Light-emitting diode based recessed light fixtures

• US 9,702,516 B1
• Filed: 04/20/2016
• Issued: 07/11/2017
• Est. Priority Date: 01/19/2012
• Status: Active Grant

• Current Assignee: Signify Holding B.V. (Signify N.V.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Vasquez, Charles Richard, Low, Jonathan Allin, Kathawate, Jyoti Gururaj
• Primary Examiner(s): Green, Tracie Y
• Application Number:
  US15/134,258
• Time in Patent Office: 447 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: F21S 8/026 intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 17/002 with provision for interchangeability, i.e. component parts being especially adapted to be replaced by another part with the same or a different function F21V17/10 takes precedence
• CPC Class Codes: F21V 17/12 by screwing
• CPC Class Codes: F21V 17/164 the parts being subjected to bending, e.g. snap joints
• CPC Class Codes: F21V 17/166 the parts being subjected to torsion, e.g. spiral springs
• CPC Class Codes: F21V 21/04 Recessed bases
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/76 with essentially identical parallel planar fins or blades, e.g. with comb-like cross-section
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A light fixture includes a light module and a trim assembly, where the trim assembly is removably coupled to the light module. The light module includes a module assembly that accommodates a light source. Further, the light module includes an additional heat sink that is optionally coupled to the module assembly. The trim assembly includes a lens, a reflector, and a trim. In particular, the reflector is coupled to the trim by inserting tabs extending downwards and substantially perpendicular from a collar of the reflector into through slots on a top collar of the trim such that the lens is securely retained and disposed in between the reflector and the trim.

Claims

1. A light fixture comprising:

a light module that includes a light source; and

a trim assembly that is removably coupled to the light module, the trim assembly comprising;

a trim comprising a top collar that extends radially outward from a top edge of the trim that defines a lens receiving opening, wherein the top collar comprises one or more through slots;

a reflector comprising;

a top edge defining a first opening,

a bottom edge defining a second opening that is disposed below the first opening,

a body extending from the top edge of the reflector to the bottom edge of the reflector,

a collar extending radially outward and substantially horizontally from the bottom edge of the reflector, and

one or more tabs extending downward and substantially perpendicular to the collar of the reflector from an outer edge of the collar; and

a lens comprising a collar and a curved surface,

wherein the lens is securely retained between the reflector and the trim such that;

(a) the collar of the lens is disposed between the collar of the reflector and the top collar of the trim, and (b) the curved surface of the lens is disposed below the second opening of the reflector and received through the lens receiving opening of the trim, and

wherein the reflector is coupled to the trim by inserting each tab of the one or more tabs of the reflector through a respective through slot of the one or more through slots on the top collar of the trim.

2. The light fixture of claim 1, wherein the trim further comprises:

a bottom collar that extends radially outward from a bottom edge of the trim that defines a light exit opening, and a trim body that extends from the top edge of the trim to the bottom edge of the trim.

3. The light fixture of claim 1, further comprising one or more torsion spring brackets and torsion springs that are coupled to the top collar of the trim, wherein the torsion spring brackets and torsion springs are configured to recess mount the light fixture.

4. The light fixture of claim 1, further comprising a plurality of coupling clips that are coupled to the top collar of the trim, wherein the plurality of coupling clips are configured to removably couple the light module to the trim assembly.

5. The light fixture of claim 1, wherein the light module is removably coupled to the trim assembly such that:

the light source of the light module is disposed adjacent to, above, and axially aligned with the first opening of the reflector, and light emitted by the light source of the light module enters the trim assembly through the first opening of the reflector.

6. The light fixture of claim 1, wherein the light module comprises a module assembly that accommodates the light source and one or more connector receptacles that provide a connection point for a connector from an external power source to supply a drive current to the light source, and wherein the light source is a light emitting diode (LED).

7. The light fixture of claim 6, wherein the light module comprises an enclosure, wherein the light source is disposed on and coupled to the enclosure, and wherein the enclosure operates as a heat sink when the light module is powered by a first range of drive currents.

