Recessed luminaire for remodel applications

Patent metadata

Field	Value
Publication number	US-9970634-B1
Application number	US-201715587287-A
Country	US
Kind code	B1
Filing date	May 4, 2017
Priority date	May 4, 2017
Publication date	May 15, 2018
Grant date	May 15, 2018

Abstract

A remodel recessed luminaire includes a housing can that defines a first slope and a junction box that defines a second slope. Further, the housing can includes a channel to retain a thermoprotector therein, the channel being defined by an indentation formed in a top wall of the housing can. The junction box includes a top cover that is coupled to a main body of the junction box and the top wall of the housing can such that the top cover encloses a wire management cavity that is formed by the channel that is communication with a second cavity defined by the main body. Furthermore, the junction box includes a coupling feature to attach an electrical component to the junction box. The first slope and the second slope operate in unison to fit the remodel recessed luminaire through small ceiling apertures and/or ceiling apertures in thick ceilings.

First claim

What is claimed is:

1. A remodel recessed luminaire comprising:
a cylindrical housing can comprising a curved side wall and a top wall that define a first inner cavity, the top wall comprising an indentation, the indentation defining a channel that is configured to retain a thermoprotector device therein,
wherein the channel is open along the top wall of the cylindrical housing can and on one side of the channel while a remainder of the channel is bounded by the top wall of the cylindrical housing can; and
a junction box comprising a top cover and a main body, the main body comprising a side wall, the junction box defining a second cavity, the junction box coupled to the top wall of the cylindrical housing can such that:
the top of the channel that is open is covered by the top cover of the junction box, and
the second cavity is in continuous communication with the channel through the one side of the channel that is open to form a wire management cavity that is disposed external to the first inner cavity of the cylindrical housing can, the wire management cavity comprising the channel and the second cavity,
wherein when the thermoprotector device is disposed in the channel, electrical wiring from an external power supply source is connected to the thermoprotector device through the wire management cavity that is external to the first inner cavity of the cylindrical housing can and via an electrical connector disposed in the second cavity defined by the junction box.

2. The remodel recessed luminaire of claim 1 :
wherein the top cover of the junction box has a securing tab and a securing rib, the securing tab extending out and away from the top cover at an acute angle, and
wherein the junction box is coupled to the cylindrical housing can such that when the thermoprotector device is disposed in the channel of the cylindrical housing can, the securing tab and the securing rib of the junction box are disposed above the channel such that they engage the thermoprotector device to:
securely retain the thermoprotector device in the channel, and
enhance a thermal contact between the thermoprotector device and the top wall of the cylindrical housing can.

3. The remodel recessed luminaire of claim 2 , wherein the top cover includes a mounting pad that is configured to attach an electrical component thereto using a fastener.

4. The remodel recessed luminaire of claim 1 , wherein
when the top cover is coupled to the main body of the junction box, a portion of the top cover encloses the second cavity while a remainder portion of the top cover overhangs from the main body.

5. The remodel recessed luminaire of claim 4 :
wherein the main body comprises a door that is hingedly coupled to the main body and is retained in a closed position using a fastening device to cover a notch defined by a bottom wall of the main body, and
wherein the fastening device is coupled to the top cover.

6. The remodel recessed luminaire of claim 4 :
wherein the remainder portion of the top cover comprises a coupling aperture and a coupling tab disposed at and extending from an edge of the top cover,
wherein the coupling tab and the coupling aperture of the top cover are configured to couple the junction box to the cylindrical housing can by engaging corresponding coupling features of the top wall of the cylindrical housing can, and
wherein the coupling features of the top wall of the cylindrical housing can comprise a cover slot that receives the coupling tab of the top cover and a cover aperture that axially aligns with the coupling aperture of the top cover to receive a fastener therethrough.

7. The remodel recessed luminaire of claim 1 :
wherein the first inner cavity of the cylindrical housing can houses a light circuit, and
wherein the thermoprotector device may be electrically coupled to the light circuit and in series with the light circuit.

8. The remodel recessed luminaire of claim 1 :
wherein the cylindrical housing can comprises a sloped wall that extends from a perimeter of the top wall to the curved side wall of the cylindrical housing can,
wherein the sloped wall is asymmetric such that the sloped wall is wider on a first side of the housing can than on a second side of the cylindrical housing can that is opposite to the first side, and
wherein the widest portion of the sloped wall defines a first slope.

9. The remodel recessed luminaire of claim 8 :
wherein the junction box is coupled to the cylindrical housing can adjacent the second side of the cylindrical housing can, and
wherein the junction box defines a complementary second slope disposed at a bottom side of the junction box, and
wherein the first slope defined by the sloped wall of the cylindrical housing can and the second complementary slope defined by the junction box operate in concert to fit the remodel recessed luminaire through a small ceiling aperture or a ceiling aperture of a thick ceiling.

10. The remodel recessed luminaire of claim 9 , wherein the thickness of the thick ceiling ranges from 1 inch to 2 inches.

11. The remodel recessed luminaire of claim 1 , wherein the junction box is configured to attach an electrical component thereto such that the electrical component is disposed in the second cavity defined by the junction box.

12. The remodel recessed luminaire of claim 11 , wherein the electrical component is a transformer.

13. The remodel recessed luminaire of claim 1 :
wherein the electrical connector is a terminal block, and
wherein the second cavity is configured to house a connector frame that supports a plurality of electrical connectors including the electrical connector.

14. A remodel recessed luminaire comprising:
a cylindrical housing can that comprises a sloped wall that extends between a top wall and a side wall of the cylindrical housing can, the sloped wall is asymmetric such that the sloped wall is wider on a first side of the cylindrical housing can than on a second side of the cylindrical housing can that is opposite to the first side of the cylindrical housing can, wherein the wider portion of the sloped wall on the first side defines a first slope; and
a junction box that is coupled to the top wall of the cylindrical housing can adjacent the second side of the cylindrical housing can and comprising a main body of the junction box that defines a complementary second slope that is disposed at a bottom side of the junction box, wherein the complementary second slope tapers towards a front wall of the main body,
wherein the junction box is coupled to the cylindrical housing can such that the front wall of the main body is disposed adjacent the second side of the cylindrical housing can and a wire receiving opening formed in the side wall on the second side of the cylindrical housing can is axially aligned with a wire receiving opening in the front wall of the main body, and
wherein the cylindrical housing can and the junction box can be inserted through an aperture in a ceiling.

15. The remodel recessed luminaire of claim 14 , wherein the junction box further comprises a top cover that is coupled to the main body such that a portion of the top cover encloses a second cavity defined by the main body while a remainder portion of the top cover overhangs from the main body.

16. The remodel recessed luminaire of claim 15 :
wherein the remainder portion of the top cover comprises a coupling aperture and a coupling tab disposed at and extending from an edge of the top cover,
wherein the coupling tab and the coupling aperture of the top cover are configured to couple the junction box to the top

Assignees

• Cooper Technologies Co

Inventors

• Wronski Grzegorz
• Lin Zhihong
• Pyshos Steven
• Ernst Oliver

Classifications

• F21V23/026 Primary

  Fastening of transformers or ballasts · CPC title

• H02G3/20

  Ceiling roses {or other lighting sets} · CPC title

• F21V21/00

  Supporting, suspending, or attaching arrangements for lighting devices (F21V17/00, F21V19/00 take precedence; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q, stands for supporting apparatus or articles in general F16M11/00); Hand grips · CPC title

• F21V21/041 Primary

  Mounting arrangements specially adapted for false ceiling panels or partition walls made of plates (F21V21/047 takes precedence) · CPC title

• F21S8/026

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