GB2510625A

GB2510625A - Lighting system

Info

Publication number: GB2510625A
Application number: GB1302382.5A
Authority: GB
Inventors: Jeff Morgan
Original assignee: OCEAN LED Ltd
Current assignee: OCEAN LED Ltd
Priority date: 2013-02-11
Filing date: 2013-02-11
Publication date: 2014-08-13
Also published as: GB201302382D0

Abstract

An adapter kit provides components which can be assembled into a mounting tube 30 with which to support an LED light source package (10, Fig. 3) in a lamp holder (2, Fig. 3) designed for a standard G8 .5 or G12 CDM arc tube. The components include a collar 100 which fits onto a heat sink 20 that can be slid telescopically along the mounting tube 30, with a lug 110 engaged in an external linear track 76 on the tube. The collar 100 can be locked relative to the mounting tube 30 to position the light source at the appropriate distance from a base of the lamp holder. Adapter tube modules 40, 60 can be interlocked in order to allow the tube to be of any required length depending on the depth of the lamp holder.

Description

Lighting System

Technical Field

[0001] The present invention relates to lighting systems for commercial use in offices and shops. More specifically, the present invention addresses the redeployment of existing light engines, optics and thermal management systems installed for use with ceramic gas discharge metal halide (CDM) lighting systems with LED lighting systems. Such CDM lighting systems will typically have a large number of ceiling or track mounted luminaires using lamp holders which have standard G8.5 and G12 fittings. These fittings comprise a 2 pin socket in the base of the lamp holder into which a 2 pin plug on the end of the CDM lamp can be removably fitted. CDM lamps employ an elongate ceramic arc tube and a spot lamp holder provides a reflective surface to direct light in the required direction. The lamp holders, when ceiling mounted are often gimbal mounted within openings created in the ceiling. The lamp holders themselves are not standardised and because of the length of the arc tube and the need to provide a reflector, the distance between a base of the lamp holder and its open mouth varies considerably.

[0002] Significant investment has been made by, for example, retailers in installing lighting equipment in ceiling spaces for use with CDM systems.

In order to install lower energy consumption LED lighting systems, it has, prior to this invention, been necessary to replace much of this equipment leading to wasted and creating a disincentive to invest in long-term energy reduction.

[0003] If the lighting system is being replaced, it would be more cost-effective if these existing ceiling openings and lamp holders did not need to be replaced. The adapter kit of the present invention provides a solution to that technical problem when the lighting system is being replaced by one using voltage LED light sources.

[0004] Because CDM lights are high-voltage systems, there are hazards if an installer or maintenance person working with a lower voltage LED system were to inadvertently plug equipment into a socket forming part of a CDM lighting system. It is therefore undesirable to have any compatibility between the electrical components of the two systems.

Disclosure of Invention

[0005] The present invention provides a method of converting a CDM luminaire for use with an LED light source, the luminaire comprising a lamp holder having an open mouth, and a two pin single ended CDM light source; comprising the steps of removing the light source and its receiving socket from a base of the lamp holder and replacing it with a mounting tube having a closed end, which is fixed to the base of the lamp holder, the tube having an external linear track with spaced locking slots extending around the tube; fitting a telescoping collar to a rear of a heat sink associated with a LED light source so that the collar cannot rotate relative to the heat sink, the collar being provided with at least one internal lug sized to engage with the linear track, the collar being adapted to slide up and down the tube; moving the collar together with the light source along the tube until the light source is positioned within the open mouth of the lamp holder; and then rotating the LED light source in order to engage with a locking slot to hold the collar at the selected position on the tube.

[0006] The present invention also provides the adapter kit which is essential to allow the implementation of the described conversion method as further defined in the appended claims. The kit provides modules so that the mounting tube can be made up to the required length using modular adapter tubes which interlock with one another. The base of the mounting tube can either be formed from the base of an adapter tube which will be sized to match a standard G12 fitting or be provided by a smaller diameter G8.5 adapter tube which is preferably coupled to a tracked G12 adapter tube by means of a plate connector. A main portion of the mounting tube is preferably formed from interconnecting short tube sections so that a variety of lengths can be built up without needing to carry a large range of pads.

