WO2012093291A1

WO2012093291A1 - A floodlight module with an elbow connector

Info

Publication number: WO2012093291A1
Application number: PCT/IB2011/050055
Authority: WO
Inventors: Daniel Beasley; Kong Yeow Lai; Yong Kong Khor; Chee Wei Soe; Hin Keat LOO
Original assignee: Iq Group Sdn Bhd
Priority date: 2011-01-07
Filing date: 2011-01-07
Publication date: 2012-07-12
Also published as: DE212011100193U1; CN203868804U

Abstract

A floodlight module (30) comprises a heat sink (31), light emitting diodes (39), a gasket (32), focusing cones (33) and a transparent cover (34). An elbow connector (10), with a bottom opening (12) and a side opening (11), is disposed between the floodlight module (30) and a mounting box (20). The elbow connector (10) can be a 90 degrees angled part or a cylindrically- shaped part. The floodlight module (30) is connectable to and tiltable about the side opening (11) of the elbow connector (10) with a tilt mechanism, and is offset from the mounting box (20) in a sideward direction. The bottom opening (12) of the elbow connector (10) is connectable to and is swingable about the top of a vertical opening (21) disposed therein the mounting box (20), with a swing mechanism.

Description

A FLOODLIGHT MODULE WITH AN ELBOW CONNECTOR

Technical Field

The present invention relates generally to a floodlight apparatus comprising essentially a mounting box, a floodlight module, associated lighting components and circuitry. It relates specifically to a floodlight module that can be swung and/or tilted, with the assistance of an elbow connector disposed between said mounting box and said floodlight module.

Background Art

Generally, a prior art floodlight apparatus comprises essentially a mounting box, a floodlight module, associated components and circuitry. More specifically, a prior art motion and/or dusk activation floodlight apparatus comprises essentially a mounting box, a floodlight module, a sensor, associated components and motion and/or dusk activation circuitry.

United States Patent Number US 5649761 discloses a motion detector with side-pivoting light fixture. The light fixture is controlled by a pyro-infrared motion detector. One or more lamp holders are attached to a base and a detector housing carrying the motion detector is also attached to the base. The lamp holder assembly is connected to the base by a support arm that is pivotably connected to a side wall of the socket housing offset from the end of the socket housing.

The main disadvantage of the US 5649761 invention is that the side-pivoting light fixture has limited freedom of movement in upward and sideward directions. Essentially, the light fixture is emitting light forward of the motion detector.

European Patent Publication Number EP 2107295 discloses a lighting device including a lamp carrier or bulb holder carrying at least one light emitting diode light source which is controlled. The lamp carrier or bulb holder is flat, with one light emitting side and the other heat dissipation side. The lamp carrier or bulb holder is adjustable to focus and direct emitted light. With the assistance of a connecting arm, the lamp carrier or bulb holder is rotatable about a horizontal pivot disposed on the lamp carrier or bulb holder. Additionally, the lamp carrier or bulb holder can be swung about a vertical axis.

One disadvantage of the EP 2107295 lighting device is that its heat sink design is not efficient. Another disadvantage is that the connecting arm and its end attachment define a U-configuration, disposed directly above the mounting box. One end of the connecting arm includes a horizontal pivot. The other end of the connecting arm includes another horizontal axis. As a result, the lamp carrier or bulb holder can be tilted. However, the illumination positions of the lamp carrier or bulb holder are restricted due to the connecting arm and the U-configuration.

Summary of the Invention

A primary object of the present invention is to offset a floodlight module from a mounting box in a floodlight apparatus in a sideward direction.

Another object of the present invention is to reduce the weight of the floodlight module while maintaining its heat dissipation with a unique heat sink design.

Yet, another object of the present invention is to simplify the connection between the floodlight module and the mounting box, by reducing the number of components used during construction.

The other object of the present invention is to allow for the swinging and/or tilting of the floodlight module.

These objects are achieved in which an elbow connector, with a bottom opening and a side opening, is disposed between the floodlight module and the mounting box. The floodlight module is connectable to and is tiltable about the side opening of the elbow connector with a tilt mechanism, and is offset from the mounting box in a sideward direction. The bottom opening of the elbow connector is connectable to and is swingable about the top of a vertical opening disposed therein the mounting box, with a swing mechanism.

