RECESSED MINI-CAN LIGHTING ASSEMBLY

• US 20150085500A1
• Filed: 09/12/2014
• Published: 03/26/2015
• Est. Priority Date: 09/23/2013
• Status: Abandoned Application

• Current Assignee: Canarm Ltd.
• Original Assignee: Canarm Ltd.
• Inventors: Cooper, James A., Kuan, Hon Man
• Application Number:
  US14/484,631
• Publication Number:
  US 20150085500A1
• Time in Patent Office: Days
• US Class Current: 362/365
• CPC Class Codes: F21K 9/20 Light sources comprising attachment means
• CPC Class Codes: F21S 8/02 of recess-mounted type, e.g. downlighters specially adapted for vehicle exteriors F21S41/00-F21S45/00
• CPC Class Codes: F21V 19/0045 by tongue and groove connections, e.g. dovetail interlocking means fixed by sliding
• CPC Class Codes: F21V 21/044 with elastically deformable elements, e.g. spring tongues
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 27/02 Cable inlets
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10T 29/49208 by assembling plural parts

Abstract

A recessed lighting assembly has an integrated junction box, a removable insert configured to be secured within the junction box/housing, and a connector for connecting the electrical components to electrical wires of the cable within the interior of the junction box/housing. The insert comprises a light emitter, such as one or more LEDs, electrical components for supplying current to the light emitter, and an exterior portion that is exposed when the assembly is mounted to the structure. The connector may include one or more quick connect members for conveniently connecting household wires to electrical leads of the insert. The assembly may be installed by initially mounting the junction box/housing to structure, forming an electrical connection between the household wires and the fixture wires, and securing the insert within the junction box/housing.

Claims

1. A recessed lighting assembly for mounting to a structure, the assembly comprising:

an integrated junction box/housing configured to be mounted to the structure and configured to admit a multi-phase electrical cable into the interior of said junction box/housing;

a removable insert configured to be secured within said junction box/housing, said insert comprising a light emitter or a mount for a light emitter, electrical components for supplying current to said light emitter or mount and an exterior portion which is exposed when said assembly is mounted to said structure; and

a connector for connecting said electrical components to electrical wires of said cable within the interior of said junction box/housing.

2. The assembly of claim 1 wherein said insert further comprises a heat sink configured to absorb and dissipate heat generated by said electric circuit and/or said light emitter.

3. The assembly of claim 2 wherein said heat sink comprises an exterior portion of said insert which is outside said junction box/housing when engaged thereto.

4. The assembly of claim 1 wherein said light emitter comprises one or more light emitting diodes (LEDs).

5. The assembly of claim 1 wherein said connector comprises at least one quick connect member to connect said electrical wires to said insert, said quick connect member comprising a first component for electrical connection to an exposed end of said wire and a second component electrically connected to said electrical components of said insert, wherein the first and second components form an electrical and a mechanical connection therebetween to transmit current from the electrical wires to the electrical components of said insert.

6. The assembly of claim 5 wherein at least the second component of said quick connect member is mounted to said insert.

7. The assembly of claim 5 wherein said at least one quick connect member comprises an integral member, wherein the first component comprises a socket within said quick connect member for receiving and engaging an exposed wire core of a corresponding one of said wires.

8. The assembly of claim 5 wherein said first and second components are separable from each other and said quick connect member comprises a receptacle for receiving a first of said wires and the first and second components comprise engagement members for fastening said components together for forming an electrical and mechanical connection therebetween.

9. The assembly of claim 1 further comprising a support member mounted to said insert wherein said connectors are mounted to said support member.

10. The assembly of claim 1 comprising a plurality of said connectors for engagement individually with said wires.

11. The assembly of claim 1 further comprising at least one fastener for mounting the junction box/housing to the structure.

12. The assembly of claim 11 wherein said fastener is configured to mount said junction box/housing to wallboard or other sheathing member of said structure.

13. The assembly of claim 12 wherein said fastener comprises at least one set of opposing clamp members configured to clamp said sheathing member between said clamp members.

14. The assembly of claim 13 wherein a first of said clamp members comprises a spring clip extending from said junction box/housing biased to move outwardly from said junction box/housing and a second of said clamp members comprises a non-moveable protrusion of said junction box/housing, wherein said spring clip is configured to bear against an inside surface of the sheathing member and the protrusion is configured to bear against an opposed outer surface of the sheathing member.

15. The assembly of claim 1 wherein said insert and said junction box/housing comprise interlocking members to fasten the insert to the junction box/housing.

16. The assembly of claim 15 wherein said interlocking members comprise at least one protrusion extending from said junction box/housing or said insert and a slot within the other of said junction box/housing or insert, wherein the slot is configured to receive said protrusion and is further configured as a cam to tighten said insert into said junction box/housing when said insert is rotated relative to the junction box/housing.

17. The assembly of claim 1 wherein said junction box/housing is configured for installation either during construction of the structure or retrofit into an existing structure.

18. The assembly of claim 1 wherein said junction box/housing comprises a mini-can.

19. A method of installing a light fixture to a structure, wherein the fixture comprises an integrated electrical junction box/housing for a lighting fixture and an insert comprising a light emitter or mount for a light emitter, electrical components for supplying current to the light emitter, a connection for connecting said electrical components to electrical wires within said junction box/housing and an exterior portion which is exposed when said assembly is mounted to said surface, the method comprising the steps of:

feeding a multiphase electrical cable into the interior of the junction box/housing,

mounting said junction box/housing to said structure,

forming an electrical connection between wires of said electrical cable and said insert, and

securing the insert within said junction box/housing.

20. The method of claim 19 wherein said insert comprises at least one quick connect member electrically connected to said electrical components within the insert and said step of forming an electrical connection comprises the further steps of attaching at least one of said wires to said quick connect member.

21. The method of claim 20 wherein said wires are attached to said quick connect member by insertion of an exposed segment of a wire core of said wire into a socket within the quick connect member.

22. The method of claim 19 wherein said insert is secured by twisting the insert to lock together the insert and junction box/housing with a camming action.

23. The method of claim 19 comprising installation of said junction box/housing either during construction of the structure or during a retrofit or renovation of an existing structure.