Junction box for LED drivers

• US 9,951,934 B2
• Filed: 03/09/2017
• Issued: 04/24/2018
• 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
• Primary Examiner(s): CASTELLANO, STEPHEN J
• Application Number:
  US15/454,476
• Publication Number:
  US 20170268758A1
• Time in Patent Office: 411 Days
• Field of Search: 220507, 220501, 220529, 220 402, 220503, 220505
• 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 a driver to be placed in a junction box without having to pull wires through holes or openings. Typically, the base is open along the top and along at least a portion of one sidewall, with the cover being L- or U-shaped to complete the enclosure. Various mounting mechanisms are disclosed for securing drivers within junction boxes. Embodiments that can house several drivers or components within one junction box are disclosed, as are weather- and water-resistant embodiments.

Claims

1. A junction box, comprising:

a horizontal base having

an open central portion open at two opposed sides, and

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

three vertical outer sidewalls, each of the three 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 four-walled compartment from the open central portion of the base, the vertical inner sidewall having a cut-out that begins at a top edge of the vertical inner sidewall and extends downwardly;

mounting structure secured, or adapted to be secured, to the open central portion of the base to mount a driver; and

a U-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

two depending side portions, the two depending side portions being sized and adapted to create a contiguous sidewall between the two four-walled compartments, 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 mounting structure comprises a pair of threaded rods spaced from one another and a bracket adapted to be placed and secured on the threaded rods.

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

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

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

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

8. The junction box of claim 1, wherein the horizontal base and the U-shaped cover are made of sheet metal.

9. The junction box of claim 1, wherein the frangible portions are round.

10. The junction box of claim 1, wherein the mounting structure 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.

11. The junction box of claim 1, wherein the vertical inner sidewalls of the four-walled compartments are removable.