Patent Application
20180328554
The present disclosure relates to lighting assemblies, and more particularly, to adjustable light-emitting diode (LED) recessed lighting assemblies with integrated electronics.
Recessed lighting assemblies or fixtures are designed to be recessed into a building member, which building member is most commonly a ceiling. Often, installation of a recessed lighting assembly includes installing and attaching many different components on the inner (upper) area or surface of the building member with the lighting components housed within a portion of the assembly and positioned within a hole in the building member. In such assemblies, typically, a support or frame is attached to the building structure above the ceiling along with additional operational components such as wiring and an electronics unit including a driver circuit for activating and operating the lighting components. Often, these components are all separate units pieced together by the installer. An additional complication often arises when installing lighting fixtures in this manner in that the installer must painstakingly ensure that all measurements and positioning of the different components complies with relevant building codes.
Further, it is often desirable to access inner or upper components of an installed lighting assembly, for maintenance of the electronics or adjustment of any elements or similar. For example, an electronics unit may house a driver circuit or branch circuit for operating the lighting components within the assembly. In recessed lighting assemblies, electronics units like these are commonly hidden behind the building member within which the lighting components are recessed. In most known recessed lighting assemblies, gaining access to the electronics unit is often burdensome, time consuming and costly in that it requires accessing the inner components from above the ceiling, cutting into the ceiling or other building structure and/or disassembling the lighting fixture or components or other parts of the assembly.
Adjustable systems and assemblies have been developed with features to assist in accessing different components. For example, some external lighting assemblies include a pivoting mechanism that allows a user to shift the lighting components downward to assist in accessing rear components. However, even in such systems, the lighting components remain positioned between a user and the electronics or require lighting components to hang into the interior of a room (below the lower surface of the ceiling), and do not provide completely open access to the rear components.
Additionally, building members within which a recessed lighting assembly can be installed vary greatly in terms of materials and thickness. For example, different lighting assemblies or mounts would be required for installation into a 0.25 inch thick ceiling versus a 0.5 inch thick ceiling, and other ceilings of thicknesses up to approximately 2.5 inches. In years prior this required many different components and unique assemblies to accommodate different building materials and thicknesses.
There is a need for an all-in-one recessed lighting assembly that solves the problems enumerated above in that it provides a standalone fully integrated assembly with depth/height adjustability that also allows movement of the front components out of the way to provide a completely open access opening for accessing the driver electronics from the opposite side of the ceiling (i.e., underneath) without the drawbacks enumerated above.
According to one disclosed embodiment, a lighting assembly has an outer frame with a lower edge and an upper edge. The upper edge is positionable on an inner portion of a building member and the frame is attachable to the building member. The frame defines an open inner cavity passing from the lower edge to the upper edge. An integrated electronics unit is fixed relative to the outer frame in a position above the upper edge. Opposite brackets each defines a multi-directional slot fixed relative to the frame on opposite sides of the frame such that the slots in the respective brackets are substantially aligned with one another. An inner sleeve holds at least one lighting component in operable communication with the electronics unit. The inner sleeve has a terminal edge and is positionable within the inner cavity. The inner sleeve includes a pair of opposite projections each extending away from the inner sleeve that are engagable within a slot in one of the opposite brackets. The position of the inner sleeve relative to the outer frame can be adjusted via movement of the projections along the slots from a lowered position with the inner sleeve within the inner cavity and the inner sleeve terminal edge below the lower edge of the outer frame to a raised position with the inner sleeve terminal edge above the upper edge of the outer frame. From the raised position, the sleeve is adjustable to an offset position with the inner sleeve at least partially above the building member, thereby providing open access to the electronics unit from the direction below the lower edge of the outer frame through an open inner cavity.
