Recessed downlight mounting fixture

• US 7,118,254 B2
• Filed: 04/20/2004
• Issued: 10/10/2006
• Est. Priority Date: 04/20/2004
• Status: Active Grant

• Current Assignee: Signify North America Corporation (Signify N.V.)
• Original Assignee: Genlyte Thomas Group LLC (Koninklijke Philips N.V.)
• Inventors: Czech, Kenneth
• Primary Examiner(s): Luebke, Renee
• Assistant Examiner(s): Zettl, Mary
• Application Number:
  US10/827,825
• Publication Number:
  US 20050231954A1
• Time in Patent Office: 903 Days
• Field of Search: 174/63, 174/52.1, 174/50, 362/147, 362/296, 362/306, 362/364, 362/370, 362/371, 362/396, 362/406, 362/365, 362/148, 29/33.M, 297/39, 297/29, 248/57, 200/297, 220/3.2
• US Class Current: 362/365
• CPC Class Codes: F21V 21/04 Recessed bases
• CPC Class Codes: Y10T 29/5313 Means to assemble electrical device
• CPC Class Codes: Y10T 29/53174 Means to fasten electrical component to wiring board, base, or substrate

Abstract

A recessed downlight mounting fixture having a fixture plate formed from a blank, the fixture plate having at least one aperture for receiving a lamp housing, a junction box formed from said the blank and foldably integral with said the fixture plate, at least one junction box door formed from the blank with the fixture plate, and, at least one mounting bar bracket formed from the blank.

Claims

1. A recessed downlight mounting fixture, comprising:

a fixture plate formed from a blank, said fixture plate having at least one aperture for receiving a lamp housing therethrough;

a junction box formed from said blank and foldably integral with said fixture plate;

at least one junction box door formed from said blank with said fixture plate; and

,

at least one mounting bar bracket formed from said blank.

2. The recessed downlight mounting fixture of claim 1 further comprising offset tabs extending from opposed sides of said fixture plate.

3. The recessed downlight mounting fixture of claim 2, each of said offset tabs being surrounded by said at least one mounting bar bracket on said blank.

4. The recessed downlight mounting fixture of claim 2, one of said at least one mounting bar brackets fastened to each of said offset tabs.

5. The recessed downlight mounting fixture of claim 2, said offset tabs being folded to an operating position from a blank layout.

6. The recessed downlight mounting fixture of claim 1, said at least one aperture for receiving said lamp housing being adjacent said junction box.

7. The recessed downlight mounting fixture of claim 1, said recessed downlight mounting fixture formed from a single tooling.

8. The recessed downlight mounting fixture of claim 1, said fixture plate having a plurality of bosses.

9. The recessed downlight mounting fixture of claim 1, wherein said at least one junction box door is two junction box doors.

10. The recessed downlight mounting fixture of claim 1 wherein said at least one mounting bar bracket is two mounting brackets.

11. The recessed downlight mounting fixture of claim 10 wherein each of said two mounting bar brackets are formed about an opposed offset tab.

12. The recessed downlight mounting fixture of claim 1, said junction box defined by foldable opposed side walls and an upper wall defined by opposed sections.

13. The recessed downlight mounting fixture of claim 12, said junction box formed by folding said opposed side walls and said opposed sections and further fastening said opposed sections.

14. The recessed downlight mounting fixture of claim 12, said junction box having a plurality of knockouts in said opposed side walls and said upper wall.

15. A recessed downlight mounting fixture, comprising:

a fixture plate having at least two opposed sides and an end;

first and second offset tabs extending from said opposed sides;

first and second mounting bar brackets formed integral with said fixture plate and adjacent said tabs;

a junction box foldably integral with said end of said fixture plate;

wherein said fixture plate, said mounting bar brackets, and said junction box are formed by a single tooling.

16. The recessed downlight mounting fixture of claim 15, said mounting bar brackets having ears extending from said a body portion.

17. The recessed downlight mounting bracket of claim 16, said ears having a plurality of mounting bar apertures.

18. The recessed downlight mounting bracket of claim 17, said mounting bar apertures providing for vertical adjustment of mounting bars.

19. The recessed downlight mounting bracket of claim 16 further comprising conduit apertures in said ears.

20. The recessed downlight mounting bracket of claim 15, further comprising a lamp housing aperture extruded through said fixture plate.

21. The recessed downlight mounting fixture of claim 20, said fixture formed in a multi-step process by said single tooling.

22. A blank layout for a recessed downlight mounting fixture, comprising:

a fixture plate having offset tabs extending from opposed sides of said fixture plate;

first and second mounting bar brackets positioned adjacent said offset tabs in said blank layout;

at least one junction box door adjacent said mounting bar brackets on said blank;

a junction box foldably integral with said fixture plate;

said fixture plate, said at least one junction box door, said mounting bar brackets, and said junction box formed from said blank.

23. The recessed downlight mounting fixture of claim 22, said frame, said at least one junction box door, said mounting bar brackets, and said junction box formed by a single tooling.

24. The recessed downlight mounting fixture of claim 22, said frame, said at least one junction box door, said mounting bar brackets, and said junction box formed during a multiple stage process by a single tool.

25. A process for forming a recessed downlight mounting fixture, comprising the steps of:

placing a blank in a tooling device;

making a plurality of tooling cuts to form various assembly parts from said blank;

retaining said assembly parts on said blank by webs located between said parts; and

,

extruding a lamp housing aperture from said blank.

26. The process of claim 25 further comprising the step of folding various parts on said blank to form a junction box.

27. The process of claim 26 further comprising the step of folding ears on said mounting bar bracket.

28. The process of claim 27 further comprising the step of folding tabs disposed on sides of said fixture plate.

29. A recessed downlight mounting fixture, comprising:

a fixture plate formed from a blank, said fixture plate having at least one extruded

aperture for receiving a lamp housing therethrough;

a junction box formed from said blank and foldably integral with said fixture plate;

at least one junction box door formed from said blank with said fixture plate; and

,

at least one mounting bar bracket foldably integral with said blank.

30. A method for forming a recessed downlight mounting frame, comprising the steps of:

positioning a blank in a single tooling;

forming a fixture plate with said single tooling;

extruding said fixture plate to define an aperture for receiving an enclosure therethrough;

punching at least one junction box door and mounting bar brackets from said blank; and

,

folding a junction box integral with said fixture plate from said blank.

31. The method of claim 30 further comprising the step of forming offset tabs on said fixture plate.

32. The method of claim 31 said mounting bar brackets being integral with said offset tabs.

33. The method of claim 30 further comprising the step of forming a plurality of bosses in said fixture plate.