Abstract:
Retrofit light fixtures suitable for installation without tools. One or more spring bands deform as the fixture is forced through a ceiling opening and resume their preloaded shape to hold the fixture in place. Some embodiments may be installed in round ceiling openings and may utilize LED light sources.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is related to and claims priority benefits from U.S. Provisional Application Ser. No. 61/685,924, filed on Mar. 27, 2012, entitled “Downlight Fixtures” (“the &#39;924 application”). The &#39;924 application is hereby incorporated in its entirety by this reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The field of the invention relates to lighting fixtures and the retrofitting of light fixtures in ceiling openings and the like. 
       BACKGROUND 
       [0003]    Known methods and apparatuses for installing downlight fixtures into ceiling openings and the like traditionally require an assortment of tools and hardware, in addition to a certain amount of corresponding dexterity. These necessities are especially troublesome given that an installer performing such an installation is typically also preoccupied with holding the light fixture(s) to be installed and maintaining his or her balance on a height support, such as a ladder, lift, or chair, during the installation process. Thus, it may be desirable to provide a downlight fixture that can be installed easily with without tools or hardware. This is especially true now as many consumers are upgrading their downlight fixtures from a conventional light source fixture to an LED light source fixture. 
       SUMMARY 
       [0004]    Certain embodiments of the present invention include a retrofit light fixture for insertion within an opening, the retrofit light fixture having a mounting ring, a support frame coupled to the mounting ring, and at least one spring band coupled to the mounting ring, wherein, the at least one spring band is adapted to deflect inwardly to permit insertion of the retrofit light fixture into the opening and, after insertion, to return to its preloaded state to resist removal of the retrofit light fixture from the opening. In some embodiments, the retrofit light fixture may also have a housing for housing light sources and a heat sink for heat dissipation. 
         [0005]    In some embodiments, the retrofit light fixture may have two or more spring bands. For example, in some embodiments, the retrofit light fixture may have three spring bands. In some embodiments, the at least one spring band may be formed of stainless steel or spring steel. 
         [0006]    In some embodiments, the retrofit light fixture may have a mounting plate and/or centering pin or bolt to ensure the spring bands remained centered during insertion through the opening. 
         [0007]    The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should not be understood to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to the entire specification of this patent, all drawings and each claim. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    Illustrative embodiments of the present invention are described in detail below with reference to the following drawing figures: 
           [0009]      FIG. 1  is a top and side perspective view of a first embodiment of a retrofit light fixture of this invention. 
           [0010]      FIG. 2  is a bottom and side perspective view of the retrofit light fixture of  FIG. 1 . 
           [0011]      FIG. 3  is a top and side perspective view of a second embodiment of a retrofit light fixture of this invention with its spring bands shown in their preloaded state. 
           [0012]      FIG. 4  is another perspective view of the retrofit light fixture of  FIG. 3  with its spring bands shown deflected inward. 
           [0013]      FIG. 5  is a side view of a third embodiment of retrofit light fixture of this invention. 
           [0014]      FIG. 6  is an enlarged perspective view an embodiment of the spring band to mounting ring coupling of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0015]    The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. 
         [0016]    Embodiments of this invention provide retrofit light fixtures. While the retrofit light fixtures are generally discussed for use with downlight fixtures that are recessed in ceiling, they are by no means so limited. Rather, embodiments of the retrofit light fixtures may be used in connection with any fixture or apparatus sought to be retrofitted into an opening. 
         [0017]      FIGS. 1-6  illustrate embodiments of a retrofit light fixture  100 . In these embodiments, the retrofit light fixture  100  may have a mounting ring  102 , a support frame  104  coupled to the mounting ring  102 , three spring bands  106  coupled to the mounting ring  102 , and a housing  108  for housing one or more light sources, such as one or more light-emitting diodes (LEDs). In some embodiments, such as the embodiments illustrated in  FIGS. 1-6 , the retrofit light fixture  100  may also have a heat sink  110  for heat dissipation. In some embodiments, the retrofit light fixture  100  may include fewer or more than three spring bands  106 . 
         [0018]    The retrofit light fixture  100  is designed to be retrofitted into an existing ceiling  200  opening  202  and/or opening of an existing mounting frame (not shown) without the use of any tools or hardware. The spring bands  106  are configured to deflect inward (e.g., toward housing  108 ) during insertion of the retrofit light fixture  100  through the opening  202 . Use of a mounting plate  112  and/or a centering pin or bolt  114 , provided in some embodiments and depicted in  FIGS. 3-5 , may help to ensure the spring bands  106  remained centered during insertion through the opening  202  (i.e., prevent the spring bands  106  from shifting laterally). After insertion, the spring bands  106  may return to their preloaded state to help retain the retrofit light fixture  100  in the ceiling  200 . In some embodiments, such as the embodiments illustrated in  FIG. 5 , a trim piece  300  may be inserted into the retrofit light fixture  100  to impart a finished or polished appearance to the installation. 
