PLASTIC DOWNLIGHT FIXTURE HAVING INTERLOCKING ATTACHMENT FEATURES

• US 20170248290A1
• Filed: 02/26/2016
• Published: 08/31/2017
• Est. Priority Date: 02/26/2016
• Status: Active Grant

• Current Assignee: Technical Consumer Products, Inc. (Quality Light Source GmbH)
• Original Assignee: Technical Consumer Products, Inc. (Quality Light Source GmbH)
• Inventors: Uhler, George J.
• Granted Patent: US 9,976,723 B2
• Time in Patent Office: Days
• 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 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 17/005 with keying means, i.e. for enabling the assembling of component parts in distinctive positions, e.g. for preventing wrong mounting
• CPC Class Codes: F21V 17/10 characterised by specific fastening means or way of fastening F21V17/02 - F21V17/08 take precedence
• CPC Class Codes: F21V 21/046 being tensioned by rotation of parts
• CPC Class Codes: F21V 23/003 the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 7/04 Optical design
• 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]

Abstract

A downlight fixture is disclosed, and includes a lens defining at least one lens opening, a reflector, and a housing. The reflector defines at least one first retaining feature and at least one second retaining feature. The at least one lens opening is shaped to receive a corresponding first reflector retaining feature to interlock the lens and the reflector with one another. The housing defines at least one housing opening shaped to receive a corresponding second retaining feature to interlock the housing and the reflector with one another. The lens, the reflector, and the housing are each constructed of plastic.

Claims

1. A downlight fixture, comprising:

a lens defining at least one lens opening;

a reflector defining at least one first retaining feature and at least one second retaining feature, wherein the at least one lens opening is shaped to receive a corresponding first reflector retaining feature to interlock the lens and the reflector with one another; and

a housing defining at least one housing opening shaped to receive a corresponding second retaining feature to interlock the housing and the reflector with one another, wherein the lens, the reflector, and the housing are each constructed of plastic.

2. The downlight fixture of claim 1, wherein the at least one first retaining feature of the reflector is a finger that includes a ramped portion, and wherein the ramped portion of the finger is contained within the at least one lens opening.

3. The downlight fixture of claim 1, wherein the at least one second retaining feature of the reflector is a finger.

4. The downlight fixture of claim 1, wherein the housing defines a bottom wall defining an inner surface, and wherein at least one locator pin projects outwardly from the inner surface of the bottom wall.

5. The downlight fixture of claim 4, comprising a heat sink positioned within the housing, wherein the heat sink defines at least one aperture shaped to receive a corresponding locator pin.

6. The downlight fixture of claim 5, comprising a light emitting diode (LED) engine positioned within the housing, wherein the LED light engine defines at least one second aperture shaped to receive the corresponding locator pin.

7. The downlight fixture of claim 6, wherein the reflector defines a first end portion, a second end portion, and a frustoconical portion, wherein a lip is located at the first end portion of the reflector and is seated against the LED light engine.

8. The downlight fixture of claim 1, comprising a driver board contained within the housing and including electronics for electrical operation of the downlight.

9. The downlight fixture of claim 8, wherein the housing defines a bottom wall defining an inner surface, and wherein at least one board retaining feature projects outwardly from the inner surface of the bottom wall of the housing and abuts against the driver board to secure the driver board in place within the housing.

10. The downlight fixture of claim 1, wherein the lens, the reflector, and the housing are constructed of polycarbonate.

11. A light emitting diode (LED) downlight fixture, comprising:

a lens defining at least one lens opening;

a reflector defining at least one first retaining feature and at least one second retaining feature, wherein the at least one lens opening is shaped to receive a corresponding first reflector retaining feature to interlock the lens and the reflector with one another; and

a housing defining at least one housing opening shaped to receive a corresponding second retaining feature to interlock the housing and the reflector with one another, wherein the lens, the reflector, and the housing are each constructed of plastic; and

an LED engine positioned within the housing.

12. The LED downlight fixture of claim 11, wherein the at least one first retaining feature of the reflector is a finger that includes a ramped portion, and wherein the ramped portion of the finger is contained within the at least one lens opening.

13. The LED downlight fixture of claim 11, wherein the at least one second retaining feature of the reflector is a finger.

14. The LED downlight fixture of claim 11, wherein the housing defines a bottom wall defining an inner surface, and wherein at least one locator pin projects outwardly from the inner surface of the bottom wall.

15. The LED downlight fixture of claim 14, comprising a heat sink positioned within the housing, wherein the heat sink defines at least one aperture shaped to receive a corresponding locator pin.

16. The LED downlight fixture of claim 15, wherein the LED light engine defines at least one second aperture shaped to receive the corresponding locator pin.

17. The LED downlight fixture of claim 16, wherein the reflector defines a first end portion, a second end portion, and a frustoconical portion, wherein a lip is located at the first end portion of the reflector and is seated against the LED light engine.

18. The LED downlight fixture of claim 11, comprising a driver board contained within the housing and including electronics for electrical operation of the downlight.

19. A method of assembling a downlight fixture, comprising:

receiving a first retaining feature of a reflector by a lens opening defined by a lens, wherein the lens opening is shaped to receive the first retaining feature of the reflector to interlock the lens and the reflector with one another; and

receiving a second retaining feature of the reflector by a housing opening defined by a housing, wherein the housing opening is shaped to receive the second retaining feature to interlock the housing and the reflector with one another.

20. The method of claim 19, comprising constructing each of the lens, the reflector, and the housing of plastic.