Direct attach ceiling-mounted solid state downlights

• US 10,054,274 B2
• Filed: 04/29/2015
• Issued: 08/21/2018
• Est. Priority Date: 03/23/2012
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Athalye, Praneet Jayant, Bernard, Randy, Snell, Nathan, Dungan, William L.
• Primary Examiner(s): Hanley, Britt D
• Application Number:
  US14/699,172
• Publication Number:
  US 20150233537A1
• Time in Patent Office: 1,210 Days
• Field of Search: None
• CPC Class Codes: F21S 8/026 intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling
• CPC Class Codes: F21S 8/04 intended only for mounting on a ceiling or the like overhead structures F21S8/02 takes precedence; details of ceiling bases F21V21/03
• CPC Class Codes: F21V 21/04 Recessed bases
• CPC Class Codes: F21V 21/044 with elastically deformable elements, e.g. spring tongues
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 23/023 Power supplies in a casing F21V23/003 takes precedence
• CPC Class Codes: F21V 29/15 Thermal insulation
• CPC Class Codes: F21V 3/02 characterised by the shape
• CPC Class Codes: F21V 3/04 characterised by materials, surface treatments or coatings
• CPC Class Codes: F21V 7/0066 specially adapted to cooperate with point like light sources; specially adapted to cooperate with light sources the shape of which is unspecified F21V7/16 - F21V7/30 take precedence
• CPC Class Codes: F21V 7/041 with conical or pyramidal surface
• CPC Class Codes: F21V 7/22 characterised by materials, surface treatments or coatings, e.g. dichroic reflectors
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/3725 Switched mode power supply [SMPS]
• CPC Class Codes: H05B 45/375 using buck topology
• CPC Class Codes: H05B 45/38 using boost topology
• CPC Class Codes: H05B 45/385 using flyback topology
• CPC Class Codes: Y02B 20/00 Energy efficient lighting technologies, e.g. halogen lamps or gas discharge lamps

Abstract

Solid state downlights include a fixture that has a solid state lighting housing, a plurality of light emitting diodes within the solid state lighting housing and a junction box, and at least one mounting structure that is configured to releasably attach the fixture directly to a ceiling to mount the fixture within an opening in the ceiling.

Claims

1. A solid state downlight, comprising:

a fixture that includes;

a solid state lighting housing;

a plurality of light emitting diodes within the solid state lighting housing; and

a junction box; and

at least one mounting structure that is configured to releasably attach the fixture directly to a ceiling to mount the fixture within an opening in the ceiling,

wherein the at least one mounting structure comprise a pair of spring mounting arms, and wherein the solid state lighting housing includes a lip that is at least partially below the ceiling when the solid state downlight is installed in the ceiling, and

wherein each spring mounting arm includes a spring section that directly engages a sidewall of the opening in the ceiling.

2. The solid state downlight of claim 1, wherein the junction box is mounted above the solid state lighting housing, the solid state downlight further comprising a driver housing that includes a driver circuit that is mounted above the solid state lighting housing.

3. The solid state downlight of claim 2, wherein the junction box and the driver housing are mounted side-by-side on a top surface of the solid state lighting housing.

4. The solid state downlight of claim 3, wherein a top surface of the junction box overlies the driver housing.

5. The solid state downlight of claim 1, wherein the junction box includes a first wire opening with a resiliently deflectable cover.

6. The solid state downlight of claim 5, wherein the resiliently deflectable cover is configured to engage an external electrical wire that enters the junction box through the wire opening to provide strain relief.

7. The solid state downlight of claim 1, wherein the spring mounting arms are configured to hold the fixture within the opening for ceilings having thickness in the range from about 0.375 inches to about 0.675 inches.

8. The solid state downlight of claim 2, further comprising a wire connection terminal that is at least partly within the junction box, the wire connection terminal configured to connect a power supply conductor and a return conductor of an external electrical wire to respective ones of a pair of electrical leads that are connected to the driver circuit.

9. The solid state downlight of claim 2, wherein the junction box is mounted to the fixture via a flexible wire conduit, wherein a pair of electrical leads that are connected to the driver circuit extend from the driver circuit through the flexible wire conduit to the junction box.

14. The solid state downlight of claim 1, wherein the solid state downlight is configured to be mounted in the ceiling and electrically connected to an external electrical wire that provides power to the solid state downlight without installing a sheet metal lighting can in the ceiling.

15. The solid state downlight of claim 2, wherein the junction box comprises an extension that covers a top surface of the driver housing.

16. The solid state downlight of claim 15, wherein the extension comprises a downwardly projecting finger having an inwardly projecting tab that is configured to fit within an opening of the driver housing.

17. The solid state downlight of claim 2, wherein the at least one mounting structure is attached to the junction box and/or the driver housing.

10. A solid state downlight fixture for mounting within an opening in a ceiling, comprising:

a solid state lighting housing having a top surface, at least one sidewall extending downwardly from the top surface and a lower lip extending outwardly from the bottom of the at least one sidewall;

a plurality of light emitting diodes mounted within the solid state lighting housing;

a junction box releasably attached to the top surface of the solid state lighting housing, the junction box including a wire opening;

a driver housing on the top surface of the solid state lighting housing;

at least one mounting structure that is attached to the junction box and/or the driver housing and is configured to releasably attach the fixture directly to the ceiling to mount the fixture within the opening in the ceiling;

and a driver circuit in the driver housing, the driver circuit including first and second leads that extend into the junction box; and

wherein the at least one mounting structure comprise a pair of spring mounting arms that are configured to directly engage a sidewall of the opening in the ceiling when the solid state downlight fixture is mounted within the opening in the ceiling, and wherein the solid state lighting housing includes a lip that is mounted at least partially below the ceiling.

11. The solid state downlight fixture of claim 10, further comprising a resiliently deflectable cover that covers the wire opening, the deflectable cover configured to engage an external electrical wire that is routed through the wire opening to provide strain relief.

12. The solid state downlight fixture of claim 11, wherein the junction box includes a second wire opening and a second resiliently deflectable cover that covers the second wire opening.

13. The solid state downlight fixture of claim 10,

wherein the junction box and the driver housing are arranged side-by-side on the top surface of the solid state lighting housing, and

wherein a top surface of the junction box overlies the driver housing.

18. The solid state downlight fixture of claim 13, wherein the junction box comprises an extension that covers a top surface of the driver housing.

19. The solid state downlight fixture of claim 18, wherein the extension comprises a downwardly projecting finger having an inwardly projecting tab that is configured to fit within an opening of the driver housing.