WO2009117123A1

WO2009117123A1 - Modular, adaptive controller for light fixtures

Info

Publication number: WO2009117123A1
Application number: PCT/US2009/001734
Authority: WO
Inventors: Mark E. Lewis; Jose Luiz Yamada; James A. Lewis
Original assignee: Laserweld, Inc.
Priority date: 2008-03-19
Filing date: 2009-03-19
Publication date: 2009-09-24

Abstract

Α controller (in enclosure 14) for releasably mounting to a light fixture (10) for selectively switching the lamps of the light fixture on and/or off. The controller includes a mount adapted for mounting the controller to the light fixture and circuitry for selectively switching the lamps of the fixture and passive and/or active temperature management. Also disclosed is a light fixture adapted for on-site assembly from component parts in any of several configurations as required to optimize the light fixture for a particular application or installation. The light fixture includes a central channel member (112), end caps (116), extensions (122) assembled to the channel member, and shields (124) that assemble either to the extensions or directly to the channel member depending upon the amount of light needed and the number of bulbs to be mounted in the fixture. The electronics for controlling the fixture, including the ballast, are mounted in the central channel and thereby isolated from the heat produced by the light bulbs mounted in the fixture.

Description

MODULAR, ADAPTIVE CONTROLLER FOR LIGHT FIXTURES

The present invention relates to a modular controller for light fixtures, and light fixtures to which the modular controller is mounted, and methods for monitoring and controlling the operation of light fixtures. In more detail, the present invention relates to a controller for light fixtures that is constructed of component parts that, because of their ease of assembly and/or dis-assembly, provide the advantages of safety, accessibility to the electronic and electrical parts of the controller, and control of the light fixture, while also allowing the fixture to be adapted for use with different bulbs and assembled in different configurations as required by a particular installation. Although not limited to this application, the modular, adaptive light fixture controller of the present invention is particularly suited for use in connection with fluorescent lamps, particularly fluorescents of the type used for high bay lighting. The need for energy efficiency has driven innovation in the development of lamps for light fixtures and control systems for lighting fixtures. Fluorescent fixtures have been retrofit to many buildings in place of metal halide fixtures, for instance, to reduce energy consumption, and even fluorescent fixtures have been improved by development of so- called T5 or T5HO fluorescent lamps and "quick start" ballasts and ballasts with electronic controls. However, the fixtures themselves have not changed but incrementally over the many years that fluorescents have been in widespread use. Such fixtures are generally constructed of a metal shroud with a metal bulkhead assembled to the underside of the shroud. Sockets and reflectors (in fixtures utilizing a reflector) are mounted to the bulkhead inside the shroud for directing light from the lamp(s) downwardly and supporting and providing electrical connections to the lamp(s), and ballast(s) are mounted on the top side of the bulkhead (between the underside of the shroud and the top surface of the bulkhead) for providing switching and start-up of the lamps in the fixture. In some fixtures, the bulkhead may be hinged to the shroud to facilitate access to the ballast(s) and in other fixtures, the reflector(s) are integral with the shroud. Although a time-tested design, existing fluorescent fixtures are characterized by a number of disadvantages and limitations. If the ballast of certain types of fluorescent fixtures fails, for instance, the lamps and reflector(s) must be removed and the bulkhead, or socket bracket, dropped out of the shroud (or in the case of a fixture in which the bulkhead is hinged to the shroud, the bulkhead is pivoted downwardly) to access the ballast(s). Removing and replacing the lamps and reflectors) (in the type of fixture in which the reflectors are not integral with the shroud) is time-consuming and, depending upon the type of fixture, requires that wires inside the fixture be unplugged and replugged into the appropriate connectors and/or cut and spliced, creating the possibility of crossed wires. Further, when the fixture is opened to access the ballasts and internal wiring, the person(s) servicing the fixture are in close proximity to the electrical parts of the fixture. Even though power to a fixture or circuit is turned off when the fixture is serviced, there is the possibility of an error that could result in contact with a live wire

(and some such fixtures operate at 480V), creating a potentially dangerous situation, especially when the fixture is located twenty or more feet above the floor of the building.

Another disadvantage of known fixtures is highlighted by the development of the above-mentioned T5/T5HO lamp. The T5 lamp is smaller than a T8 lamp, making it possible to mount, for instance, six T5 lamps in a fixture that might have been sized for four T8 lamps, thereby producing more light from the fixture. However, mounting more lamps in the, fixture creates a temperature control problem in the. fixture. The T5 lamps (like most fluorescent lamps) actually operate more efficiently at higher temperatures, but the component parts of the ballast, especially electronic ballasts, can be damaged by the heat from the T5 lamps. Ballasts are available that operate at temperatures up to 90⁰C (as compared to the 60° and 65⁰C ballasts that can fail at the temperatures to which they are exposed when used with T5 lamps), but temperature management is still a problem. Ballast manufacturers may warrant their ballast for a certain operating life, but only as long as temperature does not exceed 90⁰C, and a heat sensitive label or tape is affixed to the outside of the ballast cover to provide a visual indication when/if temperature exceeds 9O⁰C, in which case the warranty on the ballast is invalidated.