Brief Description of the Drawings

[0007] In order that the invention may be well understood, an embodiment thereof, will now be described, by way of example only, with reference to the accompanying diagrammatic drawings, in which: [0008] Figure 1 shows an exploded view of the components of an adapter kit in accordance with the invention in relation to a heat sink for an LED light source; [0009] Figure 2 shows a perspective view of a lamp holder showing a mounting tube in sitg [0010] Figure 3 shows a perspective view of the lamp holder of Figure 2 with the LED light source fitted; [0011] Figure 4 shows a perspective view of an installation tool; [0012] Figure 5 shows a section through a collar of the adapter kit; [0013] Figure 6 shows a top plan view of an adapter tube (this layout but not the scale of the G8.5 and G12 adapter tubes are similar); [0014] Figure 7 shows a side view of a G12 adapter tube; [0015] Figure 8 shows a side view of a connector plate; and [0016] Figure 9 shows an underneath view of the connector plate of Figure 8.

Mode(s) for Carrying Out the Invention [0017] Very generally, the components of the kit to be used for converting a CDM luminaire to an LED luminaire, include adapter tube modules and a collar which fits onto a heat sink so that it can be slid telescopically along a mounting tube with a lug engaged in an external linear track on the tube.

The collar can be locked relative to the mounting tube to position the light source at the appropriate distance from a base of a lamp holder. The adapter tubes can be non-rotationally interlocked in order to allow the mounting tube to be of any required length depending on the depth of the lamp holder.

[0018] For the purposes of illustration, the adapter kit of the invention will be described in relation to a lamp holder 2 which has a cylindrical base portion 4 and a flared reflector portion 6 terminating in an open mouth 8 designed to be at the ceiling level. It will be appreciated that lamp holders are available in a very wide variety of designs and the adapter kit to be described is suitable for use with many variations of this basic lamp holder depending on the design of the existing luminaires.

[0019] An LED light source comprises a generally flat package 10 containing a printed circuit board (PCB) 12 to which individual LEDs are mounted behind a protective shield which provides optical elements. The adapter is particularly suitable for use with LED light sources such as described in GB2473185A(OCEANI-LED LIMITED) 09.03.2011 but can be used with packages from other manufacturers. The light source will be provided with a two-core cable 14 for connection to the electrical components. The light source will also be associated with a heat sink element 20 for dissipating heat. For the purposes of luminaires which are to be used as replacements in existing lamp holders, it is convenient for the heat sink to be constructed from metal fins 22 which radiate away from the PCB and define an annular base 24 surrounding the PCB. The heat sink 20 has a generally conical or domed profile as illustrated, as this is easy to fit within a flared reflector portion of an existing lamp holder. The size and outer profile of the heat sink fins may vary according to the heat dissipation requirements. The heat sink provides a central hollow passage 26 to allow the cable 14 from the PCB to be passed out of the heat sink through the passage.

[0020] The adapter kit which enables CDM luminaires with standard G12 fittings or the narrower G8.5 fittings to be converted for use with LED packages comprises a kit of four distinct parts which can be assembled in varying combinations to provide a mounting tube 30 of adjustable length between a rear of the heat sink and a base of the lamp holder and which provides a channel for the cable 14 to be passed out of the lamp holder. The component parts are all illustrated in Figure 1 and comprise a G8.5 adapter tube 40, a plate connector 50, a G12 adapter tube GOof which two are shown in the drawing, and a collar 100 that couples to the heat sink 20. All of the components can preferably be moulded from resilient plastics materials such as ABS, glass reinforced plastics polypropylene or other thermally resistant plastics material. The material should be chosen to have heat resistance to at least 80 to 900 C. Each component will be described in more detail below.

G12 adapter tube [0021] The G12 adapter tube 60 is the primary component of the adapter kit.

Each tube 60 has a closed end 62 and an open end 64 and a cylindrical outer side wall 66. The tubes 60 are designed to interlock together to produce a mounting tube of greater overall length depending on the depth of the lamp fitting into which the LED package is being retrofitted. The length of each tube is preferably a nominal 5 cm. The closed end 62 has an end face 65 provided with an array of openings 68 which allow it to be fixed by screws to a base of a lamp holder and also a central opening to allow the exit of a cable from an LED package to pass through the base.

The fixing points are set at standard centres for G12 fittings. Allowances have been made for exceptions to these dimensions by the use of obround slots and some additional fixing points.

[0022] Four clip formations 70 are provided projecting around the open end 64.

Four correspondingly positioned openings 72 are provided in the side wall 66 adjacent the closed end. These allow any number of G12 tubes to be click-fitted together so that they do not rotate relative to one another. The same interlocking system is used to allow both the G12 tube 60 and the G8.5 tube 40 to connect to the plate connector 50.

