Positionable lighting systems and methods

• US 8,167,627 B1
• Filed: 10/03/2011
• Issued: 05/01/2012
• Est. Priority Date: 10/12/2007
• Status: Active Grant

• Current Assignee: Kichler Lighting, LLC (Masco Corporation)
• Original Assignee: LD Kichler Company (Masco Corporation)
• Inventors: Janos, Joseph John, Carlson, Christine
• Primary Examiner(s): Duverne, Jean F
• Application Number:
  US13/251,438
• Publication Number:
  US 20120087129A1
• Time in Patent Office: 211 Days
• Field of Search: 439/76.1, 439/236, 439242-243, 439/502
• US Class Current: 439/76.1
• CPC Class Codes: F21S 2/00 Systems of lighting devices, not provided for in main groups F21S4/00 - F21S10/00 or F21S19/00, e.g. of modular construction
• CPC Class Codes: F21V 27/00 Cable-stowing arrangements structurally associated with lighting devices, e.g. reels storing lengths of cable in general B65H; the lighting devices being vehicle headlamps F21S41/192; the lighting devices being vehicle lights F21S43/195
• CPC Class Codes: H01R 13/72 Means for accommodating flexible lead within the holder
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A lighting assembly includes a lighting unit having a housing defining an internal cavity and an opening. A light source is assembled within the internal cavity of the housing. An electrical wire is electrically connected to the light source at a first end and is configured to be contained at least in part within the housing. The opening is configured to permit withdrawal of a user selected amount of the electrical wire from within the internal cavity and/or to permit a user selected amount of the electrical wire to be inserted into the internal cavity.

Claims

1. A lighting assembly comprising at least one lighting unit, each lighting unit comprising:

a housing comprising a base portion and an outer portion, the housing being configured to define an internal cavity and a gap around an outer perimeter of the housing between the base portion and the outer portion;

a circuit board disposed within the housing;

at least one light emitting diode carried by the circuit board; and

an electrical wire having a first end for electrical connection to the circuit board, the electrical wire being configured to be wound around a hub disposed radially inward of the gap; and

a mounting plate configured to be secured to an external surface, and including a plurality of tabs that snap into engagement with the base portion of the housing to secure the lighting unit to the external surface; and

wherein at least a portion of the gap is sized to apply a retaining force to retain a wound portion of the electrical wire within the internal cavity, such that a user applied pulling force on the electrical wire overcomes the retaining force to withdraw the user selected amount of the wound portion of the electrical wire.

2. The lighting assembly of claim 1, wherein the base portion comprises a substrate, the circuit board being thermally coupled to the substrate.

3. The lighting assembly of claim 1, further comprising a voltage converter for electrical connection to a second end of the electrical wire for supplying power to the at least one light emitting diode.

4. The lighting assembly of claim 1, further comprising a second electrical wire having a first end for electrical connection to the circuit board, the second electrical wire extending through an opening in the housing for electrical connection with a second lighting unit.

5. The lighting assembly of claim 1, wherein the gap extends around the entire outer perimeter of the housing.

6. The lighting assembly of claim 1, further comprising an electrical plug electrically connected to a second end of the electrical wire of the lighting unit for supplying power to the at least one light emitting diode.

7. The lighting assembly of claim 1, wherein the at least one lighting unit comprises first and second lighting units, wherein the electrical wire of the second lighting unit is electrically connectable at a second end to the first lighting unit for communicating electricity from the first lighting unit to the at least one light emitting diode of the second lighting unit.

8. The lighting assembly of claim 7, wherein a second end of the electrical wire of the second lighting unit extends into the first lighting unit housing through an opening in the base member of the first lighting unit.

9. The lighting assembly of claim 1, wherein the mounting plate includes a mounting hole for securing the mounting plate to the external surface with a screw-type fastener.

10. The lighting assembly of claim 1, further comprising a junction box including a housing carrying a driver circuit board, a plurality of lighting unit output connectors, a junction box inlet connector for receiving a supply voltage from an associated power supply, and a junction box output connector for transmitting the supply voltage to an associated module of a modular lighting system, wherein a second end of the electrical wire of each lighting unit is configured to be connected to one of the plurality of lighting unit output connectors.

