Abstract:
Apparatuses and methods for adapting unfinished lighting fixture rough-ins to receive a lighting module, such as an incandescent light bulb or a light-emitting diode (LED) lighting device, are disclosed. According to one aspect, a universal adapter is provided that can be inserted into an existing lighting fixture rough-in, secured in place, and electrically connected to the lighting fixture rough-in. In this way, the adapter stands in place of the finishing section typically used in current lighting fixture designs. As a result, the adapter can modify an unfinished lighting fixture so that it can be used with a variety of lighting elements beyond those designed to be used with the specific configuration of the lighting fixture rough-in.

Description:
RELATED APPLICATIONS 
       [0001]    The presently disclosed subject matter claims the benefit of U.S. Provisional Patent Application Ser. No. 61/127,923, filed May 16, 2008; the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The subject matter described herein relates to lighting fixtures. More particularly, the subject matter described herein relates to recessed lighting fixtures for mounting within a wall or ceiling. 
       BACKGROUND 
       [0003]    A recessed light or downlight is a lighting fixture that is installed into a hollow opening in a ceiling or wall. A large percentage of residential recessed lighting fixtures include a metal cylinder (“can”) mounted into the ceiling using horizontal metal struts attached to the ceiling framework. A light bulb socket is mounted within the cylinder, into which a light bulb can be inserted. The light bulb is commonly a 60 W incandescent light bulb or a 15 W compact fluorescent bulb. This arrangement provides structural support and the electrical connection for the light bulb installed. Further, the cylinder can be substantially airtight around the sides and top to prevent the loss of ambient heat or cooling from the room into the ceiling cavity through the fixture, and the cylinder can shield the light bulb from any insulation placed around the can within the ceiling cavity to help prevent the light bulb from starting a fire. 
         [0004]    An insert can be installed into the can to provide a better fit for the light bulb, to reflect at least some of the light directed into the fixture, or to simply improve the aesthetic appearance of the lighting fixture. This insert is often referred to as a trim portion. By modifying the basic arrangement in this way, a single fixture can be adapted for use with a wide variety of shapes and styles of lighting elements. The ability to modify the fixture is not limited to using different trim portions to accommodate different incandescent light bulbs, though. For instance, U.S. Patent Application Pub. No. 2007/0279903 to Negley et al. discloses a lighting device containing a group of solid state light emitters (e.g., light-emitting diodes) that can be used in the kind of standard residential recessed lighting fixture discussed above. 
         [0005]    Unfortunately, the generally standardized and easily modified design of residential recessed lights is not carried over to the commercial lighting market. Because many commercial applications involve lighting being recessed in drop ceilings, there is generally no contact with insulation and thus there is not necessarily a need for a cylindrical can to be included in the fixture. Rather, a lighting fixture rough-in can be installed. As will be understood by those having skill in the art, a lighting fixture rough-in is a base structural component that can be mounted between ceiling joists or other structural members of a commercial drop ceiling and that serves as a frame to provide support for the components of the lighting fixture. For example, a lighting fixture rough-in of this kind can often simply include a frame, often referred to as a “pan”, mounted into the ceiling using horizontal metal struts attached to the ceiling framework. An example of a typical lighting fixture rough-in of this kind is shown in  FIG. 1 . The lighting fixture rough-in  10  can include a frame  12  defining an aperture  14  in which the lighting element will reside. Lighting fixture rough-in  10  also generally includes an electrical junction box  20  for connecting the fixture to the building power supply. Further, a junction head  22  having a junction socket  24  can be connected to the junction box  20 . Of course, rough-in  10  can provide support for a variety of other components, including for example wiring, additional ballast, or thermal protection. 
         [0006]    As is shown in  FIG. 2 , a finishing section  16  can then be positioned within aperture  14  and secured to frame  12  to complete the lighting fixture. The use of finishing section  16  is analogous to the use of a trim section in residential fixtures, and thus finishing section  16  can be specifically shaped to match the shape of the lighting element to be installed and to provide desirable reflective properties of the finished lighting fixture. To install finishing section  16 , junction socket  24  is generally clipped directly to finishing section  16  using mounting clips  26 . Oftentimes, one or both of the connections between finishing section  16  and frame  12  and that between finishing section  16  and junction socket  24  are specifically designed so that other finishing sections cannot be readily substituted. As a result, a user desiring to install a different kind of lighting element can be forced to replace lighting fixture rough-in  10  in its entirety rather than simply changing out finishing section  16 . 
