as) United States
`a2) Patent Application Publication 10) Pub. No.: US 2006/0176708 A1
`(43) Pub. Date: Aug. 10, 2006
`
`Gordin et al.
`
`US 20060176708A1
`
`(54)
`
`(75)
`
`SINGLE ARM MOGUL MOUNT FOR
`SPORTS LIGHTING FIXTURES
`
`Inventors: Myron K. Gordin, Oskaloosa, IA (US);
`Timothy J. Boyle, Oskaloosa, [A (US)
`
`Correspondence Address:
`MCKEE, VOORHEES & SEASE,P.L.C.
`801 GRAND AVENUE
`SUITE 3200
`
`DES MOINES,IA 50309-2721 (US)
`
`(73)
`
`Assignee: MUSCO CORPORATION,Oskaloosa,
`IA (US)
`
`(21)
`
`Appl. No.:
`
`11/333,996
`
`(22)
`
`Filed:
`
`Jan. 18, 2006
`
`Related U.S. Application Data
`
`(60)
`
`Provisional application No. 60/644,687, filed on Jan.
`18, 2005. Provisional application No. 60/644,639,
`filed on Jan. 18, 2005. Provisional application No.
`60/644,536,filed on Jan. 18, 2005. Provisional appli-
`cation No. 60/644,747, filed on Jan. 18, 2005. Pro-
`visional application No. 60/644,534, filed on Jan. 18,
`2005. Provisional application No. 60/644,720, filed
`on Jan. 18, 2005. Provisional application No. 60/644,
`
`ing to the bulb cone, and decreased moment.
`
`688, filed on Jan. 18, 2005. Provisional application
`No. 60/644,636, filed on Jan. 18, 2005. Provisional
`application No. 60/644,517, filed on Jan. 18, 2005.
`Provisional application No. 60/644,609, filed on Jan.
`18, 2005. Provisional application No. 60/644,516,
`filed on Jan. 18, 2005. Provisional application No.
`60/644,546, filed on Jan. 18, 2005. Provisional appli-
`cation No. 60/644,547, filed on Jan. 18, 2005. Pro-
`visional application No. 60/644,638, filed on Jan. 18,
`2005. Provisional application No. 60/644,537, filed
`on Jan. 18, 2005. Provisional application No. 60/644,
`637, filed on Jan. 18, 2005. Provisional application
`No. 60/644,719, filed on Jan. 18, 2005. Provisional
`application No. 60/644,784, filed on Jan. 18, 2005.
`
`Publication Classification
`
`(51)
`
`Int. CL
`(2006.01)
`F218 8/00
`(52) US. CM.
`ceeccccssscssssessssestensssessecestenessnsesevesee 362/427
`
`(57)
`
`ABSTRACT
`
`An apparatus and method for a high intensity lighting
`fixture. One aspect, a knuckle for mounting the light fixture
`by its bulb cone to a cross arm is attached along the side of
`the bulb cone. This has various potential advantages includ-
`ing decreased effective projected area, protection of water-
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`US 2006/0176708 A1
`BONDEDSEAM
`
`Petitioner Ensign
`Exhibit 1030 - Page 71 of 75
`
`Petitioner Ensign
`Exhibit 1030 - Page 71 of 75
`
`

`

`US 2006/0176708 Al
`
`Aug. 10, 2006
`
`SINGLE ARM MOGUL MOUNT FOR SPORTS
`LIGHTING FIXTURES
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`[0001] This application claims priority under 35 U.S.C. §
`119 of a provisional application U.S. Ser. No. 60/644,719
`filed Jan. 18, 2005, herein incorporated by reference in its
`entirety. This application is also a non-provisional of the
`following provisional U.S. applications, all filed Jan. 18,
`2005: U.S. Ser. No. 60/644,639; U.S. Ser. No. 60/644,536;
`USS. Ser. No. 60/644,747; U.S. Ser. No. 60/644,534; U.S.
`Ser. No. 60/644,720; U.S. Ser. No. 60/644,688; U.S. Ser. No.
`60/644,636; U.S. Ser. No. 60/644,517; U.S. Ser. No. 60/644,
`609; U.S. Ser. No. 60/644,516; U.S. Ser. No. 60/644,546;
`USS. Ser. No. 60/644,547; U.S. Ser. No. 60/644,638; US.
