Mounting system for retrofit light installation into existing light fixtures

Patent metadata

Field	Value
Publication number	US-10544925-B2
Application number	US-201213464745-A
Country	US
Kind code	B2
Filing date	May 4, 2012
Priority date	Jan 6, 2012
Publication date	Jan 28, 2020
Grant date	Jan 28, 2020

Abstract

Lighting retrofit systems and methods are disclosed that can be used with different light fixtures, but that are particularly adapted for use with retrofitting troffer-style fixtures with LED based light engines. The retrofit systems being assembled without disturbing the lighting or troffer pan or housing (“troffer pan”) for the lighting system being retrofitted. Some of these embodiments can comprise a mounting fixture or frame that can be mounted in an opening in a ceiling grid, and held in place between the grid and the troffer pan edge. The fixture or frame can comprise an opening for a light engine, with the engine being quickly and easily connected to electrical power in the troffer pan and then mountable within the frame opening. These embodiments can allow for the quick and easy construction of the retrofit system without the need for adhesives and fasteners such brackets and screws.

First claim

We claim:

1. A system for mounting a light engine in a ceiling, comprising:
an elongated light engine with at least two mount adaptors and a circuit box, said light engine comprising an inner surface, first and second opposing sides, and first and second opposing ends, with each of said sides being longer than each of said ends, said circuit box attached to and at least partially covering said second end of said light engine;
wherein said at least two mount adapters are configured to fit on either of said first and second ends and configured such that said circuit box is connected between a portion of one of said mount adaptors and said second end of said elongated light engine, at least a portion of each of said at least two mount adaptors on said inner surface of said light engine; and
end mounts configured for mounting in a ceiling opening, each of said end mounts comprising at least two mechanisms configured to mate with a respective one of said mount adaptors, at least one of said end mounts comprising a cavity sized to hold a respective one of said mount adaptors such that said mount adaptor is configured to at least partially fit within said cavity.

2. The system of claim 1 , wherein said end mounts at least partially span said ceiling opening.

3. The system of claim 1 , wherein said end mounts are configured to mate with said mount adaptors to hold said light engine in said ceiling opening.

4. The system of claim 1 , wherein said ceiling opening comprises a T-grid ceiling opening.

5. The system of claim 4 , wherein said end mounts rest on a lip of said T-grid opening.

6. The system of claim 1 , further comprising side panels spanning between said end mounts.

7. The system of claim 6 , wherein said side panels and said end mounts form a mount frame in said ceiling opening.

8. The system of claim 1 , wherein said light engine comprises connection mechanisms to connect to a source of electrical power.

9. The system of claim 1 , wherein one of said end mounts is capable of engaging with one of said mount adaptors to hold said light engine in an orientation vertical to said ceiling opening.

10. The system of claim 1 , wherein said light engine comprises an elongated light source and a reflector.

11. The system of claim 10 , wherein said light engine comprises white emitting light emitting diodes (LEDs).

12. A system for mounting a light engine in a T-grid ceiling opening, comprising:
a light emitting diode (LED) based light engine with at least two mount adaptors and a circuit box, said light engine comprising an inner surface, first and second opposing sides, and first and second opposing ends, with each of said sides being longer than each of said ends, said circuit box attached to and at least partially covering said second end of said LED based light engine;
wherein said at least two mount adapters are configured to fit on either of said first and second ends and configured such that said circuit box is connected between a portion of one of said mount adaptors and said second end of said elongated light engine, said one of said mount adaptors comprising distinct outer and inner mount adaptors, said circuit box between said outer and inner mount adaptors, at least a portion of said inner mount adaptor on said inner surface of said light engine; and
end mounts configured for mounting in said T-grid ceiling opening, each of said end mounts comprising at least two mechanisms configured to mate with a respective one of said mount adaptors, at least one of said end mounts comprising a cavity sized to hold a respective one of said mount adaptors such that said mount adaptor is configured to at least partially fit within said cavity.

13. The system of claim 12 , wherein a mount frame at least partially spans said ceiling opening.

14. The system of claim 12 , wherein a mount frame is configured to mate with said mount adaptors to hold said light engine in said ceiling opening.

15. The system of claim 12 , wherein a mount frame rests on a lip of said T-grid ceiling opening.

16. The system of claim 12 , wherein a mount frame comprises side panels and said end mounts.

17. The system of claim 12 , wherein said light engine is elongated.

18. The system of claim 12 , wherein a mount frame is capable of mating with one of said mount adaptors to hold said light engine in an orientation vertical to said T-grid ceiling opening.

19. The system of claim 12 , wherein said light engine comprises a linear array of LEDs and a reflector.

20. The system of claim 12 , wherein said light engine LEDs emit white light.

21. A method for mounting a light engine in a ceiling opening, comprising:
providing a light engine comprising first and second opposing sides and first and second opposing ends, with each of said sides being longer than each of said ends, wherein a circuit box is attached to said second end of said light engine, and wherein a first outer mount adapter is attached to said first end of said light engine and a second outer mount adapter is attached to said second end of said light engine and said circuit box, wherein said circuit box physically contacts said second outer mount adapter;
configuring at least two inner mount adapters to mate with said outer mount adapters, wherein said inner mount adapters are distinct from said outer mount adapters, forming a first mount adapter over said first end and a second mount adapter over said second end;
mounting a mounting frame within said ceiling opening, said mounting frame comprising at least two mechanisms to engage with each of said mount adaptors;
engaging the first of said plurality of mount adaptors in said mounting frame;
connecting said light engine to a power source; and
engaging the second of said mount adaptors in said mounting frame to hold said light engine in said ceiling opening, wherein said circuit box is connected between a portion of said second of said mount adaptors and said second end of said light engine.

22. The method of claim 21 , further comprising hanging said light engine from said mount frame by said first mount adaptor during said connecting of said light engine.

23. The method of claim 21 , wherein said ceiling opening comprises a T-grid ceiling opening.

24. The method of claim 23 , wherein said mounting of said mounting frame within said ceiling opening comprises resting said mounting frame on a lip of said T-grid opening.

25. The method of claim 21 , wherein said mounting frame comprises end mounts and side panels.

26. The method of claim 21 , wherein said light engine is elongated.

27. The method of claim 21 , wherein said light engine comprises white emitting light emitting diodes (LEDs).

28. A method for retrofitting a fluorescent light fixture in a T-grid ceiling opening above a room, comprising:
removing existing components of the fluorescent light fixture in said T-grid ceiling opening;
mounting first and second end mounts within and at least partially spanning said T-grid ceiling opening, said first and second end mounts being on opposing sides of said ceiling opening, each of said end mounts comprising at least two connection mechanisms, wherein each of said at least two connection mechanisms comprises a spring-action mechanism;
connecting a first outer mount adapter to said at least two connection mechanisms of said first end mount, and mating a first inner mount adapter wit

Assignees

• Pratt S Scott
• Oflaherty Patrick
• Lay James Michael
• Snell Nathan
• Ideal Ind Lighting Llc

Inventors

• Pratt S Scott
• O'Flaherty Patrick
• Lay James Michael
• Snell Nathan

Classifications

• F21V21/049 Primary

  Mounting arrangements for attaching lighting devices to the ceiling, the lighting devices being recessed in a false or stretched ceiling · CPC title

• F21S8/02 Primary

  of recess-mounted type, e.g. downlighters (specially adapted for vehicle exteriors F21S41/00-F21S45/00) · CPC title

• F21Y2115/10

  Light-emitting diodes [LED] · CPC title

• Y10T29/49117

  Conductor or circuit manufacturing · CPC title

• F21V23/009

  the casing being inside the housing of the lighting device · CPC title