Troffer light fixture retrofit systems and methods

• US 9,488,348 B2
• Filed: 09/25/2015
• Issued: 11/08/2016
• Est. Priority Date: 09/26/2014
• Status: Active Grant

• Current Assignee: Orion Energy Systems, Inc.
• Original Assignee: Orion Energy Systems, Inc.
• Inventors: Scribante, John, Bluma, Joe, Green, Scott A., Tlachac, Matthew S., Stegemann, Paul
• Primary Examiner(s): DZIERZYNSKI, EVAN P
• Application Number:
  US14/866,573
• Publication Number:
  US 20160091181A1
• Time in Patent Office: 410 Days
• US Class Current: 1/1
• CPC Class Codes: F21S 8/026 intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling
• CPC Class Codes: F21S 8/04 intended only for mounting on a ceiling or the like overhead structures F21S8/02 takes precedence; details of ceiling bases F21V21/03
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 15/01 Housings, e.g. material or assembling of housing parts F21V15/02 takes precedence housings forming signs or letters G09F13/04
• CPC Class Codes: F21V 21/02 Wall, ceiling, or floor bases; Fixing pendants or arms to the bases F21V21/08 takes precedence; bases for movable standing lamps F21V21/06
• CPC Class Codes: F21V 21/04 Recessed bases
• 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 23/02 the elements being transformers, impedances or power supply units, e.g. a transformer with a rectifier
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 7/005 with an elongated shape to cooperate with linear light sources
• CPC Class Codes: F21Y 2101/00 Point-like light sources
• CPC Class Codes: F21Y 2103/00 Elongate light sources, e.g. fluorescent tubes
• CPC Class Codes: F21Y 2113/00 Combination of light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A retrofitting kit for retrofitting an existing troffer light fixture having a troffer housing includes a door assembly and a retainer. The door assembly includes a housing and a light source within the housing. The retainer is fixed to the housing of the door assembly and configured to engage at least one of the troffer housing and a T-bar of a ceiling system to thereby selectively secure the door assembly within the ceiling system. The retainer is positioned such that the engagement between the retainer and the at least one of the troffer housing and the T-bar of the ceiling system is direct.

Claims

1. A retrofitting kit for retrofitting an existing troffer light fixture having a troffer housing, comprising:

a door assembly including;

a housing including a flange and a pair of sidewalls, the pair of sidewalls disposed on opposing sides of a centerline of the door assembly, wherein the flange extends laterally outward from at least one of the pair of sidewalls; and

a light source within the housing; and

a retainer comprising the flange fixed to the housing of the door assembly and configured to engage at least one of the troffer housing and a T-bar of a ceiling system to thereby selectively secure the door assembly within the ceiling system, wherein the retainer is positioned such that the engagement between the retainer and the at least one of the troffer housing and the T-bar of the ceiling system is direct,

wherein the flange extends downward and away from the at least one of the pair of sidewalls, wherein the door assembly at an upper edge of the flange is narrower than an opening of the ceiling system, and wherein the door assembly at a lower edge of the flange is wider than the opening of the ceiling system such that the flange comprises at least a portion of a spring lock configured to deform as the door assembly is inserted into the ceiling system and spring outward once the door assembly is in place,

wherein a maximum width of the housing of the door assembly, including the flange, is greater than a width of the opening of the ceiling system such that engagement between the T-bar of the ceiling system and the retainer at least partially holds the door assembly in place.

2. The retrofitting kit of claim 1, wherein the housing of the door assembly includes a pair of side frames disposed on opposing sides of a centerline of the door assembly and coupled to a pair of angled sidewalls, wherein the pair of angled sidewalls extend inward from the pair of side frames toward the centerline of the door assembly, and wherein at least a portion of the retainer is fixed to at least one of the pair of angled sidewalls.

3. The retrofitting kit of claim 2, wherein the retainer comprises a pressure fit system including at least one of (a) biting teeth coupled to the at least one of the pair of angled sidewalls and (b) a friction plate coupled to the at least one of the pair of angled sidewalls with a resilient member, the resilient member positioned to bias the friction plate outward, away from the at least one of the pair of angled sidewalls, wherein the friction plate is configured to engage a surface of the troffer housing to retain and hold the door assembly in the ceiling system.

4. The retrofitting kit of claim 1, wherein the housing of the door assembly includes a top portion and a lens, the top portion extending generally parallel to the lens, wherein at least a portion of the retainer is fixed to the top portion.

5. The retrofitting kit of claim 4, wherein the retainer comprises at least one of (a) biting teeth and (b) a screw system, the screw system including a threaded portion configured to engage the troffer housing, a protrusion coupled to the threaded portion, and a receiver coupled to the housing of the door assembly and configured to selectively engage the protrusion to retain and hold the door assembly in place.

