Recessed lighting unit with universal adapter

Patent metadata

Field	Value
Publication number	US-10072805-B2
Application number	US-201514726064-A
Country	US
Kind code	B2
Filing date	May 29, 2015
Priority date	May 29, 2015
Publication date	Sep 11, 2018
Grant date	Sep 11, 2018

Abstract

A recessed lighting unit for mounting to a ceiling or a wall is provided. The recessed lighting unit includes a thermally conductive housing, a light source module inside the housing, and an optical plate. The housing maybe engaged to a universal adapter through a simple twist and lock mechanism. The clips enable the universal adapter to be attached to junction boxes and recessed lighting can-type housings of different sizes. The universal adapter can receive different types of clips, without the use of screws, adhesives, or tools to attach the clips to the adapter. Such a recessed lighting unit may have a reduced set of components while ensuring its adaptability and easy installation. Other embodiments are also described and claimed.

First claim

What is claimed is:

1. A recessed lighting unit for mounting behind a ceiling or a wall comprising:
a thermally conductive housing having a trim portion, wherein the trim portion has an outer periphery and an inner periphery, wherein the housing extends rearward and inward from the inner periphery of the trim portion and forms an intermediate portion, wherein the housing extends rearward and inward from the intermediate portion and forms a base;
a light source module being attached to the base and positioned between a bottom of the base and a front-most point of the trim portion;
an optical plate attached to the intermediate portion, the light source module to illuminate a back face of the optical plate, wherein an outer periphery of the optical plate conforms to an outer periphery of the intermediate portion so that a space between the optical plate and the base is enclosed; and
a plurality of locking members, for engaging a universal adapter, that are directly formed on the intermediate portion and extend rearward from the intermediate portion of the housing.

2. The recessed lighting unit of claim 1 , wherein the thermally conductive, die-formed housing is made from one of a group consisting of aluminum, brass, copper, polymer and steel.

3. The recessed lighting unit of claim 1 , wherein the optical plate is attached to the intermediate portion by a snapping mechanism, glue, or heat stake.

4. The recessed lighting unit of claim 1 , wherein the height from the bottom of the base up to the outer periphery of the trim portion is between ⅞ inch to 2 inches, wherein the height from the outer periphery of the trim portion to the top of the optical plate is ¾ inch to 1 inch, and wherein the width distance between the outer peripheries of the trim portion is approximately 6 inches to 8 inches.

5. The recessed lighting unit of claim 1 , wherein the height from the bottom of the base up to the outer periphery of the trim portion is between ⅞ inch to 2 inches, wherein the height from the outer periphery of the trim portion to the top of the optical plate is ¾ inch to 1 inch, and wherein the width distance between the outer peripheries of the trim portion is approximately 4 inches to 6 inches.

6. The recessed lighting unit of claim 1 , wherein the universal adapter has:
an opening that is capable of receiving a base of the thermally conductive housing;
a plurality of attaching member openings capable of receiving attaching members to allow the universal adapter to be attached to a junction box;
a plurality of arcuate openings that are positioned at the same radial distance from a center of the opening, each arcuate opening capable of receiving one of the plurality of locking members on the intermediate portion of the housing; and
a plurality of clip holders capable of being attached to a plurality of clips;
wherein a portion of each of the plurality of locking members on the intermediate portion of the housing extend rearward through each of the plurality of arcuate openings on the universal adapter so that the housing and the universal adapter are in a locked position.

7. The recessed lighting unit of claim 6 , wherein one of the plurality of clip holders comprises:
a notch formed on an outer edge of the universal adapter; and
a pair of bump openings, wherein each bump opening is positioned adjacent to the notch.

8. The recessed lighting unit of claim 7 , wherein the plurality of clip holders are attached to a plurality of friction clips, the friction clip comprising:
a vertical clip portion; and
a base clip portion formed at the bottom of the vertical clip portion;
wherein the base clip portion has two parallel bars connected by a center bar,
wherein the vertical clip portion is connected to the base clip portion along the length of one of the two parallel bars,
wherein a pair of flanges extend outwardly on a lower plane from the center bar, and
wherein each flange has a bump.

9. The recessed lighting unit of claim 6 , wherein one of the plurality of clip holders comprises:
a notch formed on an outer edge of the universal adapter; and
a single bump opening that is positioned adjacent to the notch and radially inward relative to the notch.

10. The recessed lighting unit of claim 9 , wherein the plurality of clip holders are attached to a plurality of torsion spring clips, the torsion spring clip comprising:
a vertical clip portion;
a base clip portion formed at the bottom of the vertical clip portion;
wherein the base clip portion has a pair of lips and a flange,
wherein a flange is formed on a lower plane in between the pair of lips, and
wherein the flange has a bump.

11. The recessed lighting unit of claim 6 , wherein the universal adapter further comprises:
a first set of two openings capable of receiving an attaching member, each located on opposite halves of the universal adapter, that allows the universal adapter to be attached to a first junction box; and
a second set of two openings capable of receiving an attaching member, each located on opposite halves of the universal adapter, that allows the universal adapter to be attached to a second junction box;
wherein the distance between the first set of two openings is different than the distance between the second set of two openings.

12. The recessed lighting unit of claim 6 , wherein the universal adapter further comprises:
a first opening capable of receiving an attaching member that allows the universal adapter to be attached to a first junction box or a second junction box;
a second opening capable of receiving an attaching member that allows the universal adapter to be attached to the first junction box; and
a third opening capable of receiving an attaching member that allows the universal adapter to be attached to the second junction box;
wherein both the second opening and the third opening are located on opposite halves of the universal adapter relative to the first opening, and
wherein the distance between the first opening and the second opening is different than the distance between the first opening and the third opening.

13. The recessed lighting unit of claim 1 , wherein the thermally conductive housing is configured such that when the recessed lighting unit is mounted behind the ceiling, the light source module attached to the base of the thermally conductive housing is positioned above the ceiling, while the trim portion of the thermally conductive housing and the optical plate extend below the ceiling.

14. A recessed lighting unit for mounting behind a ceiling or a wall comprising:
a thermally conductive housing having a trim portion, wherein the trim portion has an outer periphery and an inner periphery, wherein the housing extends rearward and inward from the inner periphery of the trim portion and forms an intermediate portion, wherein the housing extends rearward and inward from the intermediate portion and forms a base;
a light source module being attached to the base and positioned between a bottom of the base and a front-most point of the trim portion; and
an optical plate attached to the intermediate portion, the light source module to illuminate a back face of the optical plate, wherein an outer periphery of the optical plate conforms to an outer periphery of the intermediate portion so that a space between the optical plate and the base is enclosed,
wherein a plurality of locking members, for engaging a universal adapter, are attached to the intermediate portion so that a portion of each of the plurality of locking members extends rearward from the intermediate portion of the housing.

15. The re

Assignees

• Dmf Inc

Inventors

• Bailey Michael D

Classifications

• F21S8/024 Primary

  intended to be recessed in a wall or like vertical structure, e.g. building facade · CPC title

• F21S8/026

  intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling · CPC title

• F21V29/507

  of means for protecting lighting devices from damage, e.g. housings · CPC title

• F21V15/01

  Housings, e.g. material or assembling of housing parts (F21V15/02 takes precedence {housings forming signs or letters G09F13/04}) · CPC title

• F21V21/08

  Devices for easy attachment to any desired place, e.g. clip, clamp, magnet · CPC title