Adjustment assembly for a lighting device

• US 10,274,148 B2
• Filed: 12/19/2016
• Issued: 04/30/2019
• Est. Priority Date: 04/22/2016
• Status: Active Grant

• Current Assignee: Intense Lighting, LLC (Leviton Manufacturing Company Incorporated)
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: Eidsvold, Kevin Brian, Spremo, Aida, Spicer, Jonathan
• Primary Examiner(s): Gyllstrom, Bryon T
• Application Number:
  US15/383,464
• Publication Number:
  US 20170307189A1
• Time in Patent Office: 862 Days
• Field of Search: 362235
• CPC Class Codes: F21K 9/20 Light sources comprising attachment means
• 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 21/048 Mounting arrangements for fastening lighting devices to false ceiling frameworks
• CPC Class Codes: F21V 21/14 Adjustable mountings
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A lighting fixture having an adjustable collar for accommodating different ceiling thicknesses is provided. The lighting fixture preferably includes a light module, a plaster frame, first and second support arms extending from the plaster frame, a U-shaped support assembly, an adjustment assembly for coupling the support assembly to the first and second support arms, and the collar. The adjustment assembly enabling the support assembly and the adjustable collar to be selectively movable along an axis perpendicular to the plaster frame. The adjustment assembly being configured so that, in a first configuration, the support assembly along with the light module and the collar are movable along the axis, and in a second configuration, the support assembly along with the light module and the collar are fixed to the first and second support arms so that a bottom end of the collar extends beyond a bottom surface of the plaster frame.

Claims

1. A lighting device, comprising:

an adjustable collar for accommodating different ceiling thicknesses;

a plaster frame having an opening for receiving the adjustable collar;

at least one support arm coupled to the plaster frame adjacent the opening;

a support assembly; and

an adjustment assembly for coupling the at least one support arm to the support assembly to enable the support assembly and the adjustable collar to be selectively movable;

wherein the adjustment assembly has a first configuration in which the adjustable collar is movable, and a second configuration in which the support assembly and the adjustable collar are fixed to the at least one support arm so that a bottom end of the adjustable collar extends beyond a bottom surface of the plaster frame.

2. The lighting device of claim 1, wherein the at least one support arm includes first and second support arms coupled to the plaster frame adjacent the opening, the first and second support arms extending from the plaster frame.

3. The lighting device of claim 2, wherein, in the first configuration, the adjustable collar is vertically movable towards and away from the plaster frame.

4. The lighting device of claim 2, wherein the support assembly includes first and second side portions and a top portion, the first and second side portions being coupled to the adjustable collar, the first and second side portions are positionable adjacent the first and second support arms, respectively, so that the adjustment assembly couples the first and second support arms to the first and second side portions of the support assembly.

5. The lighting device of claim 4, wherein the first and second support arms are coupled at respective first ends to the plaster frame adjacent the opening, and the first and second side portions of the support assembly are coupled at respective first ends to the adjustable collar.

6. The lighting device of claim 2, wherein the support assembly includes first and second side portions and a top portion so that the support assembly forms a generally U-shape support assembly.

7. The lighting device of claim 6, wherein, in the second configuration, the U-shaped support assembly and the adjustable collar are fixed to the first and second support arms so that a bottom end of the adjustable collar extends beyond a bottom surface of the plaster frame by a predetermined distance.

8. The lighting device of claim 6, wherein the U-shaped support assembly is fixed to the adjustable collar so that the U-shaped support assembly and the adjustable collar are movable together along an axis with respect to the plaster frame.

9. The lighting device of claim 6, wherein the adjustment assembly comprises an adjustment plate and a locking knob positioned on opposite sides of the first support arm and first side portion, wherein in the first configuration the locking knob and adjustment plate are positioned with respect to each other to enable movement of the first side portion with respect to the first support arm along the axis, and wherein in the second configuration the locking knob clamps the first support arm and the first side portion between the locking knob and the adjustment plate to lock the first support arm to the first side portion, thus preventing relative motion therebetween along the axis.

10. The lighting device of claim 9, further comprising a guide link for guiding movement of the U-shaped support assembly with respect to the plaster frame, wherein the guide link is coupled to the first side portion and is disposed through a guide slot in the first support arm, wherein the guide link is further disposed through an opening in the adjustment plate, and wherein the guide slot is oriented parallel to the axis such that the guide link is movable within the guide slot along the axis.

11. The lighting device of claim 10, wherein a first end of the guide link is axially fixed to the first side portion and is movable within the guide slot in the first support arm;

and wherein a spring is disposed between the adjustment plate and a second end of the guide link to provide tension on the guide link, thereby clamping the adjustment plate to the first support arm and the first side portion with a force sufficient to prevent free movement of the U-shaped support assembly and the adjustable collar under a weight of the U-shaped support assembly and a removable light module attached thereto.

12. The lighting device of claim 10, further comprising a ball plunger coupled to the adjustment plate, the ball plunger comprising a ball element that is biased toward the first support arm, wherein the first support arm comprises a plurality of recesses, the plurality of recesses or holes positioned in a linear array oriented parallel to the axis, each of the plurality of recesses sized and shaped to receive at least a portion of the ball plunger to allow the adjustment plate to be fixed at a plurality of discrete positions with respect to the first support arm.

13. The lighting device of claim 12, wherein the ball plunger comprises a plurality of ball plungers coupled to the adjustment plate on opposing lateral sides of the guide link, and wherein the plurality of recesses or holes comprise a plurality of groups of recesses or holes, each group of recesses or holes is positioned on the first support arm to engage a respective one of said plurality of ball plungers.

