward direction from the top portion 47, and which also have a concave-inward shape. The concave shape of the two side portions 44a and 44b (which are bent inward as shown) are configured to provide a continuous pretension force on the side surfaces of the electronic drivers 24a and 24b (See arrows 28c and 28d in FIG. 2, which represent these pretension forces). It should be understood that, in some implementations, the height 43 and/or the length (sum of the lengths 47a and 47b) of the flexible strip 40 can be varied in order to accommodate the size and/or shape of electronic drivers having different heights. In addition, the extent of the concave shape of the concave-shaped portions 42a and 42b and/or the concave side portions 44a and 44b can be adjusted to provide adequate and/or desirable pretension forces.
In some embodiments, the flexible strip 40 also includes two bottom tabs or lip- like portions 46a and 46b, which may be bent at an angle of approximately ninety degrees inward from the two side portions 44a and 44b, respectively. In some implementations, the length 45 of the two tabs 46a and 46b is longer than a depth of the outward cutouts (for example, the cutout depths of the cutouts 32a, 32b, 33a and/or 33b) to provide a grip-connection when the tabs 46a and 46b are slid under the corresponding cutouts 32a and 32b and/or 33a and 33b during assembly. In some embodiments, however, the length 45 of tabs 46a and/or 46b is shorter than the cutout depth of the cutouts 34a and/or 34b (see FIGS. 3A and 3B) so as to facilitate the tool-less assembly by using particular assembly procedures and/or movement(s) without any tools (as discussed below with reference to FIGS. 5A-5F).
It should be noted that the design of the flexible strip 40 may be changed and/or modified to accommodate different sizes of electronic drivers. For example, one or more of the dimensions 47a, 47b, 43 and/or 45 could be changed and/or modified, and one or more concave sections 42a or 42b may be changed and/or modified (as will be discussed below with regard to FIGS. 8A-8F). For example, instead of two concave portions 42a and 42b, there may be only one in some implementations, or more than two in other implementations.
FIGS. 5A-5F illustrate a step-by-step, tool-less procedure for assembling the tool-less clamping fixture, according to some embodiments. In this example, two electronic drivers 24a and 24b are inserted to (engaged with) a geartray plate 30a through an opening (like the generally rectangular opening 31 shown in FIG. 3A), and two flexible strips (like strips 40 in FIG. 4) are used to affix the electronic drivers into an assembly. Thus, in FIG. 5A, a tab 46a of the strip 40 is maneuvered to be inserted below the geartray plate 30a through the generally rectangular opening 31 near the cutout 32b (See FIG. 3a). Next, as shown in FIG. 5B, the tab 46a is inserted on a downward direction 51 to engage with the bottom portion of the geartray plate 30a. In FIG. 5C, the flexible strip 40 is moved in direction of arrow 52 so that the other tab 46b can be inserted through the cutout 34a to be gripped under the geartray plate 30a on the opposite side of the opening 31. Accordingly, the lengths 45 of each of the two tabs 46a and 46b of the flexible strip 40 are maneuvered so as to be positioned beneath the geartray plate 30a.
FIG. 5D illustrates tab 46b of the flexible strip 40 being inserted into the outward cutout 34a. The sides 44a and 44b of the flexible strip 40 are then compressed by an installer or assembler (such as a luminaire assembly worker) and moved in the direction of arrow 53 until the tabs 46a and 46b align with the pair of symmetrical cutouts 33a and 33b (See FIG. 3a), where the length 45 of each of the two tabs is longer than the depth of each of the cutouts to provide a secure grip-connection. In some embodiments, the overall connection of the flexible strip 40 to the drivers provides operational pretension forces on the top surfaces of the electronic drivers 24a and 24b (for example, see the operational forces illustrated by arrows 28a and 28b in FIG. 2). The installer or assembler then takes another flexible strip 40 and connects it in the same manner (using the same procedure explained above with regard to FIGS. 5a-5d), but this time slides the tabs of the flexible strip to engage with the cutouts 32a and 32b to form the resultant assembly shown in FIG. 5F. Thus, this second flexible strip 40 also provides operational and/or pretension forces. FIG. 5F also indicates locations 50a, 50b, 50c and 50d of the corresponding four gripping points.