[0023] Four studs 74 are also formed on the closed end 62 and these also enable the G12 tube to interlock with the plate connector 50 which has corresponding recessed sockets 58 defined in its underside. It will be appreciated that other types of interlocking mechanism can also be employed to assemble be tubes and plate connector so that there is no relative rotation between them when they have been combined in the required combinations of produce a mounting tube. The studs 74 also act as spacers to offset the adapter from a surface of the lamp base it is fixed to for a G12 lamp holder, as, in most cases, this surface is not entirely flat.

[0024] The side wall 66 defines four external linear tracks 76 that extend axially between the ends of the tube and adjoin linear tracks on any adjacent interlocked tube. A series of spaced locking slots 78 extend off each linear track and extend circumferentially around the side wall 66. These locking slots could terminate in recesses (not shown).

[0025] A large opening 80 is provided in the side wall between each external linear track in order to reduce the overall weight of the component.

Although four linear tracks have been shown, it will be appreciated that the system would work equally well with two or three and even just one.

However, a symmetrical arrangement that matches the number and position of the interlocking mechanisms is preferred as it is then impossible to interconnect the tubes without lining up the external linear tracks. The clip formations 70 are preferably aligned with the openings 80 in order to facilitate a resilient fit.

G8.5 adarter tube [0026] The G8.5 adapter tube 40 is essentially similar to the G12 connected tube except that it is shorter in length and does not require the same external linear tracks on the side wall as it acts simply as a spacer. A closed end 42 of the tube 40 has a similar array of openings 68 for fixing and exit of the power cable as described in relation to the G12 tube. As with the larger tube, clip formations 70 are provided around an open end 44 of the tube and openings 72 around the closed end in case it is necessary to clip two tubes 40 together in the case of an exceptionally long cylindrical base 4 in the lamp holder.

[0027] The studs 74 on the end face of the tube 40 that is fixed to the base of the lamp holder serve to offset the adapter from that surface in case it is not entirely flat.

Connector Plate [0028] The plate connector 50 is a component which allows the smaller G8.5 tube to befitted to a longer tube made of G12 adapter tubes 60. The plate has a first side adapted to be non-rotationally coupled to a G8.5 adapter tube and a second side adapted to be non-rotationally coupled to an end face of a G12 adapter tube 60.

[0029] The connector 50 has a central platform 52 which is of the same diameter as the G8.5 tube. The platform has a central obround opening 54 for passage of a cable from the LED package. Openings 72 are provided in side walls surrounding the central plafform and are positioned to engage with clip formations 70 on the G8.5 tube to which it is to be coupled. A flange 56 surrounds the central platform 52 and has an external diameter designed to match the larger external diameter of the G12 tube. Clip formations 70 depend from the edges of the flange 56 in order to engage with the corresponding openings 72 around the closed end of a G12 tube to which the connector plate is fitted. On the underside of the connector plate four female recesses 58 are formed in order to engage with the studs 74. The recesses 58 have channels 59 to an edge of the flange in order to allow a circular end part to expand and click fit over a corresponding stud to hold the plate securely in a non-rotatable manner on the G12 adapter tube. Both studs and clip formations 70 have been shown but the kit could be made with just one of these interlocking mechanisms.

Collar [0030] The collar 100 has a cylindrical body 102 and a peripheral rim. The body 102 is designed to slot into a rear of the heat sink 20 with the rim resting on its edge. The collar is held in position by means of an interference fit so that it does not rotate relative to the heat sink. A series of circumferential ridges 106 are formed on an external surface of the cylindrical body to facilitate engagement with the heat sink. The heat sinks may be provided with the collars bonded in position or the collar may be fitted during on-site installation.

[0031] An internal surface of the body 102 is provided with a series of internal projecting lugs 110 which are spaced around the body to match the position of the external linear tracks. The axial spacing of the lugs 110 matches the spacing of the locking slots 78, preferably so that they are exactly two or more slot separations apart.

[0032] The collar is designed to slide telescopically over an external surface of the mounting tube 30 with the lugs engaged in the tracks. Three lugs are shown and if all engage with the track then an extremely rigid connection will be made. However depending on the overall length of the mounting tube and depth of the heat sink it may be that only one or two lugs of each set will engage.

