Thin profile surface mount lighting apparatus

Patent metadata

Field	Value
Publication number	US-11293609-B2
Application number	US-202016881686-A
Country	US
Kind code	B2
Filing date	May 22, 2020
Priority date	Jun 22, 2017
Publication date	Apr 5, 2022
Grant date	Apr 5, 2022

Abstract

An LED downlighting apparatus includes a housing with a sidewall having a front facing edge and a back facing edge positioned adjacent to a ceiling when the LED downlighting apparatus is installed in an opening of the ceiling. A depth of the sidewall is less than one inch and a thickness of at least a portion of the sidewall is less than three millimeters. An LED board and a lens are coupled to the housing. The lens is disposed with respect to the LED board such that the lens is illuminated from a back side. One or more mechanical couplers snap fit the apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snap fit to the junction box through the opening of the ceiling, the housing appears to be surface mounted to the ceiling.

First claim

The invention claimed is:

1. An LED downlighting apparatus, comprising:
a housing comprising at least one sidewall having a front facing edge and a back facing edge positioned adjacent to a ceiling when the LED downlighting 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 three 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; and
at least one mechanical coupler to snap fit the apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snap fit to the junction box through the opening of the ceiling, the housing appears to be surface mounted to the ceiling.

2. The apparatus of claim 1 , wherein:
an edge thickness of the front facing edge of the at least one sidewall is less than 1.5 millimeters.

3. The apparatus of claim 1 , wherein the lens is substantially flat or flat.

4. The apparatus of claim 1 , wherein:
the LED board has a first dimension in a first plane parallel to the back side of the lens;
the lens has a second dimension in a second plane corresponding to the back side of the lens; and
the first dimension of the LED board and the second dimension of the lens are substantially the same or the same.

5. The apparatus of claim 1 , wherein the quotient of:
an LED-to-LED spacing of adjacent LEDs of the plurality of LEDs on the LED board; and
a spacing between the LED board and the lens,
is in a range of from 7.5/8 to 8.5/8.

6. The apparatus of claim 1 , wherein the plurality of LEDs are distributed uniformly on the LED board and spaced apart almost identically or identically.

7. The apparatus of claim 6 , wherein an LED-to-LED spacing of adjacent LEDs of the plurality of LEDs on the LED board is in a range of from approximately 7.5 millimeters to 8.5 millimeters.

8. The apparatus of claim 6 , wherein a spacing between the LED board and the lens is approximately or equal to eight millimeters.

9. The apparatus of claim 6 , wherein:
the LED board is circular; and
the plurality of LEDs is arranged on the LED board as a plurality of concentric rings.

10. The apparatus of claim 9 , wherein a distance between any two adjacent concentric rings of the plurality of concentric rings is the same or approximately the same.

11. The apparatus of claim 9 , wherein:
at least a first ring of the plurality of concentric rings comprises a first group of the plurality of LEDs; and
respective LEDs of the first group are spaced substantially evenly around the first ring of the plurality of concentric rings.

12. The apparatus of claim 11 , wherein:
each ring of the plurality of concentric rings comprises a different group of the plurality of LEDs; and
respective LEDs of each different group are spaced substantially evenly around a corresponding ring of the plurality of concentric rings.

13. The apparatus of claim 6 , wherein:
the LED board is rectangular; and
the plurality of LEDs is arranged substantially uniformly across an entire surface or substantially the entire surface of the LED board.

14. The apparatus of claim 13 , wherein an LED-to-LED distance between neighboring LEDs of the plurality of LEDs is in a range of from approximately 7.5 millimeters to 8.5 millimeters.

15. The apparatus of claim 1 , wherein the front side of the lens is essentially flush with the front facing edge of the at least one sidewall of the housing.

16. The apparatus of claim 1 , wherein the at least one sidewall of the housing is substantially perpendicular or perpendicular to the lens.

17. An LED downlighting apparatus, comprising:
a housing comprising at least one sidewall having a front facing edge and a back facing edge positioned adjacent to a ceiling when the LED downlighting apparatus is installed in an opening of the ceiling, wherein a thickness of at least a portion of the at least one sidewall is less than three 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; and
at least one screwless mechanical coupler to couple the apparatus to the ceiling.

18. The apparatus of claim 17 , wherein the at least one screwless mechanical coupler comprises at least one snap fit coupler.

19. The apparatus of claim 17 , wherein the at least one screwless mechanical coupler comprises at least one of a friction fit clip, a spring clip, or a magnet.

20. An assembly, comprising:
the apparatus of claim 17 ; and
an adapter ring to couple the apparatus to a junction box,
wherein the apparatus is coupled to the adapter ring via the at least one screwless mechanical coupler.

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

• F21Y2105/16

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

• F21Y2115/10

  Light-emitting diodes [LED] · CPC title

• F21S9/022

  Emergency lighting devices · CPC title

• F21V29/87

  Organic material, e.g. filled polymer composites; Thermo-conductive additives or coatings therefor · CPC title