Fluorescent fixtures are also available in which the ballasts are mounted under the shroud and/or reflectors that do not require removal of the lamps and reflector(s) for access to the ballasts. Such fixtures are common in commercial and office buildings, and some residential construction, with suspended ceilings and/or and in which headroom and/or the space between the top of the fixture and the underside of the roof or ceiling may be limited, and also in rooms such as kitchens that require energy efficient, bright area lighting. However, the ballasts of such fixtures are mounted within, or under the shroud (or reflector) where the lamps are located such that the ballasts are exposed to the heat of the lamps. The patent literature includes U.S. Patent No. 6,268,701, which describes a fixture having the ballast mounted within the housing with a fan that is switched on to blow air over the ballast when the light is turned on. However, the fixture described in that patent is itself characterized by certain disadvantages and limitations, for instance, the continual cooling of the ballast by the fan that can compromise the energy efficiency of the lamps and the ballast, that limit the utility of that invention. Specifically, as set out above, the lamps of a fluorescent fixture operate more efficiently at higher temperatures, but blowing the air through the fixture over the ballast as described in that patent cools not only the ballast but also the lamps. Note also that if ambient temperature is 30° C for instance, the fan blows hot air over the ballast, compromising its efficiency. It is, therefore, an object of the present invention to provide a lighting fixture that overcomes these disadvantages and limitations, and a modular, adaptive controller for lighting fixtures, that is adapted for use with different lamps, including without limitation fluorescents, metal halides, . LEDs, „ and halogen lamps, and assembled in different configurations as required by a particular installation. Another object of the present invention is to provide a controller that is adapted for quick and easy assembly to a lighting fixture on site and/or to an existing light fixture that is configured so that the controller can be releasably mounted to the fixture.

Another object of the present invention is to provide a lighting fixture, and a modular, adaptive controller for lighting fixtures, in which the ballasts and other electronic components are isolated from the heat produced by the lamps and that does not require disassembly of the fixture in the event the ballasts need to be replaced and/or other maintenance needs to be performed on the fixture.

Another object of the present invention is to provide a lighting fixture having a construction that is easily and quickly assembled on-site and a modular, adaptive controller that is easily and quickly assembled to the lighting fixture, or to an existing lighting fixture, on-site. Another object of the present invention is to provide a lighting fixture that is light weight but still structurally rigid to facilitate installation and increase durability.

Another object of the present invention is to provide a lighting fixture that provides access to ballasts and other electronic components from above the fixture. Yet another object of the present invention is to provide a lighting fixture that incorporates a thermal management system for optimizing the life and operating efficiency of the components of the fixture by mounting the electronic components in an enclosure, or compartment, that is separate from the lamps.

Another object of the present invention is to provide a lighting fixture incorporating passive and active temperature management for increasing the efficiency of the lamps mounted in the fixture as well as the electronic components of the fixture.

Another object of the present invention is to provide improved safety in that the structure of the fixture reduces the need for handling the electrically conductive components of the fixture, for instance, when a ballast must be changed. Similarly, it is an object of the present invention to provide a lighting fixture in which the time required to change ballasts, or otherwise service the fixture, is reduced.

Another object of the present invention is to provide a lighting fixture that is comprised of parts- that are manufactured by- extrusion, substantially reducing the time and space required for assembling the fixture while providing a fixture of increased structural rigidity and light weight.

Similarly, it is an object of the present invention to provide a lighting fixture having a construction that is adapted for releasably mounting a control module thereto for controlling the lamps in the fixture, the control module being easily and quickly detached from the fixture for ease of maintenance. Another object of the present invention is to provide a lighting fixture optimized for use with the targeted system for switching electrical appliances described in International Application No. PCT/US2008/003845, TARGETED SWITCHING OF ELECTRICAL APPLIANCES AND METHOD, filed March 24, 2008, the disclosure of which is hereby incorporated into this application in its entirety by this specific reference. This listing of several of the objects of the present invention is intended to be illustrative, and is not intended to be a complete listing of all of the objects of the invention; instead, this listing of several objects of the present invention is intended to be illustrative in the sense that the invention addresses many needs and solves many problems, not all of which are listed here. The other objects, and the many advantages of the present invention, will be clear to those skilled in the art from the detailed description of the preferred embodiments) of the invention and the drawings appended hereto. Those skilled in the art will recognize, however, that the embodiment(s) of the present invention described herein are only examples of specific embodiment(s), set out for the purpose of describing the making and using of the present invention, and that the embodiment(s) shown and/or described herein are not the only embodiment(s) of a light fixture constructed in accordance with the teachings of the present invention.

The present invention addresses the above-described needs by providing a controller for a light fixture comprising an enclosure having circuitry contained therein for selectively switching one or more lamps of the light fixture on and/or off and a connector for mounting the enclosure to the light fixture and operably connecting the circuitry in the enclosure to the one or more lamps of the fixture. In one embodiment, the connector is constructed and includes components for managing the effect of heat on the efficiency and operating life of the component parts when mounted to the fixture.