         [0007]    Thus, whereas residential fixtures can generally be easily adapted for use with a wide variety of light bulbs or other lighting elements, the options for the kinds of lighting elements that can be used with these can-less commercial fixtures are often limited by the specific configuration of the lighting fixture rough-in. 
       SUMMARY 
       [0008]    According to the present disclosure, novel assemblies for use in lighting fixtures are provided for adapting unfinished lighting fixture rough-ins to receive a lighting element, such as an incandescent light bulb or a light-emitting diode (LED) lighting device. 
         [0009]    In one aspect, the present disclosure provides a universal adapter for connecting an LED lighting module to a commercial lighting fixture rough-in. The universal adapter can include an adapter body positioned within a lighting fixture rough-in for receiving an LED lighting module. In addition, the present disclosure also provides a method for adapting a lighting fixture rough-in for use with an LED lighting module. The method can include providing a universal adapter having an adapter body, positioning the adapter body within the lighting fixture rough-in, inserting an LED lighting module into the adapter body, and connecting the LED lighting module to a power source. 
         [0010]    In another aspect, the present disclosure provides a universal adapter for connecting a lighting element to a commercial lighting fixture rough-in. The universal adapter can include an adapter body positioned within a lighting fixture rough-in, an adapter socket positioned in the adapter body, and an electrical connector operatively connected to the adapter socket. The adapter body can be adapted for receiving a lighting element, the adapter socket can serve to secure the lighting element within the adapter body, and the electrical connector can serve to electrically connect the adapter socket to a power source. 
         [0011]    Further, the present disclosure also provides a method for adapting a lighting fixture rough-in for use with a lighting element. This method can involve providing a universal adapter having an adapter body, an adapter socket positioned in the adapter body, and an electrical connector operatively connected to the adapter socket. The method can further involve positioning the adapter body within the lighting fixture rough-in and connecting a lighting element to the adapter socket. 
         [0012]    The present invention may be more fully understood with reference to the accompanying drawings and the following detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    Preferred embodiments of the subject matter described herein will now be explained with reference to the accompanying drawings of which: 
           [0014]      FIG. 1  is a perspective side view of a lighting fixture rough-in that is typical of those found in the commercial lighting market; 
           [0015]      FIG. 2  is a perspective side view of a typical lighting fixture including a finishing section; 
           [0016]      FIG. 3  is an exploded perspective view of a universal adapter for connecting a lighting element to a lighting fixture rough-in according to an embodiment of the subject matter disclosed herein; 
           [0017]      FIG. 4  is a perspective view of a universal adapter for connecting a lighting element to a lighting fixture rough-in according to the subject matter disclosed herein; 
           [0018]      FIG. 5  is a vertical cross-sectional view of a universal adapter mounted in a lighting fixture rough-in according to the subject matter disclosed herein; 
           [0019]      FIGS. 6   a - 6   f  illustrate steps in the installation of a universal adapter to a lighting fixture rough-in according to the subject matter disclosed herein; and 
           [0020]      FIG. 7  is a perspective view of a clamshell-type enclosure structure for use with the universal adapter according to the subject matter disclosed herein. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    Lighting fixtures are described herein with reference to  FIGS. 1-7 . As illustrated in  FIGS. 1-7 , some sizes of structures or portions may be exaggerated relative to other structures or portions for illustrative purposes and, thus, are provided to illustrate the general structures of the subject matter disclosed herein. Further, various aspects of the subject matter disclosed herein are described with reference to a structure or a portion being formed on other structures, portions, or both. As will be appreciated by those of skill in the art, references to a structure being formed “on” or “above” another structure or portions contemplates that additional structure, portion, or both may intervene. References to a structure or a portion being formed “on” another structure or portion without an intervening structure or portion are described herein as being formed “directly on” the structure or portion. 
         [0022]    Furthermore, relative terms such as “on” or “above” are used herein to describe one structure&#39;s or portion&#39;s relationship to another structure or portion as illustrated in the Figures. It will be understood that relative terms such as “on” or “above” are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in the Figures is turned over, structure or portion described as “above” other structures or portions would now be oriented “below” the other structures or portions. Likewise, if the device in the Figures is rotated along an axis, structure or portion described as “above” other structures or portions would now be oriented “next to” or “left of” the other structures or portions. Like numbers refer to like elements throughout. 