The floodlight module incorporating a heat sink is essentially extruded or cast as one piece, with one side for light emission and the other side for heat dissipation. One specific embodiment of the floodlight module can be flat and rectangular in shape. The rear side of another specific embodiment of the floodlight module can be curved. A unique heat sink is integrally disposed on one outer surface of the floodlight module being the heat dissipation side. The other side of the floodlight module with relevant lighting components mounted is made light-emitting. The unique heat sink design includes a plurality of elongate finned elements with at least one raised portion. In the specific embodiment shown in the figures, two raised portions at the heat dissipation side of the heat sink define a mounting space for lighting components like light emitting diodes, gasket, focusing cones, and transparent cover.

Brief Description of the Drawings

In order that the present invention may be more readily understood, the following description is given, by way of example, of one specific embodiment of an elbow connector.

Figure 1a shows a perspective view of a 90 degrees elbow connector.

Figure 1b shows a side view of the 90 degrees elbow connector as shown in Figure 1a.

Figure 1c shows a bottom view of the 90 degrees elbow connector as shown in Figure 1a.

Figure 2a shows a top perspective view of a mounting box.

Figure 2b shows a top view of the mounting box as shown in Figure 2a.

Figure 2c shows a bottom view of the mounting box as shown in Figure 2a.

Figure 3a is an exploded view of a 90 degrees elbow connector attached with a heat sink, about to be assembled with conducting plates with light emitting diode light sources, a gasket, focusing cones and a transparent cover, the elbow connector being secured to the top of the mounting box equipped with a sensor.

Figure 3b shows an exploded view of the mounting box, the 90 degrees elbow connector, a hinge box and a heat sink.

Figure 3c shows an assembled view of the hinge box, the 90 degrees elbow connector and the mounting box, and the sensor.

Figure 3d shows a cross-section view of an assembly of a floodlight module, the 90 degrees elbow connector, the mounting box and the sensor, when the floodlight module is vertically disposed and swung to one side of the mounting box whence emitted light is directed forward.

Figure 3e shows a back view in perspective of the floodlight module, with the hinge box attached.

Figure 4a shows one vertically disposed position of a floodlight module swung to one side of a mounting box correspondingly at zero degree whence emitted light is directed forward.

Figure 4b shows the relative position of a swing plate with a first catch means engaging a fixed stopper in a swing mechanism corresponding the position as shown in Figure 4a.

Figure 4c is a view of a tilt mechanism corresponding the position as shown in Figure 4a, showing the relative position of a compression plate with a rotatable stopper not engaging a fixed stopper.

Figure 5a shows another vertically disposed position of the floodlight module swung to the front of the mounting box correspondingly at 90 degrees whence emitted light is directed sideward.

Figure 5b shows the position of the swing plate with a first and a second catch means relative to a fixed stopper in a swing mechanism corresponding the position as shown in Figure 5a.

Figure 6a shows yet another vertically disposed position of the floodlight module swung to the other side of the mounting box correspondingly at 180 degrees whence emitted light is directed backward.

Figure 6b shows the relative position of the swing plate with a second catch means engages a fixed stopper in a swing mechanism corresponding the position as shown in Figure 6a.

Figure 7a shows the position of the floodlight module at one side of the mounting box, with the light-emitting side of the floodlight module tilted to 80 degrees from a vertical plane, whence emitted light is directed downwards to the ground.

Figure 7b is a cross-section view of a tilt mechanism taken along AA section of Figure 7a, showing the relative position of a compression plate with a rotatable stopper about to engage a fixed stopper.

Figure 8a shows the position of the floodlight module at one side of the mounting box, with the light-emitting side of the floodlight module tilted to 100 degrees from a vertical plane, whence emitted light is directed downwards to the ground.

Figure 8b is a cross-section view of a tilt mechanism taken along AA section of Figure 8a, showing the relative position of a compression plate with a rotatable stopper about to engage a fixed stopper.

Figure 9 shows the position of the floodlight module at one side of the mounting box, with the light-emitting side of the floodlight module tilted to 225 degrees from the vertical plane, whence emitted light is directed backward and upward to a wall.

Figure 10 is a perspective view of a cylindrical elbow connector secured to the top of a mounting box equipped with a sensor, and attached with a floodlight module comprising a heat sink, a gasket, focusing cones and a transparent cover.

Detailed Description of the Invention

For the sake of simplicity, similar components with similar functions are given same numerals. To distinguish them, suffix 'a' or 'b' is added after the numeral. A motion and/or dusk activation floodlight apparatus is shown in the drawings whereas a more general-purpose floodlight apparatus is to be covered in the scope of the present invention.