Also provided is a modular light fixture comprising an elongate channel member, extension, shield, and end plate, each of said channel member and said extension being provided with one or more profiles comprising a "C"-shaped receptacle and a screw boss, and each of said extension and said shield being provided with structure for engaging the "C"-shaped receptacle formed in the profiles for either assembling (a) said shield to said extension or said channel or (b) said extension to said channel and said shield to said extension, with said end plate being secured to either (a) said channel, said extension, and said shield, or (b) said channel and said extension, by a plurality of screws extending through said end plate into the screw boss formed in the profiles.

In another aspect, the present invention provides a modular light fixture comprising an elongate channel having a "U"-shaped cross-sectional shape comprised of upright legs with a base connecting the legs, a first profile located proximate the ends of both legs and running along at least a substantial portion of the length of the channel, and a second profile located proximate the point at which both legs are connected to the base and running along at least a substantial portion of the length of the channel, each of the first and second profiles including a boss for receiving a screw and a "C"-shaped receptacle. An elongate shield is provided having structure formed proximate a first edge that is adapted for insertion into the "C"-shaped receptacle formed in the first and second profiles formed on said channel, and a second edge forming a curve for directing light from the light fixture downwardly from the fixture, as is an elongate extension having structure formed proximate a first edge that is adapted for insertion into the "C"-shaped receptacle formed in the first and second profiles formed on said channel, and a profile formed proximate the second edge, the profile formed on the second edge of said extension including a boss for receiving a screw and a "C"-shaped receptacle.

Also provided is an elongate channel comprising the following structure when viewed in cross-section: a base, upright legs connected on opposite sides of the base to form a "U"-shaped channel, profiles located proximate the ends of each upright leg at the point at which the legs connect to the base, each profile comprising a screw boss and a "C"-shaped receptacle, and a screw spline formed integrally with the base. The elongate channel is utilized, for instance, as the main support member for a lighting fixture.

Referring now to the figures, Figures IA and IB show exploded and assembled perspective views, respectively, of a first embodiment of a light fixture constructed in accordance with the teachings of the present invention in which portions of the light fixture are not shown for purposes of clarity.

Figure 2 shows a detailed perspective view of an end of the light fixture of Fig. 1. Figures 3A and 3B show exploded and assembled perspective views, respectively, of a second embodiment of a light fixture constructed in accordance with the teachings of the present invention and in which portions of the light fixture are not shown for clarity. Figure 4 shows a detailed perspective view of an end of the light fixture of Fig. 2.

Figures 5A and 5B are top plan and longitudinal sectional views, respectively, of an embodiment of a modular controller in accordance with the present invention.

Figure 6 is an exploded perspective view of a third embodiment of a light fixture constructed in accordance with the teachings of the present invention. Figures 7 A and 7B are elevational views of the shroud and end plate, respectively, of the light fixture shown in Fig. 6. Figures 8 A and 8B are elevational views of the shroud and end plate, respectively, of the light fixture of Fig. 6 as assembled in a second configuration for providing bottom access to the ballast and/or electrical components of the fixture.

Figures 9 A and 9B are elevational views of the shroud and end plate, respectively, of the component parts of the light fixture of Fig. 6 as assembled in a third configuration.

Figure 10 is an end view of the channel member of the light fixture of Fig. 6.

Figure 11 is a detail view of the component parts of the shroud of the light fixture of Fig. 6.

Figure 12 is an end view of a portion of the shroud of the light fixture of Fig. 6 showing the assembling of the component parts of the shroud to each other.

Figure 13 is an exploded perspective view of one of the end plates of the light fixture of Fig. 6 showing an exhaust fan mounted thereto for use in active control of the temperature of the electronic components of the light fixture.

In more detail and with reference to the figures, an embodiment of the light fixture of the present invention is indicated at reference numeral 10. Fixture 10 is comprised of shroud 12 and enclosure 14, shown in exploded and assembled views, respectively, in

Figs. IA and IB. Means is provided for affixing the enclosure 14 to shroud 12 in the form of a mount, indicated at reference numeral 16,_ comprised of a stand-off 18 mounted to shroud 12 and guides 20 formed integrally with or mounted to enclosure 14. Male and female electrical connectors 22 A and 22B are mounted to shroud 12 and enclosure 14 and enclosure 14 is mounted to shroud 12 by engaging the guides 20 to stand-off 18 and then sliding the enclosure 14 relative to shroud 12 until the two halves of electrical connector

22 are firmly seated in one another. A spring-loaded lock pin 24 is provided at the end of enclosure 14 opposite the direction in which enclosure 14 slides into position that pops up when the two halves of electrical connector 22 are firmly seated so as to provide an affirmative latch and signal of the mating of the connector halves 22. As set out below, the electrical connector 22 operably connects the control circuitry (also not shown) in enclosure 14 to the electrical circuit (not shown) into which fixture 10 is wired.