         [0019]    The mounting ring  102  trims the ceiling  200  opening  202  with a vertical portion  120  that extends into the opening  202  and a flange-shaped portion  118  that lies against an underside  206  of the ceiling  200 . The mounting ring  102  also defines an entry  116  of the retrofit light fixture  100 . The dimensions of the mounting ring  102  may vary depending on the opening  202  dimensions. In some embodiments, such as the embodiments illustrated in  FIGS. 1-6 , the mounting ring  102  may have a circular shape. In other embodiments, the shape of the mounting ring  102  may resemble an oval, square, rectangle, triangle, or other similar polygon shape. The mounting ring  102  may be formed of materials including but not limited to plastics, composite plastics, steel, aluminum or other metals or metallic materials, composite materials, or other similar materials. 
         [0020]    The flange  118  and vertical portion  120  may assist in the retrofitting of the retrofit light fixture  100 . In these embodiments, the flange  118  may extend away from the entry  116  of the retrofit light fixture  100 , while the vertical portion  120  may extend within the entry  116 . In some embodiments, such as the embodiments illustrated in  FIGS. 1-6 , the flange  118  may extend horizontally away from the entry  116 . The flange  118  and vertical portion  120  may be integrally formed. 
         [0021]    The support frame  104  is coupled to the mounting ring  102  and provides support and structure for the retrofit light fixture  100 . For example, in some embodiments, the support frame  104  defines an area for the housing  108 . In some embodiments, the support frame  104  provides support for the housing  108  and/or heat sink  110 . The dimensions, shape, position, and/or configuration of the support frame  104  may vary. For example, in the embodiments illustrated in  FIGS. 1-5 , the support frame  104  is coupled to the vertical portion  120  of the mounting ring  102 . The support frame  104  may be formed of materials including but not limited to plastics, composite plastics, steel, aluminum or other metals other metallic materials, composite materials, or other similar materials. The support frame  104  may be coupled to the mounting ring  102  by a variety of mechanisms, including but not limited to adhesives, hooks, bolts, fasteners, screws, welds, pins, and other similar mechanisms. In some embodiments, the support frame  104  may be integrally formed with the mounting ring  102 . 
         [0022]    The spring bands  106  permit insertion of the retrofit light fixture  100  into the opening  202  and then retain it there. Each spring band  106  is preloaded and shaped such that it may deflect or compress inward for installation of the retrofit light fixture  100  into the opening  202 , but return to its preloaded state after such installation. In these embodiments, the at least one spring band  106  may be formed of any material possessing spring-like or biasing characteristics that permits the spring band  106  to deflect or compress inward when an external force is applied upon it, but also return to its preloaded state once the external force is removed. For example, in some embodiments, the spring band  106  may be formed of stainless steel or spring steel. Plastics, composite plastics, composite materials, and other similar materials may also be used. 
         [0023]    The spring bands  106  may assume a number of different shapes provided that the relaxed or preloaded effective diameter of the fixture  100  exceeds the diameter of the opening within which the fixture  100  is to be installed (e.g., opening  202 ). Various generally “C” shapes or “U” shapes may be usable. As can be seen in the Figures, the spring bands  106  may have multiple generally straight sections  107 ,  109 ,  111 , etc. joined at bends  113  and  115 , etc. that cumulatively result in a top section  117  and a bottom section  107  being relatively horizontal (i.e., relatively parallel to the plane of the ceiling  200  within which the fixture  100  is installed). More or fewer straight sections  107 ,  109 ,  111 , etc. could be used, and sharper or less sharp bends  113  and  115 , etc. could also be used. Alternatively, the spring band  106  could utilize a smooth curve having a relatively constant radius or a curve with a changing radius. In most instances, however, it will be desirable for a section or portion of spring band  106  near its lower point of attachment to the rest of the fixture  100 , such as bottom section  107  in  FIG. 5 , to project outward from the rest of the fixture  100  so that it extends over and can lie against an upper side  204  of the ceiling  200 , as illustrated in  FIG. 5 . 
         [0024]    The number of spring bands  106  may vary from one to several throughout embodiments. For example, in the embodiments illustrated in  FIGS. 1-4 , the retrofit light fixture  100  includes three spring bands  106 . In some embodiments, such as the embodiments illustrated in  FIG. 5 , the retrofit light fixture  100  may have only two spring bands  106 . In other embodiments, the retrofit light fixture  100  may have four or more spring bands  106 . In yet other embodiments, the retrofit light fixture  100  may have only a single spring band  106 . In some embodiments having two or more spring bands  106 , the spring bands  106  may be positioned evenly about the mounting ring  102 . For example, in the embodiments illustrated in  FIGS. 1-4 , each of the three spring bands  106  is positioned approximately every 120 degrees about the mounting ring  102 . By contrast, in the embodiments illustrated in  FIG. 5 , the two spring bands  106  are positioned approximately 180 degrees apart. 
