Lighting module for recessed lighting systems

• US 10,591,120 B2
• Filed: 05/27/2016
• Issued: 03/17/2020
• Est. Priority Date: 05/29/2015
• Status: Active Grant

• Current Assignee: DMF Incorporated
• Original Assignee: DMF Incorporated
• Inventors: Bailey, Michael D., Danesh, Michael D.
• Primary Examiner(s): Truong, Bao Q
• Application Number:
  US15/167,682
• Publication Number:
  US 20160348861A1
• Time in Patent Office: 1,390 Days
• CPC Class Codes: F21K 9/20 Light sources comprising attachment means
• CPC Class Codes: F21S 8/024 intended to be recessed in a wall or like vertical structure, e.g. building facade
• CPC Class Codes: F21S 8/026 intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling
• CPC Class Codes: F21V 23/002 Arrangements of cables or conductors inside a lighting device, e.g. means for guiding along parts of the housing or in a pivoting arm
• CPC Class Codes: F21V 23/006 the substrate being distinct from the light source holder
• CPC Class Codes: F21V 23/02 the elements being transformers, impedances or power supply units, e.g. a transformer with a rectifier
• CPC Class Codes: F21V 29/507 of means for protecting lighting devices from damage, e.g. housings
• CPC Class Codes: F21V 29/77 with essentially identical diverging planar fins or blades, e.g. with fan-like or star-like cross-section
• CPC Class Codes: F21V 29/89 Metals
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 7/24 characterised by the material
• CPC Class Codes: F21V 7/28 characterised by coatings
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A housing has a sidewall that surrounds an interior cavity that has an open rear end and an open front end, and is divided by a partition into a top cavity and a bottom cavity. The top cavity extends to the open rear end, the bottom cavity extends to the open front end. A power supply circuit board is inside the top cavity, while a light source is inside the bottom cavity and emits light through the open front end to illuminate a room. First wires pass through an opening in the partition, and are coupled to the power supply circuit board at one end and to the light source at another end, to deliver power to the light source. A lid or cover covers the open rear end enclosing the top cavity, and is secured to the housing. Other embodiments are also described and claimed.

Claims

1. A lighting module for a recessed lighting system, the lighting module comprising:

a housing having a sidewall, the sidewall surrounding an interior cavity of the housing that has an open rear end and an open front end, wherein the interior cavity is divided by a partition into a top interior cavity and a bottom interior cavity, the top interior cavity extending to the open rear end, the bottom interior cavity extending to the open front end;

a power supply circuit board positioned inside the top interior cavity of the housing;

a light source positioned inside the bottom interior cavity of the housing to emit light through the open front end of the housing that illuminates a room;

a first plurality of wires that passes through an opening in the partition, wherein the first plurality of wires is coupled to the power supply circuit board at one end and to the light source at another end, to deliver power to the light source;

a cover that covers the open rear end enclosing the top interior cavity, and is secured to the housing; and

an optic position inside of the bottom cavity of the housing, the optic having a reflector portion,

wherein the open rear end is sufficiently large so as to allow the power supply circuit board to be placed into and/or removed from the top interior cavity through the open rear end.

5. The lighting module of claim 1 further comprising a cup in which the power supply circuit board is held, wherein the cup is positioned upside down within the top interior cavity of the housing so that a base of the cup is at the top of the sidewall and a brim of the cup is at the partition.

6. The lighting module of claim 1 wherein the cover has an opening formed therein through which a second plurality of wires emerges from the housing and that are connected to an input of the power supply circuit board inside the housing, wherein the second plurality of wires delivers main electricity power to the input of the power supply circuit board.

7. The lighting module of claim 1 wherein the light source comprises a carrier having i) a top face that abuts a bottom face of the partition and ii) a bottom face on which there are a plurality light emitting diode (LED) elements, wherein the bottom face of the carrier has a plurality of electrical terminals to which the first plurality of wires is coupled, wherein the carrier routes electrical power from the terminals to the LED elements.

8. The lighting module of claim 1 wherein:

the reflector portion of the optic includes i) an inner periphery that defines a central opening which is aligned with the light source and through which the emitted light passes, and ii) an outer periphery;

the optic further includes a lens/filter that is attached to the outer periphery of the reflector portion; and

the lighting module further comprises a retaining ring attached to the housing at the open front end so as to hold or retain the optic within the bottom cavity.

9. The lighting module of claim 8 wherein the reflector portion and the attached lens/filter form a single, indivisible unit of the optic.

10. The lighting module of claim 1 wherein the housing further comprises a lip that extends laterally outward from the sidewall of the housing and surrounds the open front end of the housing, wherein the lip comprises a twist and lock mechanism to couple the housing to a trim.

11. The lighting module of claim 10 wherein the lip has an opening formed therein to receive a fastener for attaching the lighting module to a junction box or to another enclosure in which the lighting module has been inserted.

23. The lighting module of claim 1, wherein the partition and the sidewall are integrally formed as a single cast metal piece.

