Power module for high intensity discharge lamp

Electric lamp and discharge devices: systems – Combined load device or load device temperature modifying...

Reexamination Certificate

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Details

C315S056000, C315S058000, C439S947000, C361S640000

Reexamination Certificate

active

06342766

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a configurable power module for lamps. It finds particular application in providing power for high intensity discharge lamps (HID Lamps). Since the power module is configurable, it can be used to provide power to a wide variety of lamp types, including metal halide, ceramic metal halide, high-pressure sodium, and pulsed metal halide lamps.
2. Discussion of the Art
Traditionally, new lamp and/or light fixture designs have required new ballast and/or power module designs. New power modules have been required because the lamps have different starting techniques, driving voltages, power levels and possibly new backup light sources. At a minimum, most new lamps have new combinations of requirements. Where a particular combination of requirements is not being met by an existing power module, a new power module had to be designed. Furthermore, even where an existing power module meets all the requirements of a lamp, the existing power modules often do not fit in newly designed fixtures. Where existing power modules physically fit in a newly designed fixture, it is likely that the new fixture does not accommodate some other requirement, for example, the heat venting needs of the power module.
This lamp and fixture driven power module design approach has led to a confusing array of over 700 ballasts/power modules and model numbers for one manufacturer alone. Manufacturing and inventory of the multitude of power module products has become problematic for manufacturers, distributors, and retailers.
Power modules have also been traditionally built as assemblies of components. The components are wired together by hand, using a point-to-point wiring technique. This is a labor intensive, expensive, error prone manufacturing process.
In order to reduce costs and improve customer service, it is important to reduce the number of power modules in inventory. Likewise, in order to improve product quality and further reduce manufacturing costs, it is important to reduce the number of assembly steps. Thus, a need exists for a power module that can be configured to be compatible with a wide variety of lamp types, fixtures, and power sources. Permitting configuration at the point of sale or by the end user would also be preferable.
BRIEF SUMMARY OF THE INVENTION
To those ends, the present invention is a configurable power module for powering a wide variety of lamp systems. The power module includes a base plate for supporting components of the power module. A printed wiring board mounted to the base plate provides for the interconnection of a selected set of electrical components. A ballast mounted on the base plate is connected to the printed wiring board. Capacitor connectors mounted on the printed wiring board allow for the installation of a capacitor when the lamp system in question requires one. An input voltage selector mounted on the printed wiring board provides the power module with compatibility for a wide range of power sources. The printed wiring board includes an ignitor socket that accepts a wide range of ignitors. By optionally selecting and installing an ignitor, capacitor, and ballast, compatibility with a wide variety of existing lamps and future lamp designs is achieved. Other ports offer access to options such as switch quartz, bilevel, and/or wattage selection.
An advantage of the present invention is that it greatly reduces the inventory of power modules since the power module offers the flexibility of being used in multiple fixture types.
Another advantage of the present invention resides in improved power module quality as a result of reducing the amount of hand wiring required to build a power module, the power module appearing virtually wireless to the customer.
Another advantage of the present invention is found in the reduced cost since the amount of hand wiring required to build a power module is reduced.
Still another advantage of the present invention is realized by reduced costs associated with replacing a multitude of low volume power modules with a few high volume power modules.
Yet another advantage is found in the flexibility provided to the end user since the power modules can be reconfigured by the end user for new types of lighting without a substantial investment in new fixtures and power modules components.
A still further advantage of the present invention resides in the ease with which the power module can be tested and maintained.
Still other advantages and benefits of the invention will become apparent to those skilled in the art upon a reading and understanding of the following detail description.


REFERENCES:
patent: 4472015 (1984-09-01), Nicholson et al.
patent: 4488201 (1984-12-01), Webb et al.
patent: 4902943 (1990-02-01), Nicholson et al.
patent: 5148086 (1992-09-01), Costa
patent: 5448108 (1995-09-01), Quon et al.
patent: 5811937 (1998-09-01), Jiang
patent: 5811941 (1998-09-01), Barton
patent: 5946192 (1999-08-01), Ishigami et al.

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