         [0023]    According to one aspect of the subject matter disclosed herein, a universal adapter is provided for connecting a lighting element to a lighting fixture rough-in, such as a typical lighting fixture rough-in described above. Referring to  FIGS. 3-5 , a universal adapter  30  for this function can include an adapter body  32 . When coupled to a lighting fixture rough-in  10 , adapter body  32  can be positioned within an aperture  14  in the frame  12  of lighting fixture rough-in  10 . In addition, universal adapter  30  can also include an adapter socket  40  connected to adapter body  32 , and an electrical connector  42  serving to electrically connect adapter socket  40  to a power source. Electrical connector  42  can be coupled to a junction socket  24  in a junction head  22  connected to an electrical junction box  20  on lighting fixture rough-in  10 . In this way, universal adapter  30  stands in place of the finishing section  16  used in current lighting fixture designs (see  FIG. 2 ), and in doing so can adapt a single lighting fixture for use with a larger variety of lighting elements  60 . 
         [0024]    Adapter body  32  can include at least a first end and a second end and can be configured to be used with a lighting element  60  by being open at one end for receiving lighting element  60 . For instance, adapter body  32  can have a substantially cylindrical shape similar to the shape of the cylindrical can formed in many residential lighting fixtures. Adapter socket  40  can be secured to one end of the cylindrical adapter body  32 , and the opposite end of the cylindrical adapter body  32  can be an open end  33  for receiving lighting element  60 . Therefore, adapter body  32  can be used to modify a commercial lighting fixture rough-in  10  to emulate the universal can of residential downlight fixtures. As such, a wide variety of light bulbs can be used in the adapted lighting fixture, even those for which a corresponding finishing section  16  designed to fit in aperture  14  does not exist. Specifically, an LED lighting device adapted for use with standard residential downlight fixtures can be received in adapter body  32  to be used in lighting fixture rough-in  10 . 
         [0025]    One example of such an LED device is the LR6 downlight retrofit element sold by Cree LED Lighting Solutions, Inc., a subsidiary of Cree, Inc. of Durham, N.C. The LR6 is designed to be easily installed in standard 6-inch recessed lighting fixtures through the use of locking clips that are movable to engage the interior sidewalls of the cylindrical can of a standard lighting fixture. The use of universal adapter  30  thus provides a similar structure to typical residential lighting fixtures, enabling the locking clip design of the LR6 to be used with lighting fixture rough-ins  10  that do not have a can. 
         [0026]    As noted above, adapter body  32  can further be configured to be positioned within aperture  14  in frame  12 . In particular, adapter body  32  can be sized so that the end connected to adapter socket  40  and electrical connector  42  is no larger than aperture  14 . That being said, it should be noted that adapter body  32  need not fit perfectly through aperture  14 , and it can be desirable for adapter body  32  to be sized to easily pass through aperture  14  with a reasonable amount of clearance. In this way, the use of universal adapter  30  is not limited to a lighting fixture rough-in  10  having a particular size aperture  14 . 
         [0027]    When properly sized, adapter body  32  can be inserted into aperture  14  to be coupled with frame  12 . To ensure that adapter body  32  cannot be inserted completely through aperture  14 , adapter body  32  can include a flange  34  extending outwardly that cannot pass through aperture  14 . For example, flange  34  can be positioned at or near the open end  33  of adapter body  32 . When the lighting fixture rough-in  10  is installed above a ceiling, flange  34  supports adapter body  32  in place with respect to the ceiling, with open end  33  of adapter body  32  lying substantially flush with the surface of the ceiling C. Such an arrangement is desirable because it can make the finished lighting fixture as unobtrusive as possible. 
         [0028]    To couple adapter body  32  to frame  12  of lighting fixture rough-in  10  and thereby prevent universal adapter  30  from being easily dislodged from its position within aperture  14 , one or more retainers  36  can be provided on adapter body  32  (see  FIG. 3 ). Retainers  36  can include a plurality of clips positioned about adapter body  32 , with a gripping portion  38  extending away from adapter body  32  to engage frame  12 . For example, as is shown in  FIG. 3 , retainers  36  can be releasably fastened to the interior surface of adapter body  32  by fasteners  39  (e.g., bolt and wing nut fastener), with gripping portion  38  passing through adapter body  32  and engaging fame  12  about the periphery of aperture  14 . Gripping portion  38  can be sized so that, when retainers  36  are securely fastened to adapter body  32 , adapter body  32  can not be pulled through aperture  14 . 