14. The lighting device of claim 10, further comprising an additional guide slot in the first support arm and an additional guide link coupled to the adjustment plate, wherein the additional guide slot is positioned at an offset distance from the guide slot, wherein the additional guide slot is oriented parallel to the guide slot, and wherein when the U-shaped support assembly moves with respect to the plaster frame, the additional guide link is movable within the additional guide slot, and wherein the additional guide slot and additional guide link prevent rotation or pivoting of the adjustment plate with respect to the first support arm and the first side portion.

15. The lighting device of claim 9, wherein the adjustment plate has a height indicator and the first support arm includes a plurality of extension indicators arrayed parallel to the axis, wherein each of the plurality of extension indicators signifies a different predetermined distance between the bottom end of the adjustable collar and the bottom surface of the plaster frame, wherein when the U-shaped support assembly is moved with respect to the plaster frame so that the height indicator aligns with a selected one of the plurality of extension indicators, the adjustable collar portion extends beyond a bottom surface of the plaster frame by the predetermined distance associated with the selected one of the plurality of extension indicators.

16. The lighting device of claim 9, wherein the adjustment assembly comprises first and second adjustment plates and first and second locking knobs associated, respectively, with the first support arm and the first side portion, and the second support arm and the second side portion, and wherein in the first configuration the first and second locking knobs and the first and second adjustment plates enable movement of the first side portion with respect to the first support arm, and the second side portion with respect to the second support arm, along the axis, and wherein in the second configuration the first and second locking knobs preventing relative motion between the first side portion with respect to the first support arm, and the second side portion with respect to the second support arm along the axis.

17. The lighting device of claim 6, wherein the top portion includes surface features configured to couple the adjustment assembly to a removable light module such that the removable light module is movable along the axis simultaneously with the U-shaped support assembly and the adjustable collar, wherein the removable light module includes a heat sink, a plurality of LEDs and an optic.

18. A method for adjusting a lighting device for accommodating different ceiling thicknesses, comprising:

installing a lighting device in or on a ceiling structure, the lighting device including an adjustable collar, a plaster frame and a light module having a lighting element;

positioning a portion of the adjustable collar of the lighting device through a first opening in the ceiling structure and a second opening in the plaster frame; and

adjusting the position of the adjustable collar with respect to the plaster frame and the ceiling structure so that a distal end surface of the adjustable collar is positioned adjacent to a distal portion of the second opening in the ceiling structure;

wherein, during the adjusting step, a front surface of the LED remains a fixed distance from the distal end surface of the adjustable collar.

19. The method of claim 18, wherein positioning a portion of the adjustable collar of the lighting device through a first opening in the ceiling structure comprises adjusting a position of a U-shaped support assembly with respect to the plaster frame, and wherein the U-shaped support assembly is fixedly coupled to the light module and the adjustable collar.

20. The method of claim 18, further comprising, after the adjusting step, securing the position of the adjustable collar with respect to the first opening in the ceiling structure and the second opening in the plaster frame.

21. The method of claim 20, wherein the securing step comprises turning a locking knob to draw first and second support arms coupled to the plaster frame into engagement with first and second side portions of a U-shaped support assembly such that friction between the first and second support arms and the first and second side portions, respectively, prevents movement of the U-shaped support assembly and the adjustable collar with respect to the plaster frame.

22. The method of claim 21, wherein the locking knob is accessible to a user from below the ceiling structure via a central opening in the adjustable collar.

23. The method of claim 18, further comprising provisionally retaining the adjustable collar and the light module in position with respect to the plaster frame and the ceiling structure via a plunger engaged with a U-shaped support assembly and first and second support arms, wherein the first and second support arms are coupled to the plaster frame, the light module is coupled to the U-shaped support assembly, and the U-shaped support assembly is moveably coupled to the first and second support arms.

24. The method of claim 18, further comprising, after the step of installing a lighting device in or on a ceiling structure, provisionally adjusting a position of the adjustable collar and the light module by aligning a height indicator of an adjustment plate with one of a plurality of extension indicators arrayed on a first support arm coupled to the plaster frame.

25. The method of claim 24, wherein each of the plurality of extension indicators signifies a different predetermined distance between the distal end surface of the adjustable collar and the bottom surface of the plaster frame.

26. An adjustment assembly for a lighting device, comprising:

an adjustable collar for accommodating different ceiling thicknesses;

a plaster frame having an opening for receiving the adjustable collar;

first and second support arms coupled to the plaster frame;

a support assembly having first and second side portions and a top portion, the first and second side portions coupled to the adjustable collar;

an adjustment assembly coupled between at least one of (i) the first support arm and the first side portion and (ii) the second support arms and the second side portion to enable the support assembly and the adjustable collar to be selectively movable along an axis perpendicular to the plaster frame; and

an adjustment plate and a locking knob positioned on opposite sides of the first support arm and the first side portion;

wherein the adjustment assembly has a first configuration in which the adjustable collar portion is movable along the axis, and a second configuration in which the support assembly and the adjustable collar are fixed to the first and second support arms so that a bottom end of the adjustable collar extends beyond a bottom surface of the plaster frame; and

wherein in the first configuration the locking knob and adjustment plate are positioned with respect to each other to enable movement of the first side portion with respect to the first support arm along the axis, and wherein in the second configuration the locking knob clamps the first support arm and the first side portion between the locking knob and the adjustment plate to lock the first support arm to the first side portion, thus preventing relative motion therebetween along the axis.