In another embodiment of the recessed lighting assembly, a frame has a substantially cylindrical lower portion extending to a distal edge and a flange extending outward from and substantially perpendicular to the cylindrical portion proximal to the distal edge. The cylindrical portion defines a central axis and an access opening from a bottom surface to a top surface of a planar building member. An electronics unit is fixed to the frame in a front position proximal to the flange. A first bracket is fixed to the frame and positioned proximal to the flange extending substantially perpendicular to the planar building member on one side of the cylindrical portion. The first bracket defines a first slot that extends in an axial direction and a rearward direction away from the electronics unit. A second bracket is fixed to the frame and positioned proximal to the flange extending substantially perpendicular to the planar building member on the opposite side of the cylindrical portion of the first bracket. The second bracket defines a second slot that extends in the axial direction and the rearward direction. An inner sleeve for holding at least one light-emitting diode (LED) component in operable communication with the electronics unit is sized for receipt within the substantially cylindrical lower portion of the frame. The inner sleeve is engaged with both of the first and second brackets and has a terminal edge. The inner sleeve is reciprocable along the first slot and second slot in the axial direction between a lowered position with the terminal edge distal to the distal edge of the frame and a raised position with the terminal edge proximal to the flange of the frame. When the inner sleeve is in the raised position, the sleeve is reciprocable between a forward position substantially aligned with the access opening blocking access to the electronics unit from the bottom surface of the building member to a rear position exposing at least a portion of the access opening allowing access to the electronics unit from the bottom surface of the building member.
Aspects of the preferred embodiment will be described in reference to the Drawing, where like numerals reflect like elements:
Among the benefits and improvements disclosed herein, other objects and advantages of the disclosed embodiments will become apparent from the following wherein like numerals represent like parts throughout the several figures. Detailed embodiments of an adjustable recessed lighting assembly are disclosed; however, it is to be understood that the disclosed embodiments are merely illustrative of the invention that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention which are intended to be illustrative, and not restrictive.
Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrases “In some embodiments” and “in some embodiments” as used herein do not necessarily refer to the same embodiment(s), though it may. The phrases “in another embodiment” and “in some other embodiments” as used herein do not necessarily refer to a different embodiment, although it may. Thus, as described below, various embodiments may be readily combined, without departing from the scope or spirit of the invention.
In addition, as used herein, the term “or” is an inclusive “or” operator, and is equivalent to the term “and/or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,” “an,” and “the” include plural references. The meaning of “in” includes “in” and “on.
Further, the terms “substantial,” “substantially,” “similar,” “similarly,” “analogous,” “analogously,” “approximate,” “approximately,” and any combination thereof mean that differences between compared features or characteristics is less than 25% of the respective values/magnitudes in which the compared features or characteristics are measured and/or defined.
With reference initially to the side view of
In this embodiment of the standalone assembly 10, an electronics unit 24 is securely attached to the frame 12 at a front position by way of a bent flange or bracket 26. Note that the oblique bend in the flange depicted in
The inner sleeve 14 is sized and shaped to fit within the frame 24. In the depicted embodiment of the Figures, the sleeve 14 has a substantially cylindrical shape sized to be housed coaxial to the substantially cylindrical portion 20 of the frame 12 in a slidable relationship. Various fasteners, clamps or similar elements may be included to assist in maintaining the sleeve 14 and frame 12 as desired. As shown, the inner sleeve may include a plurality of tabs 44 for providing a frictional relationship to assist in maintaining the alignment of the sleeve and frame. The sleeve 14 houses lighting components, such as, for example light-emitting diode (LED) or similar units, reflectors or other light direction components, printed circuit boards (PCBs) and/or heat dissipation components. The lighting components are generally represented by reference character L in