2. A lighting module for a recessed lighting system, the lighting module comprising:

a housing having a sidewall, the sidewall surrounding an interior cavity of the housing that has an open rear end and an open front end, wherein the interior cavity is divided by a partition into a top cavity and a bottom cavity, the top cavity extending to the open rear end, the bottom cavity extending to the open front end;

a power supply circuit board positioned inside the top cavity of the housing;

a light source positioned inside the bottom cavity of the housing to emit light through the open front end of the housing that illuminates a room;

a first plurality of wires that passes through an opening in the partition, wherein the first plurality of wires is coupled to the power supply circuit board at one end and to the light source at another end, to deliver power to the light source;

a cover that covers the open rear end enclosing the top cavity, and is secured to the housing; and

an island extending from the partition into the top cavity of the housing, wherein the power supply circuit board has a face to face opening therein in which the island is positioned.

3. The lighting module of claim 2 wherein a top of the island abuts a bottom face of the cover and the cover is held in that condition by a fastener that is secured to the top of the island.

4. The lighting module of claim 3 further comprising a layer of thermal paste sandwiched directly between the bottom face of the cover and the top of the island.

12. A lighting module for a recessed lighting system, the lighting module comprising:

a housing having a sidewall, the sidewall surrounding an interior cavity of the housing that has an open rear end and an open front end, wherein the interior cavity is divided by a partition into a top interior cavity and a bottom interior cavity, the top interior cavity extending to the open rear end, the bottom interior cavity extending to the open front end;

a power supply circuit board positioned inside the top interior cavity of the housing;

a light source positioned inside the bottom interior cavity of the housing, wherein light emitted by the light source through the open front end of the housing, to illuminate a room, is produced only by a plurality of light emitting diode (LED) elements of the light source that require input power at less than 50 Volts; and

a first plurality of wires that passes through an opening in the partition, wherein the first plurality of wires is coupled to the power supply circuit board at one end and to the light source at another end, to deliver the input power at less than 50 Volts to the light source,

wherein the open rear end is sufficiently large so as to allow the power supply circuit board to be placed into and/or removed from the top interior cavity through the open rear end.

13. The lighting module of claim 12 wherein the partition is entirely solid and completely isolates the top cavity from the bottom cavity except for said opening through which the first plurality of wires passes.

14. The lighting module of claim 12 further comprising a second plurality of wires that at one end is connected to an input of the power supply circuit board inside the housing, wherein the second plurality of wires delivers main electricity power to the input of the power supply circuit board.

15. The lighting module of claim 14 further comprising a cover that covers the open rear end and encloses the top interior cavity, and is secured to the housing by a fastener, wherein the cover has an opening formed therein through which the second plurality of wires emerges from the housing.

16. The lighting module of claim 12 wherein the light source comprises a carrier having i) a top face that abuts a bottom face of the partition and ii) a bottom face on which are installed a plurality light emitting diode (LED) elements that emit the light to illuminate the room, wherein the bottom face of the carrier has a plurality of electrical terminals to which the first plurality of wires is coupled, wherein the carrier routes electrical power from the terminals to the plurality of LED elements.

17. The lighting module of claim 12 further comprising:

an optic positioned inside of the bottom cavity of the housing, wherein the optic has a) a reflector portion having i) an inner periphery that defines a central opening which is aligned with the light source and through which the emitted light passes, and ii) an outer periphery, and b) a lens/filter that is attached to the outer periphery of the reflector portion; and

a retaining ring attached to the housing at the open front end so as to hold or retain the optic within the bottom cavity, and wherein the retaining ring can be removed from the housing and reinstalled without any tool.

18. The lighting module of claim 17 wherein the reflector portion and the attached lens/filter form a single, indivisible unit of the optic.

24. The lighting module of claim 12, wherein the partition and the sidewall are integrally formed as a single cast metal piece.

19. A lighting module for a recessed lighting system, the lighting module comprising:

a housing having a sidewall, the sidewall surrounding an interior cavity of the housing that has an open rear end and an open front end, wherein the interior cavity is divided by a partition into a top cavity and a bottom cavity, the top cavity extending to the open rear end, the bottom cavity extending to the open front end;

a power supply circuit board positioned inside the top cavity of the housing;

a light source positioned inside the bottom cavity of the housing, wherein light emitted by the light source through the open front end of the housing, to illuminate a room, is produced only by a plurality of light emitting diode (LED) elements of the light source that require input power at less than 50 Volts;

a first plurality of wires that passes through an opening in the partition, wherein the first plurality of wires is coupled to the power supply circuit board at one end and to the light source at another end, to deliver the input power at less than 50 Volts to the light source; and

an island extending from the partition into the top cavity of the housing, wherein the power supply circuit board has a face to face opening therein in which the island is positioned.

20. The lighting module of claim 19 further comprising a cover that covers the open rear end of the housing and encloses the top cavity, and is secured to the housing by a fastener, wherein the cover has an opening formed therein through which the second plurality of wires emerges from the housing, and wherein a top of the island abuts a bottom face of the cover and the cover is held in that condition by the fastener.

21. The lighting module of claim 19 further comprising a cup in which the power supply circuit board is held, wherein the cup is positioned upside down within the top interior cavity of the housing so that a base of the cup is at the top of the sidewall and a brim of the cup is at the partition.

22. The lighting module of claim 21 further comprising a cover that covers the open rear end of the housing and encloses the top interior cavity and is secured to the housing by a fastener, wherein the base of the cup has an opening therein through which a top of the island abuts a bottom face of the cover and the cover is held in that condition by the fastener being secured to the top of the island.