In this disclosure, an elbow connector (10) is disposed between a mounting box (20) and a floodlight module (30). One specific embodiment of the elbow connector (10) is a 90 degrees angled part. Another specific embodiment of the elbow connector (10) is a cylindrically-shaped part. The elbow connector (10) works similarly for the two specific embodiments, with some minor modifications.

As seen in Figures 1a, 1b and 1c, a 90 degrees elbow connector (10) is substantially right-angled, with a side opening (11) and a bottom opening (12). The 90 degrees elbow connector (10) is preferably extruded or cast as one hollow piece with internal holding structures (13) at both openings. At the side opening (11), the internal holding structure (13) includes three receiver columns as well as a central opening. At the bottom opening (12), the internal holding structure (13) includes three receiver holes and a central opening.

As seen in Figures 2a, 2b and 2c, a mounting box (20) is substantially inverted L-shaped. One vertical section (27) of the mounting box (20) is meant for mounting onto a wall. The top section (26) is protruding and includes a vertical opening (21) towards its end. The bottom of this vertical opening (21) engages a sensor (22) electrically connected to motion and/or dusk activation circuitry. The top of this vertical opening (21) engages the bottom opening (12) of the elbow connector (10), with the assistance of a swing mechanism. The swing mechanism provides a swing plate (23) to attach to and to secure the internal holding structure (13) therein the top of this vertical opening (21) to the bottom opening (12) of the elbow connector (10).

As seen in Figures 3a and 3b, the 90 degrees elbow connector (10) is disposed between the mounting box (20) and a floodlight module (30). The mounting box (20) is a junction box to facilitate wall mounting and to carry a hemispherical-shaped sensor (22) and associated motion and/or dusk activation circuitry. One specific embodiment of the floodlight module (30) is substantially flat and rectangular in shape. In another specific embodiment, the rear side of the floodlight module (30) incorporating the heat sink (31) can be curved.

The present invention also teaches a unique heat sink design. The heat sink (31) is substantially extruded or cast as one piece and made from aluminium material. In Figures 3a, 3b and 3e, one specific embodiment of the heat sink (31) is substantially a flat and rectangular platform with an overall U-shaped profile. One outer side is integrally disposed with a plurality of parallel and spaced apart elongate finned elements (41) spanning the width of the platform. Two edges of the platform are raised with longer finned elements. These two raised portions (40) protrude on the two edges of the platform defining a mounting space for lighting components such as the light emitting diodes (39), gasket (32), focusing cones (33) and transparent cover (34). Raised portions (40) increase the heat dissipation capability of the floodlight module (30).

It is important to note that a plurality of conducting plates (38) carrying light emitting diodes (39) are secured to one inside surface of the mounting space. The conducting plates (38) allow heat generated to be transferred to the finned elements.

As seen in Figures 3b and 3c, the side opening (11) of the 90 degrees elbow connector (10) is swung to one side of the mounting box (20). A hinge box (35) is employed to attach to the side opening (11) of the elbow connector (10) and also to secure to the back of the heat sink (31) with screw means. The hinge box (35) is disposed substantially in the same plane as the heat sink (31). The hinge box (35) is substantially half-tubular with internal hollow compartments. It is preferably extruded or cast as one piece.

In other words, the side opening (11) of the 90 degrees elbow connector (10) is attached to the floodlight module (30) incorporating the heat sink (31), light emitting diodes (39) on conducting plates (38), with the assistance of the hinge box (35). One arm of the 90 degrees elbow connector (10) is extended, so that the floodlight module (30) is offset in a sideward direction and clear of the mounting box (20). It is important to reduce the weight of the floodlight module (30), so that a swinging and/or tilting action can be facilitated, while its heat dissipation is maintained.

A tilt mechanism comprising essentially a compression plate (37) is employed to attach to and to secure the side opening (11) of the 90 degrees elbow connector (10) with screw means. When the floodlight module (30) is tilted to a position, this compression plate (37) provides enough resistance to keep it in that position. The side opening (11) of the elbow connector (10) includes internal holding structures (13) to receive the screw means. This tilt mechanism also allows the hinge box (35) and the floodlight module (30) to tilt about the side opening (11).

