SSL retrofit fixture

Patent metadata

Field	Value
Publication number	US-10330268-B2
Application number	US-201715497062-A
Country	US
Kind code	B2
Filing date	Apr 25, 2017
Priority date	Apr 25, 2016
Publication date	Jun 25, 2019
Grant date	Jun 25, 2019

Abstract

A downlight retrofit assembly includes a reflector, the reflector defining a top reflector end and a bottom reflector end, the reflector defining a reflector bore extending through the reflector from the top reflector end to the bottom reflector end, the reflector bore defining a top reflector aperture and a bottom reflector aperture; a lens, the lens attached to the reflector proximate the bottom reflector end, the lens covering the bottom reflector aperture; and a light engine, the light engine comprising a SSL source and PCB, the SSL source attached to the PCB, the light engine covering the top reflector aperture, the SSL source disposed within the top reflector aperture, the SSL source configured to emit light through the lens.

First claim

That which is claimed is:

1. A lighting assembly comprising:
a reflector comprising a top reflector end and a bottom reflector end, the reflector defining a reflector bore extending through the reflector from the top reflector end to the bottom reflector end, the reflector bore defining a top reflector aperture and a bottom reflector aperture;
a lens, attached to the reflector proximate the bottom reflector end, and covering the bottom reflector aperture;
a backing plate; and
a light engine, comprising a solid-state lighting (“SSL”) source, a cover, and a printed circuit board (“PCB”), the SSL source attached to the PCB, the light engine covering the top reflector aperture, the SSL source disposed within the top reflector aperture, the SSL source configured to emit light through the lens, wherein the cover is directly attached to the backing plate and the PCB is arranged between the cover and the backing plate.

2. The lighting assembly of claim 1 , wherein:
the PCB is disposed within a cavity defined by the cover;
the cover defines a light aperture extending through the cover;
the light aperture is shaped and sized complimentary to the SSL source; and
the light aperture receives the SSL source.

3. The lighting assembly of claim 2 , wherein:
the light engine is attached to the backing plate;
the backing plate is attached to the top reflector end; and
the PCB is enclosed between the cover and the backing plate.

4. The lighting assembly of claim 1 , wherein:
the lens, the reflector, and the light engine define a compartment; and
the SSL source is dielectrically isolated within the compartment.

5. The lighting assembly of claim 1 further comprising a trim piece, wherein:
the trim piece defines a top trim end and a bottom trim end;
the trim piece defines a trim bore extending through the trim piece;
the trim bore defines a top trim aperture disposed at the top trim end and a bottom trim aperture disposed at the bottom trim end; and
the lens is disposed within the top trim aperture.

6. The lighting assembly of claim 5 , wherein:
the reflector defines a groove at the reflector bottom end;
the trim piece defines a collar at the top trim end; and
the groove receives the collar to secure the trim piece to the reflector.

7. The lighting assembly of claim 5 , wherein:
the trim piece defines a trim shoulder extending radially outward from the top trim aperture;
the lens defines an outer circumferential surface and a lens shoulder extending radially inwards from the outer circumferential surface; and
the trim shoulder engages the lens shoulder to secure the lens between the trim piece and the reflector.

8. The light assembly of claim 1 , wherein the light engine further comprises other solid-state lighting (“SSL”) sources, the PCB is enclosed between the cover and the backing plate with only the SSL source and the other SSL sources exposed through the cover.

9. The light assembly of claim 5 , wherein the reflector is located between the light engine and the trim piece.

10. A method of manufacturing a lighting assembly, the method comprising:
mounting a light engine to a backing plate, the light engine comprising a PCB and a cover, the cover directly attached to the backing plate and the PCB enclosed between the cover and the backing plate;
attaching the backing plate to a top reflector end of a reflector, the light engine positioned between the backing plate and the reflector, the light engine comprising an SSL source configured to emit light, the SSL source aligned with a top reflector aperture of the reflector; and
attaching a lens to a bottom reflector end of the reflector, the lens covering a bottom reflector aperture of the reflector, a reflector bore extending between the top reflector aperture and the bottom reflector aperture.

11. The method of claim 10 , further comprising enclosing a compartment defined by the light engine, the reflector, and the lens, the SSL source disposed within the compartment.

12. The method of claim 11 , further comprising attaching a trim piece to the bottom reflector end.

13. The method of claim 12 , further comprising aligning the lens with a top trim aperture defined by the trim piece.

14. The method of claim 10 , further comprising inserting a wing of the PCB into a connector notch of a PCB connector, the connector notch defined by a connector base of the PCB connector.

15. The method of claim 10 , further comprising engaging a retention tab of the cover with the PCB, the retention tab configured to secure the PCB within a cavity defined by the cover.

16. The method of claim 10 , wherein the light engine further comprises other solid-state lighting (“SSL”) sources, the PCB is enclosed between the cover and the backing plate with only the SSL source and the other SSL sources exposed through the cover.

17. The method of claim 12 , wherein the reflector is located between the light engine and the trim piece.

Assignees

• Epistar Corp

Inventors

• Shah Ashok Deepak
• Athalye Praneet Jayant
• Whitworth Christopher Lee
• Phillips Frederic Perry

Classifications

• F21V5/04

  of lens shape · CPC title

• F21V13/04

  the elements being reflectors and refractors {(for vehicle rear lights F21S43/40)} · CPC title

• F21S8/026

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

• F21K9/235

  Details of bases or caps, i.e. the parts that connect the light source to a fitting; Arrangement of components within bases or caps (F21K9/238 takes precedence) · CPC title

• H02G3/16

  structurally associated with support for line-connecting terminals within the box · CPC title