         [0029]    Retainers  36  can be moveable with respect to adapter body  32  to adjust the position of adapter body  32  with respect to frame  12 . Stated otherwise, retainers  36  can be releasably engaged with adapter body  32  and capable of sliding along the length of adapter body  32  relative to open end  33  along adapter slots S within adapter body  32 . In this way, the distance between flange  34  and gripping portion  38  is adjustable so that universal adapter  30  can be coupled to lighting fixture rough-in  10  regardless of the thickness of ceiling C. The combination of flange  34  and retainers  36  effectively clamp about the combined thickness of frame  12  and ceiling C to hold adapter body  32  in place. For instance, retainers  36  can be adjusted so that adapter body  32  extends only far enough from frame  12  to accommodate a  3 / 8  inch plyboard ceiling between frame  12  and flange  34 . Alternatively, retainers  36  can be adjusted away from flange  34  such that a thicker ceiling can be accommodated, such as a ¾ inch plaster ceiling or even a ceiling as thick as 2 inches or more. 
         [0030]    With universal adapter  30  securely mounted within frame  12 , a trim portion can be provided just as is generally done in residential lighting fixtures. As noted above, the inclusion of a trim portion can help provide a better fit for lighting element  60 , it can reflect at least some of the light directed into the fixture, and it can improve the aesthetic appearance of the lighting fixture. Alternatively, lighting element  60  can include elements serving the purpose of a trim portion. Namely, lighting element  60  can be sized to readily fit into adapter body  32 , and visible features can be designed to be visually pleasing. Further still, adapter body  32  itself can be designed to be aesthetically pleasing so that no trim portion is needed. 
         [0031]    Adapter socket  40  can be configured to receive lighting element  60 , thereby securing lighting element  60  to lighting fixture rough-in  10 . In this regard, adapter socket  40  can be of the widely used screw-in (“Edison”) type socket. Alternatively, adapter socket  40  can be a GU-24 type socket, which is designed to work with line voltage sockets used for energy-efficient compact fluorescent bulbs. 
         [0032]    Of course, adapter socket  40  not only provides physical support for lighting element  60 , but also provides an electrical connection for lighting element  60 . In this regard, electrical connector  42  serves to electrically connect adapter socket  40  to electrical junction box  20  of lighting fixture rough-in  10 . Specifically, electrical connector  42  can be a screw-in type plug where junction head  22  includes an Edison-type junction socket  24 . In this arrangement, instead of a light bulb being directly connected to electrical junction box  20  through junction socket  24 , electrical connector  42  is used to bridge the electrical connection from electrical junction box  20  to adapter socket  40 . 
         [0033]    To account for varying configurations of junction socket  24  and junction head  22  extending from electrical junction box  20 , electrical connector  42  can include an electrical conduit  48  connecting adapter socket  40  to electrical connector  42 . The inclusion of electrical conduit  48  provides flexibility in connecting and securing universal adapter  30  in place. In addition, the connection of electrical connector  42  to adapter socket  40  can be an angled fitting  50  (e.g., 90° fitting) to place the attachment in the center of the end of adapter body  32 . In addition, this kind of fitting  50  provides a low-profile connection to adapter body  32 , which can address space issues caused by the size and shape of adapter body  32  being different than finishing section  16  designed for use with lighting fixture rough-in  10 . 
         [0034]    Because junction head  22  is often designed to be coupled directly with finishing section  16  (see  FIG. 2 ), electrical connector  42  can additionally be configured to duplicate the kind of connection used in the typical fixture design. Namely, many junction heads  22  have mounting clips  26  designed to engage corresponding notches in a finishing section  16 , so electrical connector  42  can similarly include notches  44  designed to connect with mounting clips  26  to make a seamless fit between junction head  22  and electrical connector  42 . Further, electrical connector  42  can include an enclosure structure  46  to surround the connection of electrical connector  42  to junction head  22  and thus ensure that there is no exposed electrical connection. In addition, as illustrated in  FIG. 6a , an enclosure box  56  can be provided to connect electrical connector  42  to non-standard electrical junctions (e.g., Lithonia Lighting P/N LP6J6). 
         [0035]    Enclosure structure  46  can be secured onto electrical connector  42  by a tri-clip/slot mating feature with bendable tabs. With this kind of feature, which is illustrated in  FIGS. 3 and 6   b,  the tri-clip  52  on electrical connector  42  can be disengaged from slots  54  on enclosure structure  46  to allow an installer to more easily manipulate electrical connector  42  to connect it to junction socket  24 . Thus, electrical connector  42  can more easily be screwed into junction socket  24 . Once the electrical connection is made, tri-clip  52  can be reinserted into slots  54  and the bendable tabs of tri-clip  52  pressed down as is shown in  FIG. 6   c  to lock enclosure structure  46  around electrical connector  42 . Accordingly, electrical connector can be safely and securely connected to junction head  22  to provide the electrical connection to lighting element  60 . 