Installation Tool [0033] An installation tool 120 is provided as shown in Figure 4. The tool has is a circular plate 122 with an array of projecting pins 124 which will fit between the fins 22 of the heat sink and allow the heat sink to be rotated from the

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open mouth of the lamp holder. A handle portion 126 is formed on the side of the plate opposite the pins to facilitate gripping and turning of the tool.

Installation [0034] In order to convert a CDM luminaire for use with an LED light source, the following method is employed. First, the CDM arc tube and its associated socket are removed from the lamp holder. A mounting tube 30 of an appropriate length is then constructed using the relevant components of the adapter kit. The mounting tube has a closed end which is screwed to a base of the lamp holder. For a G8.5 fitting, the hollow tube is started with the smaller section adapter tube 40 to provide its closed end. The main body of the tube is made up of modules of the Gi 2 adapter tube 60 which are interlocked together and then connected to a connector plate 50 by means of the click fittings and/or the stud and recess mechanism. The G8.5 tube is then connected to the connector plate 50 by snap fitting it over the central platform 52.

[0035] For a G12 fitting, a mounting tube made solely of G12 adapter tubes 60 can be used and the closed end of that assembly screwed directly to a base of the lamp holder.

[0036] A collar 100 is fitted to the heat sink. An LED package is fitted inside its heat sink with its cable 14 extending out through the central passage in the heat sink. The cable can then be threaded through the mounting tube and out of the lamp holder at its base. The collar can then be engaged over the external surface of the tube with its lugs 110 engaging in the external tracks 76 in the side wall 66. The LED and heat sink assembly can be supported on the installation tool and rotated to the required orientation so that the collar can slide backwards along the linear track until the LED is at the required position relative to the open mouth of the lamp holder.

Subsequent rotation of the heat sink will then cause the lugs to move into their adjacent locking slots 78 to hold the LED in the set axial position.

Where the locking slots have terminal recesses, a slight downward movement can then be applied to the LED lamp source to push the lugs into the recesses and prevent any further rotational or axial movement.

[0037] If required, a decorative flange may be placed over the exposed fins of the heat sink surrounding the LED package in the open mouth of the lamp holder. Since this flange will not be supporting the weight of the heat sink, it can be provided with lightweight fittings.

Claims

Claims 1. An adapter tube (60) having an end face (65) adapted to be screwed to a base of a lamp holder and to permit passage of an electrical lead which connects to an LED light source (10), the tube having a side wall (66) provided with at least one external linear track (76) along its length adapted to engage with a lug projecting from a collar fitted to a the LED light source.
2. An adapter tube as claimed in claim what 1, wherein each external linear track has a series of circumferentially extending locking slots (78) extending off it.
3. A mounting tube (30) assembled from a series of non-rotationally interlocked adapter tubes as claimed in claim 1 or 2.
4. A connector plate (50) having a first side adapted to be non-rotationally coupled to an adapter tube (40) having an end face adapted to be screwed to a base of a lamp holder in place of a G8.5 fitting; and a second side adapted to be non-rotationally coupled to an end face of an adapter tube (60) as claimed in claim 1 or 2.
5. A mounting tube (30) assembled together in a non-rotational manner from at least one adapter tube (40) having an end face adapted to be screwed to a base of a lamp holder; a connector plate as claimed in claim 4; and an adapter tube as claimed in claim 1 or 2.
6. A system for converting existing lamp holders to use LED light sources comprising a heat sink (20) shaped to receive a circuit board (12) carrying an LED light source which is connected to an electrical lead (14); comprising a mounting tube (30) as claimed in claim 3 or 5; and a collar (100) fitted to the heat sink and having an internal surface provided with at least one projecting lug (110), the collar being sized to fit and slide telescopically over the mounting tube with the lug engaged in a linear track.
7. A method of converting a CDM luminaire for use with an LED light source, the luminaire comprising a lamp holder having an open mouth, and two pin single ended CDM light source; comprising the steps of removing the light source and its receiving socket from a base of the lamp holder and replacing it with a hollow tube having a closed end, which is fixed to the base of the lamp holder, the tube having an external linear track with spaced locking slots extending around the tube; fitting a telescoping collar to a rear of a heat sink associated with a LED light source so that the collar cannot rotate relative to the heat sink, the collar being provided with at least one internal lug sized to engage with the linear track, the collar being adapted to slide up and down the tube; moving the collar together with the light source along the tube until the light source is positioned within the open mouth of the lamp holder; and then rotating the LED light source in order to engage with a locking slot to hold the collar at the selected position on the tube.