According to some other embodiments, the tool-less procedure for assembling the tool-less clamping fixture as shown in FIGS. 5A-5F can be simplified to a certain extent by using the geartray plate 30b shown in FIG. 3B. In this embodiment, the steps demonstrated by FIGS. 5A-5C can be skipped. Instead, both tabs 46a and 46b of the flexible strip 40 inserted through the outward cutouts 34a and 34b (See FIG. 3B). Then the assembler, in a step similar to that explained above with regard to FIG. 5D, can move or slide both tabs of a first flexible strip 40 until they align with the first and second pair of symmetrical cutouts 33a and 33b, and then do the same with a second flexible strip until the tabs align with the cutouts 32a and 32b (See FIG. 3A), like in step 5E. It should be understood, however, that other configurations of cutouts could be used in a geartray plate that would serve the same purpose(s).
FIG. 6A is a three-dimensional perspective views of a fully assembled tool-less clamping fixture 60a in accordance with some embodiments that includes two electronic drivers 24a and 24b, shown prior to installation in a luminaire. FIG. 6B is three-dimensional cutaway view of a luminaire 60b having the tool-less clamping fixture of FIG. 6A installed on an internal surface of a housing 62. In some embodiments, an air gap (not shown) exists between a bottom surface of the geartray plate 30a and the internal surface of the external housing 62.
FIG. 7 is a cross-sectional side view of a luminaire 70 including a tool-less clamping fixture (such as the fixture 60a of FIG. 6A) including two electronic drivers 24a and 24b affixed to an internal surface of the housing 62. In some embodiments, two pins 74a and 74b on a fixture-door 72 provide a distributed downward force in areas 76a and 76b when the fixture-door 72 is closed (as shown in FIG. 7) to hold the geartray plate 30a at a defined position and permit the flexible strips to provide the pretension force to bias the electronic drivers 24a and 24b toward the internal surface of the housing 62. It should be noted that, in some embodiments the geartray plate 30a can be used to mount other types of electrical connections and/or connectors, which can be changed and/or replaced without any tools.
According to some further embodiments, as demonstrated in FIGS. 8A-8F, tool-less clamping fixtures as described herein can be used to connect different sizes and configurations of identical or non-identical electronic drivers to luminaires. For example, a variety of different sizes and or configurations of flexible strips can be used, and their clamping or affixation locations can be different from that which described above. FIGS. 8A-8F are top views of some examples of electronic drivers and their associated flexible strips (wherein no geartray plates are shown).
FIG. 8A is an exemplary top view 80a of an electronic driver 81a having three flexible strips 82a, 82b and 82c for connection via a geartray plate to a heatsink (not shown). Each strip may have one or more concave portions which are bent in a downward direction (for example, see portions 42a and/or 42b of flexible strip 40 in FIG. 4) to bias the electronic driver towards, for example, a heat sink when installed in a luminaire. A different size electronic driver 81a can be accommodated by appropriately designing the dimensions of the flexible strips 82a, 82b and 82c and the geartray plate.
FIG. 8B is an exemplary top view of three electronic drivers 81b, 82b and 83b, which can be identical, in which four flexible strips 84a, 84b, 84c and 84d are used for connecting them via a geartray plate to a heatsink (not shown). Each strip may have one or more of portions that are bent in a downward direction, and having a wavy or concave shape (like portions 42a or 42b in FIG. 4). Each of the flexible strips 84b and 84c has an adequate width to cover a gap between two adjacent electronic drivers (along their long-side boundaries), that is between electronic drivers 81b and 82b, and between electronic drivers 82b and 83b, respectively. These flexible strips are configured to provide a continuous force simultaneously for the two adjacent electronic drivers. In some embodiments, the flexible strips 84b and 84c are wider than the other two flexible strips 84a and 84d. In the embodiment shown in FIG. 8B, each of two flexible strips 84a and 84d covers one electronic driver 81b or 83b, respectively, around an outside long boundary.
FIG. 8C is an exemplary top view of two electronic drivers 81c and 82c having different dimensions, and which can be connected via a geartray plate to a heatsink (not shown) with corresponding flexible strips 85a, 85b and 85c, and 85d and 85e, respectively. As shown, the electronic drivers 81c and 82c have different lengths, but also can have other different dimensions such as height and/or width. The electronic driver 81c is fixed/covered by three flexible strips 85a, 85b and 85c, wherein each strip may one or more concave portions to bias the electronic drivers in a downward direction towards a heat sink (not shown) when assembled. In this example, the electronic driver 82c is associated with two flexible strips 85d and 85e, wherein each strip may have one or more concave portions that bias the electronic driver in a downward direction towards a heat sink when installed in a luminaire. Thus, a first group of flexible strips 85a, 85b and 85c is associated with the electronic driver 81c, whereas a second group of flexible strips 85d and 85e is associated with the second electronic driver 82c, wherein the flexible strips may be identical in size and shape or may be different in size and shape, depending on the respective corresponding dimensions of the electronic drivers 81c and 82c.