A second embodiment of a light fixture constructed in accordance with the present invention is indicated generally at reference numeral 26 in Figs. 3A and 3B. In the second embodiment, in which like parts are numbered with the same reference numerals utilized in Figs. 1 - 2, the direction in which the enclosure 14 is moved relative to shroud 12 to seat the two halves of connector 22 to each other is indicated by arrow 26. Referring to Fig. 4, the tip of a latch pin 28 is visible in a complimentary-shaped slot (not numbered) that provides the same function as the lock pin 24 shown in Fig. 2. As described above, the controller of the present invention is constructed to provide passive temperature management as best shown by reference to Figs. IB and 3B. Enclosure 14 is mounted to shroud 12 at a distance above shroud 12 to create a gap, or space, 30 to provide thermal isolation of the control circuitry in enclosure 14 from the heat produced by the lamps (not shown) mounted under the shroud 12 of fixture 10. Although experimentation has not shown that it generally is not needed except in extreme ambient or operating conditions, in another embodiment, gap 30 is provided with a layer of thermal insulation (not shown) to further protect the control circuitry within enclosure 14 from the heat produced by the lamps mounted under shroud 12.

To provide further temperature management and as shown in Figs. 5A and 5B, enclosure 14 is provided with components for active temperature management. The plate at one end of closure 14 is provided with one or more slits, or openings, 32 for passage of air into enclosure 14 and the plate at the other end of enclosure 14 is provided with an active thermal management device in the form of a fan 34 that exhausts air through openings 36 to pull air over the electronics mounted in enclosure 14. Fan 34 is switched as needed by a microprocessor located on an integrated circuit board 38 mounted in enclosure 14 in response to input from a temperature sensor 40 located in enclosure 14. Those skilled in the art will also recognize that active thermal management device may also be accomplished with a jet cooling device of the type available from Nuventix, Inc. (Austin, TX). In one embodiment, the microprocessor is also programmed to switch lamps in the fixture off if temperature rises above a predetermined level depending upon the operating range of the electronics, particularly ballast 42, in enclosure 14 as needed if the active thermal management device is unable to adequately cool the electronics in enclosure 14 and/or in the event of a failure of fan 34, and suitable connections and switches or relay(s) are provided from circuit board 38 within enclosure 14 to the wiring (not shown) that connects to electrical connector 22 for that purpose as known in the art. The microprocessor located on circuit board 38 is likewise programmed to control other functions and provided with suitable electrical connections and sensors (not shown) to, for instance, count start-ups of the lamps in the fixture, time-stamp the start-ups of the lamps in the fixture, date-stamp the first day of the service life of the fixture, and/or to turn one or more of the lamps in the fixture off after a predetermined period of time after they are switched on as summarized below. Other such functions and operating data will be apparent to those skilled in the art who have the benefit of this disclosure.

Referring now to Fig. 6, a third embodiment of a light fixture constructed in accordance with the teachings of the present invention is indicated generally at reference numeral 110. Light fixture 110 is comprised of a central channel member 112, shroud 114, end plates 116, and channel cover 118. As explained in more detail below, the channel member 112, shroud 114, and end plates 116 are retained to each other by a plurality of screws 120 passing through end plates 116 and into screw sockets (not visible in Fig. 1 due to the scale of the figure) formed in the ends of the component parts of shroud 114. Although not shown in the figures because they do not comprise part of the present invention, those skilled in the art will recognize that the ballasts and other electronic components of the light fixture of the present invention are mounted in the open channel provided by channel member 112 as described in more detail below and that channel cover 118 is provided to protect those electrical components.

Referring now to Figs. 7A and 7B, the end plate 116 and component parts of the shroud 114 of light fixture 110 are shown in detail. Shroud 114 is comprised of an extension 122 and shield 124 mounted to central channel member 112 and to extension 122, respectively. In the embodiment shown, each of channel member 112, extension 122, and shield 124 (and channel cover 118) is an extruded part, preferably comprised of aluminum, but those skilled in the art will recognize that any or all of channel 112, extension 122, shield 124, and/or cover 118 may be extruded from other materials, milled, or molded as may be suitable for use in construction of a light fixture and as may be cost-effective for a particular part. End plate 116 (Fig. 7B) is likewise comprised of metal or such other material as may be cost effective and capable of imparting the desired degree of structural rigidity to fixture 110, and may be cut, stamped, or molded in accordance with techniques known in the art. End plate 116 provides structural rigidity to fixture 110, and the component parts of shroud 114 are retained to each other and to channel member 112 by the screws 120 (not shown in Fig. 7B) passing through the holes 126 formed in end plate 116, the holes 126 being located so that screws 120 are received in the screw sockets 128 (Fig. 7 A and shown in detail in Figs. 10 and 12) formed in the ends of channel member 112 and the component parts of shroud 114. Additional screw holes 130 are provided in end plate 116 for receiving the screws to which the socket brackets 132 are mounted for receiving the light bulbs, socket brackets 132 being any of several types known in the art and therefore not being shown in detail here.

Figs. 8 A and 8B show the component parts of light fixture 110 assembled in a different configuration than shown in Figs. 6 and 7. In Figs. 8A and 8B, in which all the component parts are identical to the component parts of the light fixture 110 shown in Figs. 6 and 7 such that those parts are numbered with the same reference numerals, the central channel member 112 is inverted such that channel cover 118 is applied to channel member 112 on the open side facing downwardly into shroud 114 rather than on the open side facing upwardly. Those skilled in the art who have the benefit of this disclosure will recognize that the configuration of the light fixture of the present invention shown in

Figs. 6 and 7 provides so-called "top access" to the electrical components (not shown) mounted in channel member 112 and that the configuration shown in Fig. 8 provides bottom access to the electrical components. (not shown) mounted in channel member 112.