11. The lighting assembly of claim 1, wherein the base portion comprises a substrate thermally coupled to the circuit board, the substrate further comprising at least one thermally conductive projection exposed to an external environment and configured to draw heat away from the at least one light emitting diode;

further wherein the outer portion further comprising an end flange extending radially from the hub opposite the substrate, wherein the substrate, hub and end flange form a spool member for retaining the wound portion of the electrical wire;

further wherein the electrical wire includes an electrical plug connected to a second end of the electrical wire for supplying power to the at least one light emitting diode; and

further wherein the mounting plate includes a mounting hole for securing the mounting plate to the external surface with a screw-type fastener, the mounting hole being aligned with a center of the at least one lighting unit when the at least one lighting unit is assembled with the mounting plate.

12. The lighting assembly of claim 2, wherein the substrate further comprises at least one thermally conductive projection exposed to an external environment and configured to draw heat away from the at least one light emitting diode.

13. The lighting assembly of claim 2, wherein the outer portion further comprising an end flange extending radially from the hub opposite the substrate, wherein the substrate, hub and end flange form a spool member for retaining the wound portion of the electrical wire.

14. A lighting assembly comprising at least one lighting unit, each lighting unit comprising:

a housing configured to define an internal cavity and a gap around an outer perimeter of the housing between a base portion and an outer portion;

a circuit board disposed within the housing;

at least one light emitting diode carried by the circuit board; and

an electrical wire having a first end for electrical connection to the circuit board;

wherein the housing comprises a first housing member defining a hub and a second housing member forming a substrate thermally coupled to the circuit board, with the first and second housing members together defining a spool member for retaining a wound portion of the electrical wire around the hub when the wound portion of the electrical wire is wound around the hub; and

wherein the gap is configured to permit withdrawal of a user selected amount of the wound portion of the electrical wire from within the internal cavity.

15. The lighting assembly of claim 14, further comprising an electrical plug electrically connected to the second end of the electrical wire for supplying power to the at least one light emitting diode.

16. The lighting assembly of claim 14, wherein the at least one lighting unit comprises first and second lighting units, wherein the electrical wire of the second lighting unit is electrically connectable at a second end to the first lighting unit for communicating electricity from the first lighting unit to the at least one light emitting diode of the second lighting unit.

17. The lighting assembly of claim 14, wherein the gap extends around the entire outer perimeter of the housing.

18. The lighting assembly of claim 14, further comprising a mounting member including a mounting hole for securing the mounting plate to an external surface with a fastener, and a plurality of tabs that snap into engagement with the base portion of the housing to secure the lighting unit to the external surface.

19. A lighting assembly comprising:

first and second lighting units each comprising;

a housing including a base portion and an outer portion, the housing being configured to define an internal cavity, a gap around an outer perimeter of the housing between the base portion and the outer portion, and a hub disposed radially inward of the gap;

a circuit board disposed within the housing; and

at least one light emitting diode carried by the circuit board;

a first electrical wire having a first end for electrical connection to the circuit board of the first lighting unit and a second end for electrical connection to an external power source, the first electrical wire being configured to be wound around the hub of the first lighting unit, wherein the gap of the first lighting unit is configured to permit withdrawal of a user selected amount of a wound portion of the first electrical wire from within the internal cavity of the first lighting unit; and

a second electrical wire having a first end for electrical connection to the circuit board of the second lighting unit and a second end for electrical connection to the circuit board of the first lighting unit, the first electrical wire being configured to be wound around the hub of the second lighting unit, wherein the gap of the second lighting unit is configured to permit withdrawal of a user selected amount of a wound portion of the second electrical wire from within the internal cavity of the second lighting unit.

20. The lighting assembly of claim 19, wherein each of the first and second lighting units further comprises a substrate disposed within the housing and thermally coupled to the corresponding circuit board.

21. The lighting assembly of claim 19, wherein each lighting unit further comprises a mounting member including a mounting hole for securing the mounting member to an external surface with a fastener, and a plurality of tabs that snap into engagement with the base portion of the housing to secure the lighting unit to the external surface.

22. The lighting assembly of claim 19, wherein each base portion comprises a substrate thermally coupled to the corresponding circuit board, the substrate further comprising at least one thermally conductive projection exposed to an external environment and configured to draw heat away from the corresponding at least one light emitting diode;

further wherein each outer portion further comprising an end flange extending radially from the corresponding hub opposite the corresponding substrate, such that the associated substrate, hub and end flange form a spool member for retaining the wound portion of the corresponding electrical wire;

further wherein each electrical wire includes an electrical plug connected to a second end of the electrical wire for supplying power to the corresponding least one light emitting diode; and

further wherein each lighting unit includes a mounting plate having a mounting hole for securing the mounting plate to an external surface with a screw-type fastener, the mounting hole being aligned with a center of the at least one lighting unit when the at least one lighting unit is assembled with the mounting plate.