`Ser. No. 60/644,537; U.S. Ser. No. 60/644,637; U.S. Ser. No.
`60/644,784; U.S. Ser. No. 60/644,687, each of which is
`herein incorporated by reference in its entirety.
`
`represents a reasonable compromise between the desire to
`economically control high intensity light to a distant target
`while at the same time minimizing wind load, which is a
`particularly significant
`issue when fixtures are elevated
`out-of-doors to sometimes well over 100 feet in the air. A
`muchlarger reflector could controllight better. However, the
`wind load would be impractical. A significant amount of the
`cost of sports lighting systems involves how the lights are
`elevated. The more wind load, the more robust and thus
`more expensive,
`the poles must be. Also, conventional
`aluminum bowl-shapedreflectors are formed by a spinning
`process.
`
`[0009] Therefore, competing interests and issues provide
`challenges to sports lighting designers. Someofthe interests
`and issues can be at odds with one another. Designers have
`to balance a numberoffactors, for example, cost, durability,
`size, weight, wind load, longevity, and maintenance issues,
`to name a few. Attempts to advance the art have mainly
`focused on discrete aspects of sports lighting.
`
`INCORPORATION BY REFERENCE
`
`II]. SUMMARY OF THE INVENTION
`
`[0002] The contents of the following U.S. Patents are
`incorporated by reference by their entirety: U.S. Pat. Nos.
`4,816,974; 4,947,303; 5,161,883; 5,600,537; 5,816,691;
`5,856,721; 6,036,338.
`
`I. BACKGROUND OF THE INVENTION
`
`[0003] A. Field of the Invention
`
`[0004] The present invention relates to lighting fixtures
`that produce high intensity, controlled, and concentrated
`light beamsfor use atrelatively distant targets. In particular,
`the invention relates to such lighting fixtures, their methods
`of use, and their use in systems where a plurality of such
`fixtures are used in combination, usually elevated on poles,
`to compositely illuminate a target area energy-efliciently,
`with reduced glare andspill light, and with the capability to
`lower capital and/or operating costs. One primary example
`is illumination of a sportsfield.
`
`[0005] B. Problemsin the Art
`
`Illumination of sports fields is generally called
`[0006]
`sports lighting. FIGS. 1A-1G illustrate one such sports
`lighting configuration. Football field 5 of FIG. 1A is illu-
`minated by a set of arrays 1 of light fixtures 2 elevated on
`poles 6 (see FIG. 1A). As is well knownin theart, there are
`known methods to design the number, type, and position of
`poles 6 and fixtures 2 to provide a desired or required
`amount and uniformity of light for the field. There are
`usually pre-designed lighting quantity and uniformity speci-
`fications to follow.
`
`[0007] The most conventional form of sports lighting
`fixture 2 is a several feet in diameter bowl-shaped aluminum
`reflector with a transparent glass lens 3 suspended from a
`cross arm 7 fixed to a pole 6 by an adjustable knuckle 4 (see
`FIG. 1B). Each light fixture 2 has some adjustability both
`around vertical and horizontal axes. Each fixture 2 can
`
`therefore be uniquely aimed relative to the target area or
`field 5 by adjustment of knuckle 4 relative cross arm 7.
`
`[0010] The present invention relates to a lighting fixture
`and structure to suspend it adjustably from a cross-arm. A
`relatively thin, single arm comprises the connection between
`cross-arm and mounting mogul or bulb cone, which in turn
`supports the remainder of the fixture. The single-arm pro-
`vides several benefits for the fixture.
`
`[0011] A. Objects, Features, or Advantages, of the Inven-
`tion
`
`Itis therefore a principal object, feature, or advan-
`[0012]
`tage of the present invention to present a high intensity
`lighting fixture, its method of use, and its incorporation into
`a lighting system, which improves over or solves certain
`problemsand deficiencies in theart.
`
`features, or advantages of the
`[0013] Other objects,
`present invention include such a fixture, method, or system
`which can accomplish one or more of the following:
`
`a) is robust and durable for most sports lighting or
`[0014]
`other typical applications for high intensity light fixtures of
`this type, whether outside or indoors;
`
`b) can provide for decreased wind load or EPA for
`[0015]
`the fixture;
`
`c) can provide for increased protection of wiring to
`[0016]
`the fixture;
`
`d) can provide for decreased moment between the
`[0017]
`fixture and the mount.