A third configuration of the component parts of the light fixture is shown in Figs. 9A and 9B, in which the light fixture of the present invention is assembled without the extension 122. By comparison of Figs. 9A and 9B to either of Figs. 7A, 7B or 8 A, 8B, it can be seen that the width of the shroud 114 and end plate 116 shown in Figs. 9A and 9B is less than the width of the shroud 114 and end plate 116 shown in Figs. 7 A, 7B and 8 A, 8B. The shield 124 of shroud 116 assembles directly to central channel member 112 in the same manner that extension 124 assembles to channel member 112 to provide the configuration shown in Figs. 9A, 9B, which is intended for use as a fixture for four T8 bulbs or six T5 bulbs. Those skilled in the art will recognize that the number and type of bulbs mounted in the fixture of the size shown in Figs. 9A, 9B will depend upon the socket brackets (not shown) mounted to the end plate 116 shown in Fig. 9B. Referring to Figs. 10 and 11, it can be seen that each of central channel member

112 and extension 122 is provided with a profile 134 (so-named because, as shown, channel 112 and extension 122 are manufactured by extrusion), channel 112 forming an elongate channel having a "U"-shaped cross-sectional shape comprised of upright legs 136 with a base 138 connecting the legs 136. As shown in Fig. 10, a profile 134 is located proximate the ends of both of legs 136 and proximate the point at which both of the legs 136 are connected to the base 138 of channel 112. As best shown in Fig. 11, the extension 122 is likewise provided with a profile 134. Each of the profiles 134, regardless of whether they are located on channel 112 or extension 122, includes a screw boss 140 for receiving a screw 120 as described above for assembling end plate 116 to the channel 112 and the extension 122 and/or shield 124 and a "C"-shaped receptacle 142 for receiving a reglet 144 formed proximate the edges of both extension 122 and shield 124.

The interaction of reglet 144 and "C"-shaped receptacle 142 is shown in Figs. 11 and 12 and allows extension 122 to be assembled to channel 112, and shield 124 to be assembled to extension 122, without sliding the parts relative to one another. Instead, and referring first to assembly of shield 124 to extension 122, reglet 144 is introduced into a "C"-shaped receptacle 142 along the length of shield 124 and extension 122 with shield 124 oriented in a first position at an acute angle relative to extension 122 {see shadow lines in Fig. 12). Reglet 144 is not rounded to the same radius as "C"-shaped receptacle 142 and is instead elongated in one direction, forming a boot 148 with a radiused toe 150 and rounded heel 152, and the acute angle between extension 122 and shield 124 allows the boot 148 to fit "toe down" into receptacle 142. With reglet 144 positioned in "C"- shaped receptacle 142 with shield 124 oriented at an acute angle relative to extension 122, the shield is then pivoted relative to extension 122 in the direction of arrow 146 to rotate reglet 144 in receptacle 142. As noted above, the boot 148 of reglet 144 is elongated and in the embodiment shown, the long dimension of boot 148 is slightly longer than the diameter of "C"-shaped receptacle, but the elongate lever arm provided by rotation of shield 124 relative to extension 122 exerts enough force to rotate the heel 152 of reglet 144 past the bullnose surface 154 forming the opening of receptacle 142 as shield 124 is rotated to the second, assembled position shown in Fig. 12. Rotation of shield 124 from the first position at an acute angle relative to extension 122 to the second, assembled position is limited by the interaction of the overhanging lip 156 (Fig. 11) formed on shield 124 and the landing 158 of extension 122 and by the interference between the surface of the neck 160 of reglet 144 and bullnose 154. As described above, profiles 134 are located proximate the ends of the legs 136 of channel 112 and proximate the connection between the legs 136 and base 138 of channel 112, and each profile 134 includes a receptacle 142 for receiving a reglet 144 formed proximate the edge of either extension 122 or shield 124 in the same manner as the reglet 144 formed on shield 124 is received in the receptacle 142 formed proximate the edge of extension 122.

Regardless of whether shield 124 is assembled to extension 122 and extension 122 is assembled to channel 112 or shield 124 is assembled directly to channel 112, channel 112 acts as the "spine" or main support member for the light fixture. As a result of this construction, the different configurations of the light fixture of the present invention shown in Figs. 7-9 are enabled, and it is for this reason (and another reason to be made clear below) that the light fixture of the present invention is referred to herein as being "modular" in its construction and "adaptive" in its many uses and operation.