8. The light fixture of claim 6, wherein an additional heat sink is removably coupled to the enclosure when the light module is powered by a second range of drive currents, and wherein the second range of drive currents is greater than the first range of drive currents.

9. A trim assembly, comprising:

a trim comprising;

a trim body that extends from the top annular edge to the bottom annular edge of the trim, wherein the top annular edge defines a lens receiving opening and the bottom annular edge defines a light exit opening,

a top collar that extends radially outward from a top edge of the trim, wherein the top collar comprises one or more through slots,

a bottom collar that extends radially outward from a bottom edge of the trim;

a reflector comprising a collar that extends radially outward from a bottom edge of the reflector, and one or more tabs extending downward and substantially perpendicular to the collar of the reflector from an outer edge of the collar; and

a lens comprising a curved surface and a collar extending radially outward from a top edge of the lens,

wherein the lens is securely retained between the reflector and the trim such that;

(a) the collar of the lens is disposed between the collar of the reflector and the top collar of the trim, and (b) the curved surface of the lens is disposed below the reflector and received through the lens receiving opening of the trim, and

wherein the reflector is coupled to the trim by inserting each tab of the one or more tabs of the reflector through a respective through slot of the one or more through slots on the top collar of the trim.

10. The trim assembly of claim 9, wherein the trim assembly is configured to be removably coupled to a light module that comprises a light source.

11. The trim assembly of claim 9, wherein the trim assembly further comprises one or more coupling clips that are coupled to the top collar of the trim and configured to removably couple the trim assembly to a light module comprising a light source.

12. The trim assembly of claim 9, wherein the trim assembly further comprises one or more torsion spring assemblies that are coupled to the top collar of the trim, wherein each torsion spring assembly comprises a torsion spring bracket and a torsion spring that is attached to the torsion spring bracket.

13. The trim assembly of claim 9, wherein the top collar of the trim further comprises one or more through apertures configured to couple at least one of a torsion spring bracket and a coupling clip to the trim using fasteners.

14. The trim assembly of claim 9, wherein the bottom edge of the reflector defines a second opening, wherein the reflector comprises a top edge that defines a first opening and a reflector body that extends from the top edge to the bottom edge, and wherein the diameter of first opening is smaller than the second opening.

15. A light fixture comprising:

a light module comprising;

a module assembly, wherein the module assembly comprises;

an enclosure,

a wire cover member that is disposed below and coupled to the enclosure, wherein the wire cover member includes an opening, and

a light source coupled to the enclosure and disposed in between the enclosure and the wire cover member such that the light source is configured to emit light through the opening of the wire cover member; and

a trim assembly that is removably coupled to the light module, the trim assembly comprising;

a lens;

a trim comprising a top collar that extends radially outward from a top edge of the trim that defines a lens receiving opening, wherein the top collar comprises one or more through slots; and

a reflector comprising a collar and one or more tabs extending downwards and substantially perpendicular to the collar of the reflector from an outer edge of the collar,

wherein the reflector is coupled to the trim by inserting each tab of the one or more tabs of the reflector through a respective through slot of the one or more through slots on the top collar of the trim such that the lens is securely retained between the reflector and the trim.

16. The light fixture of claim 15, wherein the module assembly further comprises a plurality of connector receptacles that is disposed between the enclosure and the wire cover member, and wherein the plurality of connector receptacles provide a connection point for a connector from an external power source to supply drive current to the light source.

17. The light fixture of claim 15, wherein the enclosure comprises a plurality of heat sink fins, and wherein the enclosure operates as a heat sink to dissipate heat generated by the light source.

18. The light fixture of claim 15, wherein the enclosure of the light module is configured to be removably coupled to an additional heat sink.

19. The light fixture of claim 15, wherein the lens comprises a substantially dome shaped surface and a collar that extends radially outward from an edge of the dome shaped surface.

20. The light fixture of claim 19, wherein the reflector is coupled to the trim such that:

(a) the collar of the lens is disposed in between the collar of the reflector and the top collar of the trim, and (b) the substantially dome shaped surface of the lens is disposed below the reflector and received through the lens receiving opening of the trim.