WireWay
Metal stamping housing for an HID luminaire
A metal stamping housing for an HID luminaire which comprises a two piece, fold-up metal stamping housing which provides exceptional strength with minimal usage of materials to support a very heavy ballast therein. The metal stamping housing is suitable for a low cost highbay luminaire with high watt ballasts for Metal Halide and High Pressure Sodium, Mercury Vapor (HID) light sources.
The metal stamping housing provides reflector adjustability for different size lamps and light centers. A top metal stamping stamping defines a central ballast shelf on which a ballast is mounted, and first and second ends of the top stamping are bent 90° on opposite sides of the central ballast shelf. The first and second ends of the top stamping are further bent back 180° upon themselves to form a double wall.
The first and second ends of the top stamping are further bent 90° to project towards each other. The very ends of the first and second ends of the top stamping are further bent and interconnected to form a three wall top hanging system, and to form a top metal stamping housing. First and second ends of a bottom metal stamping stamping are bent 90° about a central section to form a bottom metal stamping housing.
Accordingly, it is a primary object of the present invention to provide a metal stamping housing for an HID luminaire.
A further object of the subject invention is the provision of a metal stamping housing which is suitable for a low cost highbay luminaire with high watt ballasts for Metal Halide and High Pressure Sodium and Mercury Vapor light sources. The metal stamping housing for the two different light source technologies provides reflector adjustability for different size lamps and light centers.
In accordance with the teachings herein, the present invention provides a two piece, fold-up metal stamping housing for a luminaire which provides strength with minimal usage of materials to support a heavy ballast. A top metal stamping stamping defines a central ballast shelf on which a ballast is mounted, and first and second ends of the top stamping are bent 90° on opposite sides of the central ballast shelf. The first and second ends of the top stamping are further bent back 180° upon themselves to form a double wall. The first and second ends of the top stamping are further bent 90° to project towards each other. The very end of the first end of the top stamping is further bent 90° to form a first wall of a top wall hanging system. The second end of the top stamping is further bent 90° to form a second wall of the top wall hanging system, and is further bent 180° back upon itself while encompassing the first wall hanger to form a third wall of the top wall hanging system, to form a top metal stamping housing.
First and second ends of a bottom metal stamping stamping are bent 90° about a central section to form a bottom metal stamping housing. The bottom metal stamping housing is secured to the top metal stamping housing to form an assembled metal stamping housing for the luminaire in a rigid monocoque design.
In greater detail, a heat shield is formed along one end of the central ballast shelf, which is bent 90° relative to the central ballast shelf to form a heat shield adjacent to the central ballast. The heat shield separates the hot ballast from a capacitor, starter and wiring compartment.
The ballast is secured to the central ballast shelf by mounting fasteners, such as bolts, screws, rivets, etc. which extend through holes in the central ballast shelf into mounting holes in the core of the ballast, such that the rigidity of the ballast core reinforces the top housing. The central ballast shelf defines a central ballast mounting hole which allows coils of the ballast to project therethrough, to allow the ballast core to rest directly against the central ballast shelf. Clearance holes are also provided in the central ballast shelf to provide clearance for fastener (bolt) heads which extend from the ballast into the mounting shelf.
The ballast shelf is mounted with a wireway duct being defined below the mounted ballast. The ballast is mounted offset in the top metal stamping housing with the ballast steel core in close proximity to three sides of the upper housing, such that the close proximity of the ballast to the three walls assists in the transfer of heat directly from the ballast to the housing to increase the surface area available for cooling.
Vent holes are provided in a lower portion of two end panels of the bottom housing to draw air into the housing over the capacitor and ballast, and vent holes are also provided in a top portion of front and rear panels of the top housing to provide for venting of the hot air.
A lamp socket is mounted to the bottom housing with the wires thereto running under the ballast coil into the capacitor compartment.
The capacitor is mounted on a capacitor end panel of the bottom housing by a metal strap. A first end of the metal strap is inserted into and secured in a recess, and a second end of the strap is secured by a screw to a hole in the capacitor panel.
The foregoing objects and advantages of the present invention for a metal stamping housing for an HID luminaire may be more readily understood by one skilled in the art with reference being had to the detailed description of several preferred embodiments thereof, taken in conjunction with the accompanying drawings wherein like elements are designated by identical reference numerals throughout the several views.
While several embodiments and variations of the present invention for a metal stamping housing for an HID luminaire are described in detail herein, it should be apparent that the disclosure and teachings of the present invention will suggest many alternative designs to those skilled in the art.
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