Another reason that channel member 112 functions as the main support member of the light fixture is clear from Fig. 9. The base 138 of the "U"-shaped channel 112 provides a point of attachment for the electronics of the light fixture, an integrated circuit board 162 and ballast 164 being shown supported up off the surface of base 138 on the T- heads 166 formed integrally with base 138_and_ secured to the base 138 of channel 112 by screws 168 (only one such screw showing in the end view shown in Fig. 10) received in screw spline 170 formed integrally with the base 138 of channel member 112. As noted above, heat is detrimental to the electronics mounted in channel 112, and the mounting of the electronics in channel 112 results in the isolation, or compartmentalization, of the heat source (the light bulbs) and the electronics (the circuit board 162 and ballast 164), and further isolation of the electronics from the heat produced by the bulbs is accomplished by mounting the electronics up off the surface of the base 138 of channel 112 on T-heads 166 to allow for the circulation of air under the electronics. In one embodiment, a thermal insulator 172 is sandwiched between the electronics and the top of T-heads 166 to provide even greater isolation of circuit board 162 and ballast 164 from the heat produced by the light bulbs mounted in fixture 110. To provide passive management of the temperature at which the electronics of light fixture 110 operate, and as described above, the cover 118 is assembled to channel 112 to form an enclosure for the electronics that is effectively thermally isolated from the heat produced by the bulbs. The underside of cover 118 is provided with two spaced nipples 174, and by reference to Figs. 7-11, it can be seen that the nipples 174 are spaced so as to interact with and complete a friction fit between nipples 174 and the corners 176 of the profiles 134 formed either proximate the ends of legs 136 or proximate the point at which both of the legs 136 are connected to the base 138 of channel 112 depending upon whether the fixture is to be assembled for top access (Figs. 7 and 11) or bottom access

(Fig. 8) to the electronics mounted in the enclosure formed by cover 118 and channel 112.

To provide active temperature management in the enclosure formed by cover 118 and channel 112, one of the end plates 116 of fixture 110 is provided with one or more slits, or openings, 178 (see Fig. 9B) for passage of air into the enclosure and the end plate at the other end of fixture 110 is provided with a small fan 180 as shown in Fig. 10 that exhausts through the openings 182 (Figs. 7B and 8B) to pull air through the enclosure over the electronics mounted therein. Operation of fan 180 is as described above in connection with the embodiments shown in Figs. 1-5. The microprocessor is also programmed to switch one or more of the lamps in the fixture off if temperature rises above a predetermined level (generally selected based on the operating range of the electronics, particular ballast 164) as_ needed ifjan 180 is_ unable to provide adequate cooling of the electronics mounted in channel 112 and/or in the event of a failure of fan 180, and suitable connections and switches or relay(s) are provided from circuit board 162 to the wiring between the ballast 164 and electrical socket brackets 132 for that purpose as known in the art. The microprocessor located on circuit board 162 is likewise programmed to control and/or monitor other functions in the same manner as described above in connection with the embodiments shown in Figs. 1-5. In another embodiment, the light fixture of the present invention is provided with a plug-in module, shown schematically at reference numeral 184 that mounts to one of the end plates 116 on pins (not numbered) that includes the target LED, microprocessor, and appropriate connectors and outputs, all as described in the above-incorporated International Application No. PCT/US2008/003845, TARGETED SWITCHING OF ELECTRICAL APPLIANCES AND METHOD, filed March 24, 2008, for targeted switching of the lamps in fixture 110 on and off in accordance with the invention described and claimed in that application. The pin connector on plug-in module is received in a ribbon connector (not shown) mounted to the end plate that terminates on integrated circuit board 162 to provide the necessary connections to the bulbs in fixture 110. Briefly, that prior application describes on/off switching and/or step dimming for light fixtures and/or other electrical appliances in a commercial installation that is adaptable for different levels of control and that is comprised of multiple control components including a hand-held, transportable remote for targeted switching of fixtures and/or appliances, a coordinator for managing the system in accordance with operator- selectable operations rules, and an optional system administrator for receiving operational data, changing operations rules, and managing other tasks and capabilities of control components. The coordinator receives (via hard-wired or wireless network) operational information from fixtures and/or appliances to manage the system in accordance with user-specific operations rules and employs a real time clock (RTC) that enables time- related functions and features. Each fixture or appliance in an installation utilizing the system described in this prior application employs a current sensor to monitor and report on the individual fixture's/appliance's actual energy consumption. This information is used to validate system performance (as compared to system specifications), allowing operators to accurately document relative advantages in using different ballast/lamp manufacturers, a capability useful in, for instance, validating compliance with governmental and non-governmental incentives for energy efficiency, as well as providing a useful management tool and a feature that makes possible many related advantages in operation and application, including:

Temperature Management. The system monitors and controls the temperature of the fixtures/appliances through the use of temperature sensors and selected operations rules. Management of fixture temperatures is essential in achievement of maximum energy efficiency of the lamp/ballast combination.

Temperature management of electronic ballasts and controls is also important in extending the useful life and optimum functioning of those components.

Temperature management includes the recording and processing of data and specific responses or actions of temperature control, for example, temperature sensors detect an internal electronic module temperature of 32⁰C. The fixture's controller switches a cooling fan on and the fixture continues operation routine and the coordinator is informed through routine operating data collection. If the reported temp is greater than 5O⁰C for example, the fan remains on, a temperature alert is issued to the coordinator, and the coordinator implements the user-specific operating rule to determine action. For example, if the fixture's group affiliation is such that it can be dimmed safely, the coordinator may turn off two (of six, for instance) operating lamps to contain fixture operating temperature within pre- established parameters (i.e., temperatures within the specified ballast warranty @60°C). On information and belief, this system provides several previously unavailable advantages in the operation of the light fixture(s), for instance, controlling operating temperatures to assure maximum system energy efficiency (watts/lumen) and extending the useful life of the system, therefore reducing operating costs and disposal burdens on the environment. The system also enables users to document compliance with the terms of warranty for the components of the system (electronics, lamps, etc).