`
`[0018] These and other objects, features, advantages and
`aspects of the present invention will become more apparent
`with reference to the accompanying specification and
`claims.
`
`IW. BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0019] All references to Figures are to the drawings in
`attached Appendix A.
`
`[0020] A. General Sports Lighting Systems
`
`[0008] This general configuration of sports lighting fix-
`tures 2 has remainedrelatively constant over many years
`because it is a relatively economical and durable design. It
`
`[0021] FIG. 1A andits sub-parts B-Gillustrate generally
`a sports lighting system, and conventional componentsfor a
`sports lighting system.
`
`Petitioner Ensign
`Exhibit 1030 - Page 72 of 75
`
`Petitioner Ensign
`Exhibit 1030 - Page 72 of 75
`
`

`

`US 2006/0176708 Al
`
`Aug. 10, 2006
`
`[0022] B. General Parts of Fixture 10
`
`[0023] FIG. 2 is a diagrammatic, partial exploded view of
`a light fixture 10 according to an exemplary embodimentof
`the present invention.
`
`[0024] FIGS. 3A and B and FIGS. 4A and B show
`different assembled versions of Fixture 10.
`
`[0025] C. Reflector Frame 30 (Diverging Bottom and/or
`Side Shift)
`
`[0026] FIG. 5A and its sub-parts are plan views of one
`example of a reflector frame according to an exemplary
`embodiment of the present invention.
`
`[0027] D. Lamp Cone 40
`
`[0028] FIG. 6A and its sub-parts are various plan, sec-
`tional, and isolated views of a lamp cone according to an
`aspect of the invention.
`
`[0029] E. Knuckle Plate 60
`
`[0030] FIG. 7A andits sub-parts are a perspective view,
`various plan views, sections, and isolated views of a knuckle
`plate according to an aspect of the invention.
`
`[0031] FIG. 8A and sub-parts illustrate a gasket used with
`Fixture 10.
`
`[0032] FIG. 9A and its sub-parts are various views of a
`bolt for holding a knuckle of FIG. 14 to the lamp cone of
`FIG.6.
`
`[0033] FIG. 10A andits sub-parts are various views of an
`O-ring the seal the knuckle bolt of FIG. 9AA.
`
`[0034] FIG. 11A andits sub-parts are various views of a
`washer useable with the knuckle bolt.
`
`[0035] FIG. 12A and its sub-parts are various views of a
`washer useable with the knuckle O-ring of FIG. 10A.
`
`[0036] FIG. 13A andits sub-parts are various views of a
`knuckle cone strap bolt useable with the knuckle of FIG.
`14A and the lamp cone of FIG. 6A.
`
`[0037]
`
`F. Knuckle 50
`
`[0038] FIG. 11A andits sub-parts are various views of a
`knuckle connectable between the knuckle plate of FIG. 7A
`and the lamp cone of FIG. 6A.
`
`[0039] FIG. 154Aandits sub-parts are front and side views
`of a zero alignment gauge useable with the knuckle of FIG.
`14A and the lamp cone of FIG. 6A.
`
`[0040] FIG. 16A and sub-parts illustrate an alignment
`gauge usable with Fixture 10.
`
`[0041] FIGS. 17A, 18A, and 19A,and their subparts, are
`various views, respectively, of an inside strap, outside strap,
`and inside stop strap useable with lamp cone of FIG. 6A to
`provide for accurate repositioning of the lamp cone if moved
`from factory alignment, for example, for maintenance pur-
`poses.
`
`[0042] G. Miscellaneous Parts
`
`[0043] FIG. 20A and its sub-parts are various views of a
`reflector gasket to seal the reflector frame at its connection
`to the lamp cone.