FIG. 8D is an exemplary top view of two electronic drivers 81d and 82d, which may or may not be identical, and which can be connected via corresponding flexible strips 86a and 86b, and 86c and 86d, via a geartray plate to a heatsink (not shown). Electronic drivers 81d and 82d are placed in a "T" configuration, so that the geartray plate (not shown) may also have a "T" shape and may include two openings (instead of just one generally rectangular opening) . Each of the electronic drivers is fixed/covered with two flexible strips (placed on the top of each of the electronic drivers). As explained above, the flexible strips have one or more concave portions to bias the heat sinks in a downward direction towards a heat sink when installed in a luminaire (not shown). In this embodiment, the two groups of flexible strips 86a and 86b, and 86c and 86d may or may not be identical, and have dimensions which accommodate the dimensions of the electronic drivers 81d and 82d.
FIG. 8E is an exemplary top view of two electronic drivers 81e and 82e that are associated with corresponding flexible strips 87a and 87b in one direction, and with a flexible strip 88 in another direction (here, perpendicular to the other two strips). In some implementations, the construction of the flexible strips 87a, 87b and 88 are varied. For example, each strip may include two concave portions to bias the electronic drivers in a downward direction towards a heat sink when installed in a luminaire (not shown). Alternatively, the flexible strips 87a and 87b may have two concave portions while the flexible strip 88 has on only one concave portion, and other variations are possible.
FIG. 8F is an exemplary top view of two electronic drivers 81f and 82f, having different lengths and placed parallel to each other and their associated flexible strips 89a, 89b and 89c, respectively. The flexible strips 89a, 89b may include at least two concave portions configured to bias each of electronic drivers 81f and 82f in a downward direction towards a heat sink when installed in a luminaire. In addition, the flexible strip 89c may have only one concave portion which can provide a further biasing force to the longer electronic driver 81f to provide additional support/pretension.
Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one having ordinary skill in the art to which this disclosure belongs. The terms "first", "second", and the like, as used herein, do not denote any order, quantity, or importance, but rather are employed to distinguish one element from another. Also, the terms "a" and "an" do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. The use of "including," "comprising" or "having" and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as additional items. The terms "connected" and "coupled" are not restricted to physical or mechanical connections or couplings, and can include electrical and optical connections or couplings, whether direct or indirect.
Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. The various features described, as well as other known equivalents for each feature, can be mixed and matched by one of ordinary skill in this art, to construct additional systems and techniques in accordance with principles of this disclosure.
In describing alternate embodiments of the apparatus claimed, specific terminology is employed for the sake of clarity. The invention, however, is not intended to be limited to the specific terminology so selected. Thus, it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions.
It is to be understood that the foregoing description is intended to illustrate and not to limit the scope of the invention, which is defined by the scope of the appended claims. Other embodiments are within the scope of the following claims.
It is noted that various non-limiting embodiments described and claimed herein may be used separately, combined or selectively combined for specific applications.
Further, some of the various features of the above non-limiting embodiments may be used to advantage, without the corresponding use of other described features. The foregoing description should therefore be considered as merely illustrative of the principles, teachings and exemplary embodiments of this invention, and not in limitation thereof. For completeness, various aspects of the invention are set out in the following numbered clauses:

1. A tool-less clamping fixture for a luminaire comprising:
- a geartray plate comprising an opening configured for accommodating at least one electronic driver; and
- at least one flexible strip having a top section having at least one concave portion, a first side wall having a first tab on a first side of the top section, and a second side wall having a second tab on a second side of the top section, wherein the flexible strip is configured to provide a continuous pretension force to a top portion of an electronic driver when the first tab is connected to a first side of the opening of the geartray plate and the second tab is connected to a second side of the opening opposite the first side of the geartray plate using a tool-less assembly procedure.
2. The tool-less clamping fixture of clause 1, further comprising a heat sink and wherein, when the electronic driver is inserted through the opening in the geartray plate and secured with the flexible strip using the tool-less assembly procedure, an air gap is formed between a bottom side of the geartray plate and a top portion of the heat-sink.
3. The tool-less clamping fixture of clause 2, wherein the heat-sink part comprises a portion of a housing of a luminaire.
4. The tool-less clamping fixture of clause 1, further comprising a predefined pattern of outward cutouts in the geartray plate comprising:
- two or more cutouts at predetermined distances from each other on the first side of the opening;
- two or more cutouts on the second side of the opening opposite the two or more cutouts on the first side of the opening to form at least a first opposing pair and a second opposing pair of cutouts; and
- at least a first outward cutout on the first side of the opening having a deeper cutout depth than any of the other cutouts to facilitate connection of at least one flexible strip to the geartray plate using the tool-less assembly procedure.
5. The tool-less clamping fixture of clause 4, wherein when the electronic driver is inserted through the opening in the geartray plate to contact a top portion of the heat-sink in a luminaire, the predefined tool-less procedure for the flexible strip comprises:
- aligning the first tab of the flexible strip along a first side of the electronic driver near a first side of the geartray plate opposite an outward cutout formed on the other side of the opening;
- inserting the first tab under the geartray plate;
- inserting the second tab into the outward cutout such that the at least one concave portion of the flexible strip contacts a top portion of the electronic driver;
- sliding the first and second tabs of the flexible strip along a bottom portion of the geartray plate in a direction towards the first cutout and the second cutout on opposite sides of the opening in the geartray plate; and
- locking the flexible strip in place by aligning the first tab with the first cutout and the second tab with the second cutout to provide a secure connection.
6. The tool-less clamping fixture of clause 1, wherein the top section of the flexible strip has and overall length substantially equal to a distance between the two opposite sides of the opening in the geartray plate, and wherein the first side wall and the second side wall having at least one concave portion bent inwardly to provide a continuous pretension force on a first side surface and on a second side surface of an electronic driver.
7. The tool-less clamping fixture of clause 4, wherein the predefined pattern of cutouts on the opposite sides of the opening comprises:
- a second outward cutout on the second side of the opening located opposite the first outward cutout and having a same cutout depth as the at first outward cutout.
8. The tool-less clamping fixture of clause 7, wherein when the electronic driver is inserted through the opening in the geartray plate to contact a top portion of the heat-sink in a luminaire, and the predefined tool-less procedure comprises:
- placing a concave top portion of the flexible strip to contact a top portion of the electronic driver and aligning the first and second tabs of the flexible strip with a first outward cutout of the geartray plate and an opposing second outward cutout of the geartray plate;
- inserting the first tab through the first outward cutout and the second tab through the second outward cutout to contact a bottom portion of the geartray plate respectively; and
- sliding the flexible strip until the first and second tabs align with a pair of symmetrical and opposing cutouts, where a length of each of the first and second tabs is longer than a depth of each of the symmetrical and opposing cutouts to provide a secure connection and a pretension force to the electronic driver.
9. The tool-less clamping fixture of clause 1, further comprising at least a second electronic driver and at least a second flexible strip.
10. The tool-less clamping fixture of clause 9, wherein the at least a second electronic driver has identical dimensions as the original electronic driver.
11. The tool-less clamping fixture of clause 9, wherein the at least second flexible strip is configured to provide a continuous pretension force on the second electronic driver.
12. The tool-less clamping fixture of clause 9, wherein each of the first and second flexible strips provides a continuous pretension force simultaneously on the first and second electronic drivers.
13. The tool-less clamping fixture of clause 9, wherein the first and second flexible strips are configured for providing a continuous pretension force simultaneously along boundaries of the first and second electronic drivers.
14. The tool-less clamping fixture of clause 9, wherein the first flexible strip differs from the second flexible strip in at least one of a height dimension and a length dimension.
15. The tool-less clamping fixture of clause 9, wherein the geartray plate is composed of a metallic material.
16. The tool-less clamping fixture of clause 9, wherein the flexible strip is composed of a material having a desired spring property.
17. The tool-less clamping fixture of clause 9, wherein the material comprises at least one of a metal, a plastic, or a composite with the desired spring property.
18. The tool-less clamping fixture of clause 9, wherein at least one of a bottom surface of the electronic driver and a corresponding top surface of the heat-sink part are fine-polished.