Lamp Life Optimization. This system also has the distinct advantage of simultaneously optimizing lamp life and extending required service intervals. In accordance with the. method of the present invention, fixtures report any change in operation of status to a coordinator. The coordinator also routinely "polls" fixtures to audit, or verify, that operations are properly logged and that energy consumption complies with user-specific parameters. The coordinator records and stores operational data for each set of lamps for each fixture and uses this data to activate certain operations rules. For example, if the user specifies that the sequence of lamp use should be rotated when the first set of lamps reaches 100% of lamp manufacturer's rated life, then the coordinator changes the relay sequence so that this group of lamps moves from first to last in the relay activation sequence. The lamps are still available if full illumination is required of the fixture; however, lamps with longer remaining useful life are activated first, maximizing the useful life of the lamps and extending the maintenance intervals. This documentation of lamp utilization is very useful in determining which lamps to replace and the warranty status on any lamp that fails prematurely. Lamp/Ballast Failure Response. The system and method of the present invention is also capable of detecting a ballast and/or lamp failure and responding in accordance to user-defined operating rules. During the course of operation, the coordinator compares the operation status of the fixture with its reported energy usage to detect a malfunction in fixture operation. For example, if fixture status indicates two lamp operation and energy usage is out of typical consumption for two lamp operation (as defined by the user), the coordinator identifies a malfunction that is reported to the system administrator so that service can be scheduled and warranty status determined. The advantage of this feature is that the malfunctioning group is replaced automatically and that properly functioning groups will assume the relay sequence of the malfunctioning group. Because the coordinator knows the location and identity of the malfunctioning unit, effort and cost can be saved in trouble shooting and searching for malfunctioning lamps.

Additional Equipment Monitoring. The coordinator of the system of the present invention is capable of processing inputs from additional electrical appliances beyond the light fixtures. Using this feature, other energy consuming appliances become part of the network, reporting their operational data to the coordinator which can then process, report or act upon those inputs. This configuration of the system of the present invention allows wireless or hard- wired communication between the coordinator and a system administrator to monitor and evaluate the energy consumption of a broader group of appliances. This network can also be used to convey data for other purposes such as scheduling.

Those skilled in the art who have the benefit of this disclosure will recognize that the light fixture of the present invention provides a level of adaptability and ease of assembly that allows the fixture to be utilized in many installations, the fixture being assembled on-site as needed for the particular installation and serviced on-site by detaching and replacing the controller without dis-assembling the fixture and/or disconnecting any wires quickly and with minimal exposure to electrical current. Further, the ability of the controller of the present invention to monitor and control operating temperature, and to monitor and control other operating parameters of the lighting fixture, makes further adaptation of the fixture possible for use even in demanding installations of, for instance temperature extremes. It will also be apparent that the definition of the word "lighting fixture" as used herein is broad enough to encompass, for instance, a sodium vapor street light having the controller mounted in the light pole so that the lamp is controlled, and the controller is serviced, from street level without the need for a lift and the attendant safety concerns. Similarly, those skilled in the art will recognize that although the description set out herein is a description of a controller adapted for use with a light fixture in which fluorescent lamps are mounted, the present invention also contemplates the mounting of other lamps in the fixture of the present invention. For instance, halogen lamps generate substantial heat such that the light fixture described herein is particularly well suited for use in a fixture utilizing halogen lamps because the lamps are separated and insulated from the electronic components by the compartmentalization of the electronics. The light fixture of the present invention is also adaptable for use with LED light sources and metal halide fixtures.

Those skilled in the art who have the benefit of this disclosure will also recognize that certain changes can be made to the component parts of the apparatus of the present invention without changing the manner in which those parts function and/or interact to achieve their intended result. By way of example, those skilled in the art who have the benefit of this disclosure will recognize that it is possible to more than one extension 122 can be assembled to the central channel member 112 between shield 124 and channel 112. It will also be recognized that the cover 118 may be provided with a grommet or other structure for passing wires or electrical conduit into the interior of the enclosure formed by cover 118 and channel 112. Also, the underside of each of extensions 122 and shield 124 may be formed in the shape of a reflector (or reflectors) for directing more light from the bulbs mounted in fixture 110 downwardly and/or the socket brackets 132 that are mounted to end plates 116 may be provided with structure for supporting one or more reflectors shaped to direct light downwardly from fixture 110. Likewise, either of extension 122 and shield 124 or socket brackets 132 could be configured to support a diffuser for the light produced by the bulbs mounted in fixture 110. All such changes, and others that will be clear to those skilled in the art from this description of the preferred embodiment(s) of the invention, are intended to fall within the scope of the following, non-limiting claims.

Claims

WHAT IS CLAIMED IS:

1. A controller adapted for mounting to a light fixture for selectively switching one or more lamps in the light fixture on and/or off comprising: an enclosure; a mount integral with said enclosure and adapted for releasably mounting said enclosure to a light fixture; and electrical circuitry within said enclosure which, when said enclosure is mounted to a light fixture, is operable to selectively switch one or more lamps in the light fixture on and/or off.