`
`IV. DETAILED DESCRIPTION OF EXEMPLARY
`EMBODIMENTS
`
`[0044] A. Overview
`
`[0045] An embodimentofa light fixture will be described
`in the context of sports lighting, sports lighting fixtures, and
`sports lighting systemsfor the illumination ofathletic fields
`such as shown in FIGS. 1A and 1C. The lighting must light
`the field and a volumeof space abovethe field (collectively
`sometimes called the target area or target space), according
`to predetermined lighting level and uniformity specifica-
`tions. The embodiment relates to fixtures that utilize high
`intensity discharge (HID) lamps, presently normally 1,000
`watts or higher, of the metal halide type. Such installations
`generally have several arrays offixtures usually elevated on
`two or morerelatively tall poles (35 feet to 100 or more
`feet).
`
`[0046] B. Exemplary Apparatus
`
`[0047]
`
`1. Lighting Fixture 10 Generally
`
`[0048] FIG. 2 shows the basic components of sports
`lighting fixture 10 in exploded form. FIGS. 3A and B show
`it in perspective form. FIGS. 4A and B show an alternative
`form. Fixture 10 has some similar general components to
`state-of-the-art sports lighting fixtures, but introduces some
`different structural components and concepts. Mounting or
`knuckle plate 60 (360 Aluminum with polyester powder
`coat) bolts to the underside of a cross arm 7. It has adjust-
`ability around vertical axis 62 (see FIG. 7A). Knuckle 50
`(360 Aluminum with polyester powdercoat) bolts at one end
`to the bottom of knuckle plate 60 and extends to a pivot
`connection to lamp cone 40 along axis 52 at its other end
`(See FIG. 4). It should be appreciated that knuckle 50
`essentially supports the remainderoffixture 10 and does so
`with essentially one arm extending from a cross arm down
`to one side of lamp cone 40. Knuckle 50 is a relatively
`non-complex structure.
`
`[0049] Lamp cone 40 (360 Aluminum with polyester
`powdercoat) pivots around axis 52 relative to knuckle 50.
`Tt contains a socket 154 (see FIG. 19A, commercially
`available) which is bolted to the flat web 160 between the
`arms 156 and 158 of yoke 80 (see FIG. 19A). Lamp 20
`(Musco Corporation Z-Lamp™)has a threaded base that can
`be screwed in and out of socket 154 (shown screwed into
`operating position in FIG.2) to install or remove lamp 20.
`
`[0050]
`60
`
`2. Lamp Cone40, Knuckle 50, and Knuckle Plate
`
`[0051] Lamp cone 40, knuckle 50, and knuckle plate 60
`form the adjustable joint between cross arm 7 and reflector
`frame 32. Lamp cone 40 also supports lamp 20. FIG. 6A and
`subpartsillustrate details about lamp cone 40. Lamp cone 40
`is basically enclosed except for front opening 132 to which
`reflector frame 30 is bolted and sealed with a gasket, and
`several opening in the side (e.g., for the knuckle bolt and a
`pinion gear).
`
`[0052] Lamp cone 40 pivotally attaches to knuckle 50 by
`inserting laterally projecting boss or pivot 136 on the side of
`lamp cone 40 into a complimentary circular cut-out or
`receiver 172 in one lateral side of knuckle 50 (see FIG.
`14C). Knuckle bolt 174 (see FIGS. 9A, 10-12), with appro-
`priate nut and washers, holds lamp cone 40 from separation
`from knuckle 50 when assembled together. Gasket 176
`
`Petitioner Ensign
`Exhibit 1030 - Page 73 of 75
`
`Petitioner Ensign
`Exhibit 1030 - Page 73 of 75
`
`

`

`US 2006/0176708 Al
`
`Aug. 10, 2006
`
`(FIGS. 8A-D)fits between lamp cone 40 and knuckle 50
`concentrically about pivot receiver 172 and opening 174 and
`knuckle 50 to deter water, insects, or dirt from entering into
`knuckle 50. As can be seen in FIGS. 6 and 14, when these
`parts are assembled, complimentary structure on the inter-
`faces of lamp cone 40 and knuckle 50 act as bearing surfaces
`and retaining structure to provide for smooth, accurate
`rotation of lamp cone 40 relative to knuckle 50.
`
`[0053] As shownin the drawings, knuckle 50 connects to
`knuckle plate 60 (see FIG. 7A) which in turn is fixedly
`mounted to cross arm 7. Arm portion 178 of knuckle 50
`extends to a mounting end 180. Knuckle plate 60 bolts to the
`bottom of cross arm 7 by one bolt into each curved slot 194
`and 196. This allows rotational adjustment of knuckle plate
`60 relative to cross arm 7 overthe range of curved slots 194
`and 196.
