Casing for lighting assembly

Patent metadata

Field	Value
Publication number	US-11242983-B2
Application number	US-202016779865-A
Country	US
Kind code	B2
Filing date	Feb 3, 2020
Priority date	Nov 16, 2015
Publication date	Feb 8, 2022
Grant date	Feb 8, 2022

Abstract

A fire-resistant, recessed lighting unit that obviates the need for a separate junction box and a separate incandescent “can”. Other embodiments are also described and claimed.

First claim

The invention claimed is:

1. An apparatus, comprising:
a casing formed of injection molded plastic, the casing comprising:
a sidewall surrounding a cavity having a vertical height and adapted to contain a light source module in the cavity, the sidewall having an edge defining an opening; and
a closed top end coupled to the sidewall and at an opposite end of the cavity from the opening, the closed top end including a first plurality of wiring passageways,

wherein the vertical height of the cavity of the casing is sufficiently large to contain:
all of the light source module;
a substantial portion of a crown of a trim coupled to the light source module;
at least a portion of a first pair of building electrical power wires to supply power to the light source module; and
at least a portion of a second pair of building electrical power wires to supply the power to another light source module of a nearby lighting unit.

2. The apparatus of claim 1 , wherein:
the sidewall includes a second plurality of wiring passageways;
at least a first wiring passageway of the second plurality of wiring passageways is positioned on the sidewall proximate to the closed top end; and
the vertical height of the cavity of the casing is sufficiently large such that when the light source module is completely contained in the cavity and the substantial portion of the crown of the trim coupled to the light source module is contained in the cavity, the light source module and the trim are below the first wiring passageway and do not obstruct the first wiring passageway.

3. The apparatus of claim 2 , wherein the vertical height of the cavity of the casing is sufficiently large to accommodate a crown vertical height of the substantial portion of the crown of the trim in a range of from 1 inch to 2.5 inches.

4. The apparatus of claim 1 , further comprising:
the light source module disposed in the cavity of the casing, the light source module comprising:
a housing;
a light source, disposed within the housing, having one or more light emitting diodes (LED's) to emit light; and
a driver, coupled to the housing, to receive the power and to regulate electrical energy to the light source.

5. The apparatus of claim 4 , further comprising:
at least the portion of the first pair of building electrical power wires to supply the power to the light source module from either an electrical power wiring network of a building or another lighting unit.

6. The apparatus of claim 5 , further comprising:
at least the portion of the second pair of building electrical power wires.

7. The apparatus of claim 5 , wherein the first pair of building electrical power wires is either a metal flexible conduit or a non-metallic sheathed cable.

8. The apparatus of claim 1 , further comprising:
a holding bracket, disposed in the cavity of the casing, having an arm with a slot; and
an attaching member, coupled to the sidewall of the casing, that passes through the slot of the arm such that the holding bracket is slidably adjustable relative to the cavity along the slot.

9. The apparatus of claim 8 , further comprising:
the light source module coupled to the holding bracket such that the light source module moves with the holding bracket as the holding bracket is slidably adjusted; and
at least the portion of the first pair of building electrical power wires to supply the power to the light source module,
wherein the light source module is located between a first position where the light source module is disposed inside the cavity of the casing and a second position where a portion of the light source module is disposed outside the cavity of the casing such that the light source module still covers the opening of the sidewall thereby preventing access to the first pair of building electrical power wires.

10. The apparatus of claim 9 , wherein the holding bracket at the first position is pivotable about the attachment member.

11. The apparatus of claim 1 , further comprising:
a first hangar bar, slidably coupled to the casing, having a first mounting block; and
a second hangar bar, slidably coupled to at least one of the first hanger bar and the casing and telescopically slidable with respect to the first hangar bar, having a second mounting block,
wherein the first mounting block and the second mounting block include one or more attachment mechanisms to couple to at least one of a wood joist or a t-bar.

12. The apparatus of claim 11 , further comprising:
the light source module disposed in the cavity of the casing, the light source module comprising:
a housing; and
a light source, disposed within the housing, having one or more light emitting diodes (LED's) to emit light; and a driver to receive the power and to regulate electrical energy to the light source.

13. The apparatus of claim 12 , further comprising the trim coupled to the light source module, wherein a crown vertical height of the substantial portion of the crown of the trim is in a range of from 1 inch to 2.5 inches.

14. The apparatus of claim 1 , further comprising:
a casing holder directly coupled to the sidewall and not coupled to the closed top end such that at least a portion of the casing holder is slidably adjustable with respect to the casing.

15. The apparatus of claim 14 , wherein:
the casing holder comprises a plate portion that conforms to a shape of the sidewall such that at least the portion of the casing holder is only slidably adjustable with respect to the casing.

16. The apparatus of claim 14 , further comprising:
a first hangar bar, slidably coupled to the casing holder, having a first mounting block; and
a second hangar bar, slidably coupled to the casing holder and telescopically slidable with respect to the first hangar bar, having a second mounting block,
wherein the first mounting block and the second mounting block include one or more attachment mechanisms to couple to at least one of a wood joist or a t-bar.

17. The apparatus of claim 16 , wherein:
the first hangar bar is telescopically slidable with respect to the second hangar bar along a first axis; and
at least the portion of the casing holder is slidably adjustable with respect to the casing along a second axis; and
the second axis is not parallel with the first axis.

18. The apparatus of claim 16 , further comprising:
the light source module disposed in the cavity of the casing, the light source module comprising:
a housing; and
a light source, disposed within the housing, having one or more light emitting diodes (LED's) to emit light; and

a driver to receive the power and to regulate electrical energy to the light source.

19. The apparatus of claim 18 , further comprising the trim coupled to the light source module, wherein a crown vertical height of the substantial portion of the crown of the trim is in a range of from 1 inch to 2 . 5 inches.

20. The apparatus of claim 14 , further comprising:
a bolt/screw combination coupled to the casing holder and inserted through a sidewall opening in the sidewall of the casing; and
a nut, disposed within the cavity of the casing and coupled to the bolt/screw combination, to prevent relative movement between the casing holder and the casing when the nut is sufficiently tightened.

21. The apparatus of claim 14 , wherein the casing holder is coupled to the sidewall via a single bolt/screw combination.

22. The apparatus of claim 1 , wherein at least a portion of the sidewall has a subs

Assignees

• Dmf Inc

Inventors

• Danesh Michael D
• Peng Xinzhi

Classifications

• F21V23/001 Primary

  the elements being electrical wires or cables · CPC title

• F21S8/02 Primary

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

• F21V17/18

  Latch-type fastening, e.g. with rotary action · CPC title