         [0036]    The connection of electrical connector  42  to junction socket  24  can be further shielded by an additional, secondary enclosure structure. For instance, a clamshell-type enclosure structure  57  can be positioned to surround electrical connector  42  and junction head  22 . One example of such clamshell enclosure  57  is illustrated in  FIGS. 5 ,  6   d,  and  7 . This additional clamshell enclosure  57  provides a mating head design that matches the wide variety of Edison socket shields (i.e., enclosure structure  46 ) well enough to pass electrical and safety code. Specifically, for example, in order to pass UL, the electrical connection needs to be completely enclosed. Therefore, clamshell enclosure  57  is clamped around the mated junction head  22  and electrical connector  42  in order to provide the desired electrical shield. 
         [0037]    In another aspect, the disclosed subject matter can include a method for using the above described universal adapter  30  to adapt a lighting fixture rough-in  10  for use with a lighting element  60 . Just as disclosed above, lighting fixture rough-in  10  can include a frame  12  defining an aperture  14  therethrough and an electrical junction box  20 . Connecting universal adapter  30  to lighting fixture rough-in  10  can involve connecting electrical connector  42  to electrical junction box  20  of lighting fixture rough-in  10 . As noted above, and as illustrated in  FIG. 6   b,  this connecting can be accomplished by connecting mounting clips  26  on junction head  22  with notches  44  formed in electrical connector  42 . Further, as illustrated in  FIGS. 3 and 6   c,  the step of connecting can also include manipulating a tri-clip/slot mating feature to lock an enclosure structure  46  about electrical connector  42 . 
         [0038]    The now-connected junction head  22  and electrical connector  42  can further be enclosed inside clamshell enclosure  57 , as is depicted in  FIG. 6   d . Guide tabs  58  can be inserted into corresponding enclosures slots SL to align and join two halves of clamshell enclosure  57 , ensuring that the junction-side conduit exits through a top center opening O of clamshell enclosure  57  and the adapter-side electrical conduit  48  exits through an opening on the side of clamshell enclosure  57 . As is depicted in  FIG. 7 , sets of removable tabs  59  can be removable from clamshell enclosure  57  to form this side opening for routing the adapter-side electrical conduit  48  out of clamshell enclosure  57 . Multiple sets of removable tabs  59  can be provided so as to allow for multiple configurations of junction head  22  and electrical connector  42 . Two halves of clamshell enclosure  57  can be locked together, for example, using a fastener (e.g., a single screw) on one side of clamshell enclosure  57  where two fastening holes FH line up in registration one with the other. 
         [0039]    Once the electrical connection is made and the connectors safely enclosed, adapter body  32  can be inserted through aperture  14  in frame  12  of lighting fixture rough-in  10 . Flange  34  can brace adapter body  32  against the ceiling or wall above which lighting fixture rough-in  10  is installed. In the other direction, the position of retainers  36  can be adjusted so that they engage frame  12  and support adapter body  32  in place with respect to aperture  14 . For instance, as is shown in  FIGS. 3 and 6e , retainers  36  can be adjusted to be in their highest position relative to open end  33  of adapter body  32  and fasteners  39  lightly tightened to temporarily hold retainers  36  in this position. Adapter body  32  can then be inserted through aperture  14  until flange  34  encounters the ceiling or wall, and thus adapter body  32  is in the desired position. Once adapter body  32  is properly positioned, as illustrated in  FIG. 6f , fasteners  39  can be loosened and retainers  36  can be pressed downwardly until gripping portion  38  engages frame  12  (see also  FIG. 5 ). With retainers  36  in the desired locking position, fasteners  39  can again be tightened to lock retainers  36  in place. In this way, adapter body  32  can be effectively locked onto lighting fixture rough-in  10 . If additional support is desired, additional fasteners (e.g., sheet metal screws) can be used to secure adapter body  32  to frame  12 . 
         [0040]    Lighting element  60  can be inserted into open end  33  of adapter body  32  and connected to adapter socket  40  to create a completed lighting fixture. As noted above, depending on the configuration of lighting element  60 , a trim portion can be provided to help provide a better fit for lighting element  60 , reflect at least some of the light directed into adapter body  32 , and/or improve the aesthetic appearance of any exposed portions of the lighting fixture. 
         [0041]    It will be understood that various details of the presently disclosed subject matter may be changed without departing from the scope of the presently disclosed subject matter. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation.