LED lighting apparatus with adapter bracket for a junction box

Patent metadata

Field	Value
Publication number	US-11047538-B2
Application number	US-202017085636-A
Country	US
Kind code	B2
Filing date	Oct 30, 2020
Priority date	Jun 22, 2017
Publication date	Jun 29, 2021
Grant date	Jun 29, 2021

Abstract

An LED lighting apparatus comprises a housing having at least one sidewall, an LED board, a lens having a back side facing the LED board and a front side opposite to the back side, and a driver module cover. The lens is disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens. An adapter bracket is employed to couple the LED lighting apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snapped into the junction box, the driver module cover is at least partially disposed in the junction box.

First claim

The invention claimed is:

1. A system comprising:
an LED lighting apparatus, comprising:
a housing comprising a rear side and at least one sidewall having a front facing edge and a back facing edge surrounding the rear side and positioned adjacent to a ceiling when the LED lighting apparatus is installed in an opening of the ceiling, wherein:
a depth of the at least one sidewall of the housing, between the front facing edge and the back facing edge, is less than one inch; and
a thickness of at least a portion of the at least one sidewall is less than five millimeters;

an LED board coupled to the housing, the LED board comprising a plurality of LEDs;
a driver to receive an input voltage of at least one of 120 or 277 Volts AC and to convert the input voltage to provide a lower output voltage to the LED board; and
a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens; and

at least one adapter bracket to couple the LED lighting apparatus to a junction box, the junction box being installed above a ceiling in a building, the at least one adapter bracket comprising:
a ring-shaped base, disposed on the rear side of the housing of the LED lighting apparatus, surrounding a first hole, the ring-shaped base including a plurality of second holes, smaller than the first hole, disposed in the ring-shaped base to accommodate a plurality of screws to attach the at least one adapter bracket to the junction box; and
a collar around a perimeter of the first hole and integrally formed with the ring-shaped base,

wherein the LED lighting apparatus includes a plurality of coupling elements to couple the apparatus to the at least one adapter bracket.

2. The system of claim 1 , wherein:
the lens is coupled to a front side of the housing;
the LED lighting apparatus further comprises a driver module cover coupled to the rear side of the housing;
the plurality of coupling elements is disposed around a perimeter of the driver module cover; and
the driver module cover fits through the first hole of the ring-shaped base of the at least one adapter bracket.

3. The system of claim 2 , wherein:
the LED lighting apparatus is snapped into the at least one adapter bracket to couple the apparatus to the junction box; and
the plurality of coupling elements includes a plurality of spring-loaded elements.

4. The system of claim 3 , wherein the plurality of spring-loaded elements includes one of a plurality of spring clips or a plurality of friction fit clips.

5. The system of claim 3 , wherein the plurality of spring-loaded elements engage with the collar of the at least one adapter bracket to facilitate snapping the LED lighting apparatus into the at least one adapter bracket.

6. The system of claim 5 , wherein:
the driver is housed inside the driver module cover coupled to the rear side of the housing; and
the plurality of LEDs includes at least one hundred LEDs.

7. The system of claim 6 , wherein:
the input voltage, when present, is from an electrical power wiring network of the building in which the junction box is installed; and
the LED lighting apparatus further comprises wires passing through the driver module cover to provide the input voltage from the electrical power wiring network of the building in which the junction box is installed.

8. A system, comprising:
an LED lighting apparatus, comprising:
a housing comprising a rear side and at least one sidewall, wherein a thickness of at least a portion of the at least one sidewall is less than five millimeters;
an LED board coupled to the housing, the LED board comprising a plurality of LEDs;
a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens;
a driver module cover coupled to the housing; and
a driver housed inside the driver module cover; and

at least one adapter bracket to couple the apparatus to a junction box installed above a ceiling in a building or a structure, the at least one adapter bracket comprising:
a ring-shaped base, disposed on the rear side of the housing of the LED lighting apparatus, surrounding a first hole and including a plurality of second holes, smaller than the first hole, disposed in the ring-shaped base to accommodate a plurality of screws to attach the at least one adapter bracket to the junction box; and
a collar around a perimeter of the first hole and integrally formed with the ring-shaped base,

wherein:
in operation, the driver receives an input voltage of at least one of 120 or 277 Volts AC from an electrical power wiring network of the building in which the junction box is installed and provides a stable output voltage or current to the plurality of LEDs; and
the driver module cover includes a plurality of coupling elements disposed around a perimeter of the driver module cover to couple the apparatus to the at least one adapter bracket.

9. The system of claim 8 , wherein:
the LED lighting apparatus is snapped into the at least one adapter bracket to couple the apparatus to the junction box; and
the plurality of coupling elements includes a plurality of spring-loaded elements.

10. The system of claim 9 , wherein the plurality of spring-loaded elements includes one of a plurality of spring clips or a plurality of friction fit clips.

11. The system of claim 9 , wherein the plurality of spring-loaded elements engage with the collar of the at least one adapting bracket to facilitate snapping the apparatus into the at least one adapter bracket.

12. The system of claim 8 , wherein the driver module cover includes at least one vertical groove perpendicular to the rear side of the housing.

13. A system, comprising:
an LED lighting apparatus, comprising:
a housing comprising at least one sidewall;
an LED board coupled to the housing, the LED board comprising at least one hundred LEDs;
a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens; and
a driver module cover coupled to the housing; and

at least one adapter bracket to couple the LED lighting apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snapped into the junction box, the driver module cover is at least partially disposed in the junction box and the at least one adapter bracket is disposed between the housing of the LED lighting apparatus and the junction box.

14. The system of claim 13 , wherein the at least one adapter bracket comprises:
a ring-shaped base surrounding a first hole, the first hole having a dimension so as to accommodate the driver module cover;
a plurality of second holes, smaller than the first hole, to accommodate a plurality of screws to attach the at least one adapter bracket to the junction box; and
a collar around a perimeter of the first hole.

15. The system of claim 14 , wherein the housing of the LED lighting apparatus includes a plurality of coupling elements to facilitate snapping the apparatus into the at least one adapter bracket.

16. The system of claim 15 , wherein the plurality of coupling elements includes a plurality of spring-loaded elements.

Assignees

• Dmf Inc

Inventors

• Danesh Michael D
• Williams Vincent
• Jongewaard Mark

Classifications

• F21S8/026 Primary

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

• F21Y2105/18

  annular; polygonal other than square or rectangular, e.g. for spotlights or for generating an axially symmetrical light beam · CPC title

• F21Y2105/16

  square or rectangular, e.g. for light panels · CPC title

• F21V23/04

  the elements being switches (safety devices F21V25/00) · CPC title

• F21V21/047

  Mounting arrangements with fastening means engaging the inner surface of a hole in a ceiling or wall, e.g. for solid walls or for blind holes · CPC title