6. The retrofitting kit of claim 1, wherein the retainer comprises at least one of a magnet and an adhesive applied to the flange of the door assembly and positioned to engage a face of the T-bar.

7. A retrofitting kit for retrofitting an existing troffer light fixture having a troffer housing, comprising:

a door assembly including;

a housing including a flange and a pair of sidewalls, the pair of sidewalls disposed on opposing sides of a centerline of the door assembly, wherein the flange extends laterally outward from at least one of the pair of sidewalls; and

a light source within the housing; and

a retainer fixed to the housing of the door assembly and configured to engage at least one of the troffer housing and a T-bar of a ceiling system to thereby selectively secure the door assembly within the ceiling system, wherein the retainer is positioned such that the engagement between the retainer and the at least one of the troffer housing and the T-bar of the ceiling system is direct, wherein the retainer comprises a clasp slidably coupled to the flange and selectively repositionable between an extended position and a retracted position, wherein the clasp is configured to at least one of receive and engage the T-bar of the ceiling system when in the extended position,

wherein a maximum width of the housing of the door assembly, including the flange, is greater than a width of an opening of the ceiling system such that engagement between a T-bar of the ceiling system and the retainer at least partially holds the door assembly in place.

8. A light fixture, comprising:

a troffer housing;

a door assembly including;

a housing including a flange and a pair of sidewalls, the pair of sidewalls disposed on opposing sides of a centerline of the door assembly, wherein the flange extends laterally outward from at least one of the pair of sidewalls; and

a light source within the housing; and

a retainer comprising the flange fixed to the housing of the door assembly and configured to engage at least one of the troffer housing and a T-bar of a ceiling system to thereby selectively secure the door assembly within the ceiling system, wherein the retainer is positioned such that the engagement between the retainer and the at least one of the troffer housing and the T-bar of the ceiling system is direct,

wherein the flange extends downward and away from the at least one of the pair of sidewalls, wherein the door assembly at an upper edge of the flange is narrower than an opening of the ceiling system, and wherein the door assembly at a lower edge of the flange is wider than the opening of the ceiling system such that the flange comprises at least a portion of a spring lock configured to deform as the door assembly is inserted into the ceiling system and spring outward once the door assembly is in place,

wherein a maximum width of the housing of the door assembly, including the flange, is greater than a width of the opening of the ceiling system such that engagement between the T-bar of the ceiling system and the retainer at least partially holds the door assembly in place.

9. The light fixture of claim 8, wherein the housing of the door assembly includes a pair of side frames disposed on opposing sides of a centerline of the door assembly and coupled to a pair of angled sidewalls, wherein the pair of angled sidewalls extend inward from the pair of side frames toward the centerline of the door assembly, and wherein at least a portion of the retainer is fixed to at least one of the pair of angled sidewalls.

10. The light fixture of claim 9, wherein the retainer comprises a pressure fit system including at least one of (a) biting teeth coupled to the at least one of the pair of angled sidewalls and (b) a friction plate coupled to the at least one of the pair of angled sidewalls with a resilient member, the resilient member positioned to bias the friction plate outward, away from the at least one of the pair of angled sidewalls, wherein the friction plate is configured to engage a surface of the troffer housing to retain and hold the door assembly in the ceiling system.

11. The light fixture of claim 8, wherein the housing of the door assembly includes a top portion and a lens, the top portion extending generally parallel to the lens, wherein at least a portion of the retainer is fixed to the top portion.

12. The light fixture of claim 11, wherein the retainer comprises at least one of (a) biting teeth and (b) a screw system, the screw system including a threaded portion configured to engage the troffer housing, a protrusion coupled to the threaded portion, and a receiver coupled to the housing of the door assembly and configured to selectively engage the protrusion to retain and hold the door assembly in place.

13. The light fixture of claim 8, wherein the retainer comprises at least one of a magnet and an adhesive applied to the flange of the door assembly and positioned to engage a face of the T-bar.

14. A light fixture, comprising:

a door assembly including;

a housing including a flange and a pair of sidewalls, the pair of sidewalls disposed on opposing sides of a centerline of the door assembly, wherein the flange extends laterally outward from at least one of the pair of sidewalls; and

a light source within the housing; and

a retainer fixed to the housing of the door assembly and configured to engage at least one of the troffer housing and a T-bar of a ceiling system to thereby selectively secure the door assembly within the ceiling system, wherein the retainer is positioned such that the engagement between the retainer and the at least one of the troffer housing and the T-bar of the ceiling system is direct, wherein the retainer comprises a clasp slidably coupled to the flange and selectively repositionable between an extended position and a retracted position, wherein the clasp is configured to at least one of receive and engage the T-bar of the ceiling system when in the extended position,

wherein a maximum width of the housing of the door assembly, including the retainer, is greater than a width of an opening of the ceiling system such that engagement between a T-bar of the ceiling system and the retainer at least partially holds the door assembly in place.