For the ease of explanation, a first vertical plane is defined, whence an axial plane of the side opening (11) of the 90 degrees elbow connector (10) is vertically disposed. Tilting angle is measured from this first vertical plane to the light-emitting side of the floodlight module (30). A preferred range of tilting angles is zero degree to 340 degrees. At zero degree, the light-emitting side is substantially in alignment with the first vertical plane where emitted light is directed forward in one way. At 340 degrees, the light-emitting side is substantially in alignment with the first vertical plane where emitted light is directed backward in the other way.

As seen in Figures 3c and 3d, the compression plate (37) secures the hinge box (35) as well as the floodlight module (30) to the side opening (11) of the 90 degrees elbow connector (10).

Also seen in Figure 3d, a swing plate (23) passes through the vertical opening (21) of the mounting box (20) to engage and secure the bottom opening (12) of the 90 degrees elbow connector (10). The swing plate (23) is an essential component of the swing mechanism and it functions very much like the compression plate (37).

For the ease of explanation, a second vertical plane is defined, whence an axial plane of the vertical opening (21) of the mounting box (20) is vertically disposed and perpendicular to the forward axis of the mounting box (20). Swinging angle is measured from this second vertical plane to the light-emitting side of the floodlight module (30). A preferred range of swinging angles is zero degree to 180 degrees. At zero degree, the light-emitting side is substantially in alignment with the second vertical plane where emitted light is directed forward. At 180 degrees, the light-emitting side is substantially in alignment with the second vertical plane where emitted light is directed backward.

Various orientations of the present invention relative to the mounting box (20) are now explained, after swinging about the vertical plane of the mounting box (20) to a selected position, and tilting about the vertical plane of the side opening (11) of the 90 degrees elbow connector (10) to a selected position. The mounting box (20) is mounted vertically onto a wall.

As shown in Figure 4a, the floodlight module (30) is disposed at one side of the mounting box (20) at a swing position at zero degree. The floodlight module (30) is orientated almost vertically to the ground, whence emitted light is directed forward. This position is also known as the tilt position at zero degree.

As shown in Figure 4b, a swing plate (23) is attached to the bottom opening (12) of the 90 degrees elbow connector (10). A first catch means (24a) on the swing plate (23) engages one side of a fixed stopper (25) in a swing mechanism at this orientation.

As shown in Figure 4c, the floodlight module (30) is attached to the side opening (11) of the 90 degrees elbow connector (10). The plane of the floodlight module (30) is disposed vertically, with the light-emitting side facing forward. A rotatable stopper (28) of the compression plate (37) does not engage the fixed stopper (25) in a tilt mechanism at this orientation.

As shown in Figure 5a, the floodlight module (30) is disposed at the front of the mounting box (20). It is orientated almost vertically to the ground, whence emitted light is directed sideward. This orientation can be considered as a swing position at 90 degrees and a tilt position at zero degree.

As shown in Figure 5b, the first and second catch means (24a, 24b) on the swing plate (23) do not engage the fixed stopper (25) at this orientation.

As shown in Figure 6a, the floodlight module (30) is disposed at the other side of the mounting box (20). It remains orientated almost vertically to the ground, whence emitted light is directed backward. This orientation can be considered as a swing position at 180 degrees and a tilt position at zero degree.

As shown in Figure 6b, a second catch means (24b) on the swing plate (23) engages the other side of the fixed stopper (25) in a swing mechanism.

As shown in Figure 7a, the floodlight module (30) is disposed at one side of the mounting box (20). It is tilted at 80 degrees from the vertical plane, whence emitted light is directed forward and downward. This orientation can be described as a tilt position at 80 degrees and a swing position at zero degree.

As shown in Figure 7b, the rotatable stopper (28) on the compression plate (37) is about to engage the fixed stopper (25) in a tilt mechanism at this orientation.

As shown in Figure 8a, the floodlight module (30) is disposed at one side of the mounting box (20). It is tilted at 100 degrees from a vertical plane, whence emitted light is directed forward. This orientation can be described as a tilt position at 100 degrees and a swing position at zero degree.

In Figure 8b, the rotatable stopper (28) on the compression plate (37) is about to engage the fixed stopper (25) in a tilt mechanism at this orientation.

An advantage of the floodlight module (30) with the 90 degrees elbow connector (10) is shown in Figure 9. The light-emitting side of the floodlight module (30) is tilted to 225 degrees from the vertical plane, whence emitted light is directed backward and upward.

