Junction Box for LED Drivers

• US 20190063737A1
• Filed: 10/29/2018
• Published: 02/28/2019
• Est. Priority Date: 03/17/2016
• Status: Active Grant

• Current Assignee: Elemental LED, Inc. (Elemental Led LLC)
• Original Assignee: Elemental LED, Inc. (Elemental Led LLC)
• Inventors: Buck, Wesley, Petersen, Russell
• Granted Patent: US 10,655,827 B2
• Time in Patent Office: Days
• CPC Class Codes: F21V 17/12 by screwing
• CPC Class Codes: F21V 23/001 the elements being electrical wires or cables
• 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 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21W 2131/10 Outdoor lighting
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H02G 15/10 protected by boxes, e.g. by distribution, connection or junction boxes
• CPC Class Codes: H02G 3/088 Dustproof, splashproof, drip-proof, waterproof, or flameproof casings or inlets
• CPC Class Codes: H05K 5/0091 Housing specially adapted for small components for resistors H01C; for capacitors H01G; for integrated circuits H01L23/00
• CPC Class Codes: H05K 5/03 Covers

Abstract

Junction boxes for enclosing and making electrical connections to LED drivers are disclosed. The junction boxes include a bottom or base and a cover. Dividers arising from the base divide the junction box into high-voltage and low-voltage compartments. A cut-out open at the top of each divider allows drivers to be placed in a junction box without having to pull wires through holes or openings. Typically, the base is open along one long sidewall, with the cover being L-shaped to complete the enclosure. Various mounting mechanisms are disclosed for securing drivers within junction boxes.

Claims

1. A junction box, comprising:

a horizontal base having

a central portion open along one long sidewall, and

two opposite end portions, each end portion having a three-walled compartment arising from the horizontal base, the three-walled compartments being at least substantially identical and spaced from one another by the central portion, each of the three-walled compartments including

two vertical outer sidewalls, each of the two vertical outer sidewalls being aligned with an edge of the horizontal base and defining a portion of a sidewall of the junction box, and each of the three vertical outer sidewalls having at least one frangible portion that is adapted to be broken away to form an opening, and

a vertical inner sidewall separating the three-walled compartment from the open central portion of the base;

at least one mounting position including or being associated with mounting structure secured, or adapted to be secured, to the central portion of the base to secure a driver;

a cut-out in each of the vertical inner sidewalls, the cut-outs corresponding in position to the at least one mounting position, and the cut-outs in the respective vertical inner sidewalls being aligned with one another across a length of the open central portion of the base, each of the cut-outs beginning at a top edge of one of the vertical inner sidewalls and extending downwardly; and

an L-shaped cover having

an upper face with a size and shape matching a size and shape of a lower face of the horizontal base, and

a depending side portion being sized and adapted to close the three-walled compartments of the opposite end portions and to create a contiguous sidewall along the open long sidewall of the base, such that when installed, the cover forms a closed enclosure with the base.

2. The junction box of claim 1, wherein the junction box is a rectangular prism with the cover installed on the horizontal base.

3. The junction box of claim 1, wherein the cut-outs on the inner sidewalls of the three-walled compartments are U-shaped.

4. The junction box of claim 1, wherein each of the three-walled compartments includes a grounding screw adapted to secure a ground wire.

5. The junction box of claim 4, wherein each of the vertical inner sidewalls includes a horizontal flange with a threaded opening for the grounding screw.

6. The junction box of claim 1, wherein the cover is perforated.

7. The junction box of claim 1, wherein the horizontal base and the cover are made of sheet metal.

8. The junction box of claim 1, wherein each of the three-walled compartments includes at least one opening or frangible portion along an exterior wall.

9. The junction box of claim 1, wherein each of the mounting structures comprises one or more Z-brackets;

clips;

fixed straps that engage with a buckle;

fixed straps that engage with a quick-release;

a hinged bracket;

depending wedges on an underside of the upper face of the cover;

or depending spring clips on the underside of the upper face of the cover.

10. The junction box of claim 1, wherein each of the mounting structures is staggered in position with respect to the others.

11. The junction box of claim 1, wherein the mounting structure comprises a single, common mounting structure that is adapted to secure the driver at each of the two or more mounting positions.

12. The junction box of claim 11, wherein the single, common mounting structure comprises a bracket.

13. The junction box of claim 12, wherein the single, common bracket includes at least one downwardly-extending portion to define a lateral spacing between respective mounting positions.

14. The junction box of claim 12, wherein the downwardly-extending portions extend to the horizontal base and are adapted to be secured to the horizontal base.

15. A junction box, comprising:

a horizontal base having

an open central portion open along one long sidewall, the open central portion having at least one mounting position, and

two opposite end portions, each end portion having a multi-wall compartment arising from the horizontal base, the compartments being at least substantially identical and spaced from one another by the open central portion, and each of the compartments being separated from the open central portion of the base by a vertical inner sidewall; and

an L-shaped cover having an upper face with a size and shape matching a size and shape of a lower face of the horizontal base, and a depending side portion sized to close the long open sidewall of the central portion.

16. The junction box of claim 15, further comprising a cut-out in each of the vertical inner sidewalls, the cut-outs corresponding in position to the at least one mounting position, and the cut-outs in the respective vertical inner sidewalls being aligned with one another across a length of the open central portion of the base, each of the cut-outs beginning at a top edge of one of the vertical inner sidewalls and extending downwardly.

17. The junction box of claim 15, each of the three-walled compartments includes at least one opening or frangible portion along an exterior wall.