Claims

A tool-less clamping fixture for a luminaire comprising:
a geartray plate (10, 30a, 30b) comprising an opening configured for accommodating at least one electronic driver 24a, 24b; and

at least one flexible strip (12a, 12b, 40, 42) having a top section having at least one concave portion (42a,42b), a first side wall (44a) having a first tab (46a) on a first side of the top section (47), and a second side wall (44b) having a second tab 46b on a second side of the top section (47), wherein the flexible strip (12a, 12b, 40, 42) is configured to provide a continuous pretension force to a top portion of an electronic driver when the first tab (46a) is connected to a first side of the opening (10a) of the geartray plate (10, 30a, 30b), and the second tab (46b) is connected to a second side of the opening (10a) opposite the first side of the geartray plate (10, 30a, 30b), using a tool-less assembly procedure.
The tool-less clamping fixture of claim 1, further comprising a heat sink (22) and wherein, when the electronic driver (24a, 24b) is inserted through the opening (10a) in the geartray plate (10, 30a, 30b) and secured with the flexible strip (12a, 12b, 40) using the tool-less assembly procedure, an air gap (25) is formed between a bottom side of the geartray plate (10, 30a, 30b) and a top portion of the heat-sink (22).
The tool-less clamping fixture of claim 2, wherein the heat-sink part (22) comprises a portion of a housing (62) of a luminaire.
The tool-less clamping fixture of any preceding claim, further comprising a predefined pattern of outward cutouts (11a-11e, 32a, 32b, 33a, 33b, 34a, 34b) in the geartray plate (10, 30a, 30b) comprising:
two or more cutouts (11a-11e, 32a, 32b, 33a, 33b, 34a, 34b) at predetermined distances from each other on the first side of the opening (10a);

two or more cutouts (11a-11e, 32a, 32b, 33a, 33b, 34a, 34b) on the second side of the opening (10a) opposite the two or more cutouts on the first side of the opening to form at least a first opposing pair (11a, 11d) and a second opposing pair of cutouts (11b, 11e); and

at least a first outward cutout (11c) on the first side of the opening having a deeper cutout depth than any of the other cutouts to facilitate connection of at least one flexible strip (12a, 12b) to the geartray plate (10, 30a, 30b) using the tool-less assembly procedure.
The tool-less clamping fixture of claim 4, wherein when the electronic driver (24a) is inserted through the opening (11a) in the geartray plate (10, 30a, 30b) to contact a top portion of the heat-sink (22) in a luminaire (70), the predefined tool-less procedure for the flexible strip comprises:
aligning the first tab (46a) of the flexible strip (12a, 40) along a first side of the electronic driver (24a) near a first side of the geartray plate (10, 30a, 30b) opposite an outward cutout formed on the other side of the opening (10a);