A lighting orientation is chosen by selecting a swing action and a tilt action of the floodlight module (30). The light-emitting side of the floodlight module (30) can be directed forward or backward at various lighting orientations when the floodlight module (30) is disposed at either side of the mounting box (20). The light-emitting side of the floodlight module (30) can be directed sideward when the floodlight module (30) is disposed at the front of the mounting box (20). These lighting orientations are different from the lighting orientations of the flat light module as taught in EP 2107295 document.

As seen in Figure 10, another specific embodiment of the elbow connector (10) is a cylindrically-shaped part, which incorporates a side opening (11) and a bottom opening (12), very much the same as the 90 degrees elbow connector.

Claims

A floodlight apparatus comprising essentially a mounting box (20), a floodlight module (30), associated lighting components and circuitry is characterized in which

an elbow connector (10), with a bottom opening (12) and a side opening (11), is disposed between the floodlight module (30) and the mounting box (20);

the floodlight module (30) is connectable to the side opening (11) of the elbow connector (10), and is offset from the mounting box (20) in a sideward direction;

the bottom opening (12) of the elbow connector (10) is connectable to the top of a vertical opening (21) disposed therein the mounting box (20),

whereby the floodlight module (30) can be swung and/or tilted.
A floodlight module (30) with an elbow connector (10) as in Claim 1 in which the mounting box (20) is further equipped with a sensor (22), motion and/or dusk activation circuitry.
A floodlight module (30) with an elbow connector (10) as in Claim 1 in which the elbow connector (10) is a 90 degrees angled part.
A floodlight module (30) with an elbow connector (10) as in Claim 1 in which the elbow connector (10) is a cylindrically-shaped part.
A floodlight module (30) with an elbow connector (10) as in Claim 1 in which

the floodlight module (30) comprises a heat sink (31), light emitting diodes (39), a gasket (32), focusing cones (33) and a transparent cover (34);

the heat sink (31) is essentially one piece with one side for light emitting and the other side for heat dissipation; a plurality of elongate finned elements (41) are disposed on the heat dissipation side of the heat sink (31), with at least one raised portion (40) with longer finned elements (41); a mounting space is defined on the light-emitting side, to receive the light emitting diodes (39), gasket (32), focusing cones (33) and the transparent cover (34),

whereby the weight of the floodlight module (30) is reduced while the heat dissipation is maintained with said heat sink design.
A floodlight module (30) with an elbow connector (10) as in Claim 5 in which the floodlight module (30), incorporating the heat sink (31), is flat and rectangular in shape.
A floodlight module (30) with an elbow connector (10) as in Claim 5 in which the rear side of the floodlight module (30), incorporating the heat sink (31), has a curved profile.
A floodlight module (30) with an elbow connector (10) as in Claim 5 in which the heat sink (31) and the elbow connector (10) are extruded.
A floodlight module (30) with an elbow connector (10) as in Claim 5 in which the heat sink (31) and the elbow connector (10) are cast.
A floodlight module (30) with an elbow connector (10) as in Claim 1 in which the floodlight module (30) is separately selected to tilt about the side opening (11) of the elbow connector (10) with the assistance of a tilt mechanism.
A floodlight module (30) with an elbow connector (10) as in Claim 10 in which the tilting angle is zero to 340 degrees from a first vertical plane of the side opening (11) wherein the first vertical plane is defined whence an axial plane of the side opening (11) of the elbow connector (10) is vertically disposed.
A floodlight module (30) with an elbow connector (10) as in Claim 1 in which the floodlight module (30) is separately selected to swing about the top of the vertical opening (21) of the mounting box (20) with the assistance of a swing mechanism.
A floodlight module (30) with an elbow connector (10) as in Claim 12 in which the swinging angle is zero to 180 degrees from a second vertical plane of the vertical opening (21) wherein the second vertical plane is defined whence an axial plane of the vertical opening (21) is vertically disposed and perpendicular to the forward axis of the mounting box (20).
A floodlight module (30) with an elbow connector (10) as in Claim 1 in which the light-emitting side of the floodlight module (30) can be directed forward or backward at various orientations when the floodlight module (30) is disposed at either side of the mounting box (20).
A floodlight module (30) with an elbow connector (10) as in Claim 1 in which the light-emitting side of the floodlight module (30) can be directed sideward when the floodlight module (30) is disposed at the front of the mounting box (20).