`
`It should be noted that knuckle 50 is essentially a
`[0054]
`single arm suspending most of fixture 10 by its pivotal
`connection along the side of lamp cone 40. Unlike some
`existing fixtures which have the knuckle extenddirectly into
`the back of the lamp cone, and a pivot joint between the
`cross arm and the lamp cone, knuckle 50 provides certain
`functional advantages. First, although fixture 10 might be
`somewhatheavier than a spun aluminum reflector fixture, by
`placing the pivot point along the side of lamp cone 40, there
`is less moment caused by lamp cone 40, reflector frame 30,
`lamp 20, visor 70 and the other components onthe distal side
`of that connection point. It is believed the momentis cut
`approximately in half. This is beneficial for long-term dura-
`bility, especially for fixtures experiencing a variety of out-
`doors forces and conditions,
`including high winds. Less
`momentfor the connection also deters slippage or change in
`relationship between the lamp cone and cross arm, which
`could affect aiming. Secondly,it allows for a shorterfixture,
`in the sensethe fixture is pulled closer to the vertical plane
`of the cross arm. This helps present a lower EPA. Third,
`knuckle 50 provides for minimum exposure of power wires
`to the environment. The wires pass through knuckle plate 60
`(from the interior of cross arm 7), through the interior of
`knuckle 50, and into the interior of lamp cone 40, completely
`enclosed by structure. Fourth,
`it
`is part of a relatively
`non-complex structure for the support and aiming of the
`fixture.
`
`[0055] Round opening 182 at the mounting end of 180 of
`knuckle 50 fits around downwardly extending tube 192 on
`the bottom of knuckle plate 60. Bolts through bolt holes 184
`and 186 of mounting end 180 of knuckle 50 extend into
`curved slots 194 and 196 in knuckle plate 60. This combi-
`nation allowsa range of rotational adjustment of knuckle 50
`relative to knuckle plate 60 (over the range defined by
`curved slots 194 and 196 of knuckle plate 60). In this
`manner, there is some adjustability of knuckle 50 around a
`vertical axis, once knuckle plate 60 is mounted to the
`underside of cross arm 7.
`
`[0056] Curved slot 188 in knuckle 50 provides a limit for
`pivoting of lamp cone 40 about knuckle 50. Knuckle 50 can
`therefore be used for aiming fixtures 10 to either side of
`cross arm 7. Additionally, lamp cone 40 can beset to a given
`aiming angle relative knuckle 50 as follows. An inside stop
`strap 142 can be fixed to boss 144 in the face of lamp cone
`40. Inner and outer stop straps 146 and 148 can be bolted on
`opposite sides of curved slot 188 of knuckle 50 in a position
`
`so that when lamp cone 40 is rotationally adjusted relative
`to knuckle 50 for its intended aiming angle, inner and outer
`straps 146 and 148 would come into abutment with stop
`strap 142. Thus, the installer of the light system can have a
`factory-preset stop at the correct aiming angle for each
`fixture 10. This avoids individual aiming of each fixture
`when the system is installed at the field. Additionally,
`it
`allows easier maintenance. Bolt 174 holding lamp cone 40
`to knuckle 50 can be loosened, lamp cone 40 andreflector
`frame 30 etc. can be swung down. Maintenance can be
`performed. Without realigning or re-aiming, the worker then
`only has to swing that reflector frame 30 etc. back up until
`it hits stop strap 142 and retighten lamp cone 40 to knuckle
`50. Knuckle 50 can be die cast and removable mounted to
`
`die cast reflector frame 30 with gaskets or other structure to
`prevent leaks at that interface of parts.
`
`[0057] C. Assembly and Use
`
`In practice, a set of fixtures 10, such as described
`[0058]
`above, would be usedin a sports lighting system customized
`for a particular sports field. Lighting specifications (usually
`including light quantity and uniformity minimums; and
`sometimesglare, spill, and halo light limitations) are usually
`prepared or known. As is well known in the art, computer
`software can design the lighting system,
`including what
`types of beams and beam shapes from how manyfixtures at
`whatlocations are needed to meet the specifications. It can
`generate a re