As shown, the frame 12 includes a pair of inner side brackets 16 on opposite sides of the cylindrical portion 20. In the depicted embodiments, the brackets 16 are fixed on the annular flange 22 by a plurality of fasteners. This particular mechanism of attachment is nonlimiting in that the brackets may be attached at a different location or by a different means. Each bracket 16 defines a multi-directional slot 18 having at least an axial or vertical portion 18a and a lateral portion 18b extending in the direction away from the electronics unit 24. The particular depicted embodiment includes a slot 18 that has an inverted substantially U-shape. The U-shaped slot has been found to be particularly useful in manufacturing the assembly 10 in that the same bracket component can be used on both sides of the frame 14 instead of requiring two separate brackets with L-shaped slots that are mirror images of one another. The inner sleeve 14 includes a pair of pins or bolts 30 extending outwardly, each bolt 30 slidingly engaged within a slot 18. With reference to the cross sectional view of
With reference to the assembly installation shown in
The assembly 10 is configured such that the distal edge 36 of the cylindrical portion of the frame 12 is positioned within the thickness of a typical ceiling structure 35 with the flange 22 abutting the upper surface 39 and the lower surface 37 of the ceiling distal to the distal edge 36. In the installed and working condition of the assembly 10, the inner sleeve is adjusted vertically along the vertical portion 18a of the slots 18 until the desired height relative to the ceiling structure 35 is reached. Typically the sleeve 14 is adjusted vertically until the terminal edge 38 is approximately at the position of the lower surface 37 of the ceiling with the trim cap 48 on the outside of the ceiling recess (see
Further to the vertical adjustability and versatility described above, the multi-directional slot 18 allows full unimpeded access to the electronics unit 24 from the bottom 37 of the ceiling structure 35. More specifically, if and when the electronics unit 24 in an installed assembly 10 requires maintenance, the inner sleeve 14 can be reciprocated upward along the vertical portion 18a until its terminal edge 38 rises above the upper plane defined by the top (inner) surface 39 of the ceiling member 35 (the fully raised position). Once in the fully raised position, the inner sleeve 14 can be reciprocated rearward over the ceiling member 35 with the bolts 30 traveling along the lateral portion 18b of the slot to yield an unobstructed access opening 40 to the electronics unit 24 from the bottom (outer) side of the ceiling member 18. Since the electronics unit 24 is fixed to a portion of the frame 12, the sleeve 14 is movable independent of the electronics unit.
Unlike known recessed lighting systems, the fully integrated recessed lighting assembly 10 includes notable elements, such as the frame 12, inner sleeve 14 with lighting components, electronics unit 24, wiring and wire conduit 28 in a standalone system. Thus, the electronics unit 24 can be freely and openly accessed at any time without requiring (a) disassembly or removal of the lighting assembly 10 from the ceiling recess, (b) removal of the assembly from the recess, (c) cutting into the ceiling or drywall, or (d) accessing from the top (inner) side of the ceiling. Of further note is that the exact manufacturing specifications of the assembly 10 can be altered in order to comply with all known regulations, for example, UL safety compliance code. With reference to
D≥75+Dx+Dy [Formula I]
where D, Dx and Dy are all measured in millimeters (mm). In another embodiment, the assembly is designed with an access opening of at least approximately 150 mm.
The particular materials, sizes, comparative measurements and shapes of the elements described with respect to the disclosed preferred embodiments may vary without departing from the inventive concepts of the disclosed lighting assembly. For example, the preferred embodiments have been described with reference to a cylindrical inner sleeve 14 and cylindrical portion 20 of the frame. However, these shapes are nonlimiting in that embodiments exist with a sleeve and cooperative portion of the frame that take on a rectangular prismic or ovular shape. Further, it is not essential that the sleeve and portion of the frame take on the same shape as each other so long as the sleeve is adjustable along the multiple directions to provide an open access opening to the electronics unit as described herein. Similarly, while a particularly preferred embodiment includes a frame, sleeve and brackets formed from stainless steel, other rigid and strong materials may be substituted, such as polymeric materials or other metals, for example. Further, the diameter or other lateral extent of the access opening can within a typical range of approximately 2-8 inches, while the thickness of the building member within which the assembly can be installed (and that the sliding sleeve can accommodate) varies within a typical range of approximately 0.25 inches to 2.5 inches.
While a preferred embodiment has been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit of the invention and scope of the claimed coverage.