inserting the first tab under the geartray plate (10, 30a, 30b);

inserting the second tab (46b) into the outward cutout (11c) such that the at least one concave portion of the flexible strip (40) contacts a top portion of the electronic driver (24a);

sliding the first and second tabs (46a, 46b) of the flexible strip (40) along a bottom portion of the geartray plate (10, 30a, 30b) in a direction towards the first cutout (11e) and the second cutout (11b) on opposite sides of the opening in the geartray plate (10, 30a, 30b); and

locking the flexible strip (12a, 40) in place by aligning the first tab (46a) with the first cutout (11e) and the second tab (46b) with the second cutout (11b) to provide a secure connection.
The tool-less clamping fixture of any preceding claim, wherein the top section of the flexible strip (40) has and overall length substantially equal to a distance between the two opposite sides of the opening (10a) in the geartray plate (10, 30a, 30b), and wherein the first side wall (44a) and the second side wall (44b) having at least one concave portion bent inwardly to provide a continuous pretension force on a first side surface and on a second side surface of an electronic driver (24a).
The tool-less clamping fixture of claim 4, wherein the predefined pattern of cutouts (32a, 32b, 33a, 33b, 34a) on the opposite sides of the opening comprises:
a second outward cutout (34b) on the second side of the opening (10a) located opposite the first outward cutout (34a) and having a same cutout depth as the at first outward cutout.
The tool-less clamping fixture of claim 7, wherein when the electronic driver 24a is inserted through the opening (10a) in the geartray plate (10, 30a, 30b) to contact a top portion of the heat-sink (22) in a luminaire (70), and the predefined tool-less procedure comprises:
placing a concave top portion of the flexible strip (12a, 40) to contact a top portion of the electronic driver (24a) and aligning the first and second tabs (46a, 46b) of the flexible strip (12a, 40) with a first outward cutout of the geartray plate (10, 30a, 30b) and an opposing second outward cutout of the geartray plate (10, 30a, 30b);

inserting the first tab (46a) through the first outward cutout and the second tab (46b) through the second outward cutout to contact a bottom portion of the geartray plate (10, 30a, 30b), respectively; and

sliding the flexible strip (12a, 40) until the first and second tabs (46a, 46b) align with a pair of symmetrical and opposing cutouts (11a-11e, 32a, 32b, 33a, 33b, 34a, 34b), where a length of each of the first and second tabs (46a, 46b) is longer than a depth of each of the symmetrical and opposing cutouts to provide a secure connection and a pretension force to the electronic driver (24a).
The tool-less clamping fixture of any preceding claim, further comprising at least a second electronic driver (24b) and at least a second flexible strip (12b, 42).
The tool-less clamping fixture of claim 9, wherein the at least a second electronic driver (24b) has identical dimensions as the original electronic driver (24a).
The tool-less clamping fixture of claim 9, wherein the at least second flexible strip (12b, 42) is configured to provide a continuous pretension force on the second electronic driver (24b).
The tool-less clamping fixture of claim 9, wherein each of the first and second flexible strips (12a, 40, 12b, 42) provides a continuous pretension force simultaneously on the first and second electronic drivers (24a, 24b).
The tool-less clamping fixture of claim 9, wherein the first and second flexible strips (12a, 40, 12b, 42) are configured for providing a continuous pretension force simultaneously along boundaries of the first and second electronic drivers (24a, 24b).
The tool-less clamping fixture of claim 9, wherein the first flexible strip (12a, 40) differs from the second flexible strip in at least one of a height dimension and a length dimension.
The tool-less clamping fixture of any preceding claim, wherein the flexible strip (12a, 40, 12b, 42) is composed of a material having a desired spring property.