         [0025]    The spring bands  106  may be coupled to mounting ring  102  in a variety of ways. For example, in some embodiments, such as the embodiments illustrated in  FIGS. 1-6 , a first end  122  of the spring band  106  may be coupled to the vertical portion  120  of the mounting ring  102 . In some embodiments, such as the embodiments illustrated in  FIGS. 1-6 , the first end  122  of the spring band  106  may pass through a slot  124  in vertical portion  120  from the outside and curve up and back to form a hook  126 , as best illustrated in  FIG. 6 . In these embodiments, because the spring band  106  protrudes from slot  124  a little above and at an acute angle to the plane of the flange  118 , the upper side  204  of ceiling  200  may be trapped or pinched between the spring band  106  and the flange  118  during installation of the fixture  100 , thereby securing fixture  100  to the ceiling  200 . 
         [0026]    A second end  128  of the spring band  106  may be coupled to an upper portion  130  of the retrofit light fixture  100  to ensure consistent compression and decompression of the spring band  106 . In some embodiments, the second end  128  of each spring band  106  may be attached to the heat sink  110 . In other embodiments, the second end  128  of each spring band  106  may be attached to the support frame  104 . In some embodiments, the second end  128  of each spring band  106  may be attached to the mounting plate  112  centered on the upper portion  130  of fixture  100 . The mounting plate  112  may be permanently fixed to heat sink  110  as shown in  FIG. 1 , or may be permitted to go up and down centering pin or bolt  114 , as illustrated in  FIGS. 3-4 . 
         [0027]    The centering pin or bolt  114  may permit vertical movement of the mounting plate  112 , and thereby second ends  128  of the spring bands  106 , during installation of the retrofit light fixture  100 , but also ensure the spring bands  106  remained centered relative to the balance of the retrofit light fixture  100  by preventing the spring bands  106  from shifting laterally. The centering pin or bolt  114  may also facilitate the inward deflection or compression of the spring bands  106  relative to the retrofit light fixture  100 , and thereby the overall installation process, by displacing the second ends  128  of the spring bands  106  away from the opening  202 , as illustrated in  FIG. 4 . 
         [0028]    In embodiments having only a single spring band  106 , the single spring band  106  may surround the upper portion  130  of the retrofit light fixture  100  such that the second end  128  of the single spring band  106  couples to a different portion of the mounting ring  102  than the first end  122 , somewhat akin to embodiments having two spring bands  106 , such as the embodiment illustrated in  FIG. 5 . 
         [0029]    The retrofit light fixture  100  may also have a housing  108  configured and shaped to house one or more light sources, such as a plurality of LEDs (not shown). In these embodiments, the housing  108  may be coupled to the support frame  104 . In some embodiments, the housing  108  may be integrally formed with the support frame  104 . The housing  108  may be formed of materials including but not limited to plastics, composite plastics, steel, other metallic materials, composite materials, or other similar materials. The dimensions of the housing  108  may vary throughout embodiments, and in particular, may vary dependent on the light source to be housed within the housing  108 . 
         [0030]    As discussed above, the retrofit light fixture  100  may be installed into an existing ceiling opening, an opening of an existing mounting frame, a rough-cut hole in ceiling construction, and similar cavities, such as opening  202 , without the use of any tools or hardware. For example, as illustrated in  FIG. 5 , the retrofit light fixture  100  may be inserted into the opening  202  using the spring bands  106 . The span of the spring bands  106 , as illustrated by example in  FIGS. 1-3 , may initially prevent the retrofit light fixture  100  from being fully inserted into the opening  202 . As upward pressure is applied to the retrofit light fixture  100 , however, an edge (not shown) of the opening  202  may engage and slide along the spring bands  106 , causing the spring bands  106  to deflect or compress inwardly to provide the necessary clearance for the retrofit light fixture  100  to fully insert into the opening  202 . In some embodiments, the use of the mounting plate  112  and/or the centering pin or bolt  114  may help facilitate the deflection or compression of the spring bands  106  and help ensure the spring bands  106  remained centered during insertion through the opening  202  (i.e., prevent the spring bands  106  from shifting laterally). Once the spring bands  106  clear the opening  202 , the spring bands  106  may return to their relaxed or preloaded state, wherein they may help retain the retrofit light fixture  100  in the opening  202 , as illustrated by example in  FIG. 5 , by abutting the ceiling  200  or frame (not shown). In this way, the retrofit light fixture  100  is easily retrofitted into existing frame or ceiling openings, and the like, from below, without the need for tools of other hardware. When the retrofit light fixture  100  is positioned in the opening  202  as described above, the mounting ring  102  seats against the ceiling  200  to trim the opening  202  and secure the fixture  100  in place. 
         [0031]    The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Further modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention. Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and subcombinations are useful and may be employed without reference to other features and subcombinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications can be made without departing from the scope of the claims below.