2. The controller of claim 1 wherein said enclosure is mounted to a light fixture on said mount with a gap between said enclosure and the light fixture.

3. The controller of claim 1 wherein said electrical circuitry is connected to the circuit into which the light fixture is wired when mounted to said light fixture.

4. The controller of claim 1 additionally comprising an electrical connector for connecting said electrical circuitry to the circuit into which the light fixture is wired when said enclosure is mounted to the light fixture.

5. The controller of claim 1 additionally comprising a thermostatically- controlled fan for cooling said electrical circuitry.

6. The controller of claim 1 additionally comprising a receiver for sensing a signal from a wireless remote control, said receiver being operably connected to said electrical circuitry for switching one or more lamps in the light fixture on and/or off.

7. A modular light fixture comprising: an elongate channel having a "U"-shaped cross-sectional shape comprised of upright legs with a base connecting the legs, a first profile located proximate the ends of both legs and running along at least a substantial portion of the length of the channel, and a second profile located proximate the point at which both legs are connected to the base and running along at least a substantial portion of the length of the channel, each of the first and second profiles including a boss for receiving a screw and a "C"-shaped receptacle; an elongate shield having structure formed proximate a first edge that is adapted for insertion into the "C"-shaped receptacle formed in the first and second profiles formed on said channel, and a second edge forming a curve for directing light from the light fixture downwardly from the fixture; and an elongate extension having structure formed proximate a first edge that is adapted for insertion into the "C"-shaped receptacle formed in the first and second profiles formed on said channel, and a profile formed proximate the second edge, the profile formed on the second edge of said extension including a boss for receiving a screw and a "C"-shaped receptacle.

8. The modular light fixture of claim 7 wherein said shield is assembled to either of said channel or said extension.

9. The modular light fixture of claim 7 wherein the structure formed on the second edge of said shield that is adapted for insertion into the "C"-shaped receptacle formed in the first and second profiles of said channel, or the "C"-shaped receptacle in the profile formed on the second edge of said extension, includes an elongated boot and said shield is rotated from a first position at an acute angle relative to said channel, or at an acute angle relative to said extension, to an assembled position in which the elongated boot is frictionally engaged to the inside surface of the "C"-shaped receptacle.

10. The modular light fixture of claim 9 wherein said shield is provided with an overhanging lip for interacting with a landing formed on said extension for limiting rotation of said shield relative to said extension.

11. The modular light fixture of claim 9 wherein the long dimension of the elongated boot is longer than the diameter of the "C"-shaped receptacle.

12. The modular light fixture of claim 7 additionally comprising a cover for releasably engaging said channel member.

13. The modular light fixture of claim 12 wherein said cover is provided with first and second spaced nipples for engaging the corners of the first and second profiles formed on said channel.

14. The modular light fixture of claim 7 additionally comprising an end plate, said end plate being provided with a plurality of holes for receiving screws for securing said end plate to the screw boss formed in one or more of the first and second profiles formed on said channel and the screw boss formed in the profile formed on said extension.

15. The modular light fixture of claim 14 wherein said end plate is provided with a hole for the passage of air into the channel member.

16. A modular light fixture comprising an elongate channel member, an elongate extension, an elongate shield, and an end plate, each of said channel member and said extension being provided with one or more profiles comprising a "C"-shaped receptacle and a screw boss, and each of said extension and said shield being provided with structure for engaging the "C"-shaped receptacle formed in the profiles for either assembling (a) said shield to said extension or said channel or (b) said extension to said channel and said shield to said extension, with said end plate being secured to either (a) said channel, said extension, and said shield, or (b) said channel and said extension, by a plurality of screws extending through said end plate into the screw boss formed in the profiles.

17. The modular light fixture of claim 16 wherein the profile formed on said extension is located along one edge of said extension and the structure on said shield for engaging the "C"-shaped receptacle formed in the profile on said extension is located along one edge of said shield.

18. The modular light fixture of claim 17 wherein the structure formed on said shield for engaging the "C"-shaped receptacle comprises a reglet having an elongated boot for insertion into the "C"-shaped receptacle, the boot of said reglet frictionally engaging the inside surface of the "C"-shaped receptacle to retain said reglet therein.

19. The modular light fixture of claim 16 wherein the structure on said extension for engaging the "C"-shaped receptacle formed in the profiles on said channel is located along one edge of said extension.

20. The modular light fixture of claim 16 wherein said shield is rotated from a first position at an acute angle relative to said extension to a second, assembled position when engaged to said extension.

21. The modular light fixture of claim 16 additionally comprising a cover for releasably engaging said channel.

22. An elongate channel member comprised of the following structure when viewed in cross-section: a base; upright legs connected on opposite sides of said base to form a "U"-shaped channel; profiles located proximate the ends of each of said upright legs and at the point at which both said legs connect to said base, each of said profiles comprising a screw boss and a "C"-shaped receptacle; and a screw spline formed integrally with said base.

23. The channel member of claim 22 additionally comprising one or more T- heads formed integrally with said base.

24. The channel member of claim 22 additionally comprising a thermal insulator applied to said base.