Replaceable baffles for light fixtures

A light fixture can include a housing having at least one housing wall having an inner surface that forms a cavity, where the inner surface of the at least one housing wall has at least one baffle coupling feature disposed thereon. The light fixture can also include a baffle removably coupled to the housing, where the baffle includes at least one baffle wall having an outer surface, where the outer surface of the at least one baffle wall has at least one housing coupling feature disposed thereon. The baffle can be coupled to the housing and decoupled from the housing without use of tools.

TECHNICAL FIELD

Embodiments described herein relate generally to light fixtures, and more particularly to systems, methods, and devices for baffles for light fixtures.

BACKGROUND

Baffles are used in light fixtures to soften the effects of light emitted by one or more light sources of a light fixture. Baffles are common in certain types of light fixtures, such as down can light fixtures (also known as recessed light fixtures and downlight fixtures). Baffles can have different features disposed on their inner surface to have the desired effect (e.g., reduced glare) on emitted light.

SUMMARY

In general, in one aspect, the disclosure relates to a light fixture that can include a housing having at least one housing wall having an inner surface that forms a cavity, where the inner surface of the at least one housing wall has at least one baffle coupling feature disposed thereon. The light fixture can also include a baffle removably coupled to the housing, where the baffle includes at least one baffle wall having an outer surface, where the outer surface of the at least one baffle wall has at least one housing coupling feature disposed thereon. The baffle can be coupled to the housing and decoupled from the housing without use of tools.

In another aspect, the disclosure can generally relate to a baffle for a light fixture that can include at least one wall having an inner baffle surface and an outer baffle surface, where the inner baffle surface is configured to control effects of light emitted by the light fixture. The baffle can also include at least one housing coupling feature disposed on the outer baffle surface of the at least one wall. The at least one housing coupling feature can be configured to detachably couple to at least one baffle coupling feature disposed on an inner housing surface of a housing of the light fixture. The at least one housing coupling feature can be configured to couple to the at least one baffle coupling feature and decouple from the at least one baffle coupling feature without use of tools.

In yet another aspect, the disclosure can generally relate to a housing for a light fixture that can include at least one wall having an inner surface, where the inner surface is configured to receive at least a portion of a baffle of the light fixture, where the inner surface of the at least one wall has disposed thereon at least one baffle coupling feature. The at least one baffle coupling feature can be configured to detachably couple to at least one housing coupling feature disposed on an outer surface of the baffle of the light fixture. The at least one baffle coupling feature can be configured to couple to the at least one housing coupling feature and decouple from the at least one housing coupling feature without use of tools.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The example embodiments discussed herein are directed to systems, methods, and devices for replaceable baffles for light fixtures. While example embodiments are described herein as being used with downlight can light fixtures, example embodiments can also be used with other types of light fixtures that include a baffle. The light fixtures described herein can use one or more of a number of different types of light sources, including but not limited to light-emitting diode (LED) light sources, fluorescent light sources, organic LED light sources, incandescent light sources, and halogen light sources. Therefore, light fixtures described herein should not be considered limited to a particular type of light source.

The downlight can fixtures shown and described herein can be of any of a number of sizes (e.g., 4 inches, 6 inches). Similarly, other types of light fixtures that can be used with example embodiments can be any of a number of sizes. A user may be any person that interacts with a light fixture. Examples of a user may include, but are not limited to, an engineer, an electrician, an instrumentation and controls technician, a mechanic, an operator, a consultant, a contractor, a maintenance technician, a homeowner, a tenant, a building manager, a landlord, and a manufacturer's representative.

As discussed below, light fixtures described herein include multiple components. Each of these components can be made of one or more of any number of materials. Such materials can include, but are not limited to, metal (e.g., aluminum, steel), rubber, ceramic, plastic (e.g., nylon), thermoplastic, and glass. Some components can be a portion of another component of the light fixture, while other components can be independent of the remaining components of the light fixture.

In certain example embodiments, light fixtures with example replaceable baffles are subject to meeting certain standards and/or requirements. For example, the National Electric Code (NEC), the National Electrical Manufacturers Association (NEMA), the International Electrotechnical Commission (IEC), Underwriters Laboratories (UL), the Federal Communication Commission (FCC), the Bluetooth Special Interest Group, and the Institute of Electrical and Electronics Engineers (IEEE) set standards that can be applied to electrical enclosures (e.g., light fixtures), wiring, location services, and electrical connections. Use of example embodiments described herein meet (and/or allow a corresponding device to meet) such standards when required.

Any light fixtures, or components thereof (e.g., housings, example baffles), described herein can be made from a single piece (e.g., as from a mold, injection mold, die cast, 3-D printing process, extrusion process, stamping process, or other prototype methods). In addition, or in the alternative, a light fixture (or components thereof) can be made from multiple pieces that are mechanically coupled to each other. In such a case, the multiple pieces can be mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to epoxy, welding, fastening devices, compression fittings, mating threads, tabs, and slotted fittings. One or more pieces that are mechanically coupled to each other can be coupled to each other in one or more of a number of ways, including but not limited to fixedly, hingedly, removeably, slidably, and threadably.

Components and/or features described herein can include elements that are described as coupling, fastening, securing, abutting, or other similar terms. Such terms are merely meant to distinguish various elements and/or features within a component or device and are not meant to limit the capability or function of that particular element and/or feature. For example, a feature described as a “coupling feature” can couple, secure, fasten, abut, and/or perform other functions aside from merely coupling.

A coupling feature (including a complementary coupling feature) as described herein can allow one or more components and/or portions of a light fixture to become coupled, directly or indirectly, to another portion of the light fixture and/or some other feature/component. A coupling feature can include, but is not limited to, a tab, a snap, a clamp, a portion of a hinge, an aperture, a recessed area, a protrusion, a slot, a spring clip, a tab, a detent, and mating threads. One portion of a light fixture can be coupled to another component of the light fixture by the direct use of one or more coupling features.

In addition, or in the alternative, a portion of a light fixture can be coupled to another component of the light fixture using one or more independent devices that interact with one or more coupling features disposed on a component (e.g., a baffle, a housing) of the light fixture. Examples of such devices can include, but are not limited to, a pin, a hinge, a fastening device (e.g., a bolt, a screw, a rivet), epoxy, glue, adhesive, tape, and a spring. One coupling feature described herein can be the same as, or different than, one or more other coupling features described herein. A complementary coupling feature (also sometimes called a corresponding coupling feature) as described herein can be a coupling feature that mechanically couples, directly or indirectly, with another coupling feature.

If a component of a figure is described but not expressly shown or labeled in that figure, the label used for a corresponding component in another figure can be inferred to that component. Conversely, if a component in a figure is labeled but not described, the description for such component can be substantially the same as the description for the corresponding component in another figure. The numbering scheme for the various components in the figures herein is such that each component is a three digit number and corresponding components in other figures have the identical last two digits. For any figure shown and described herein, one or more of the components may be omitted, added, repeated, and/or substituted. Accordingly, embodiments shown in a particular figure should not be considered limited to the specific arrangements of components shown in such figure.

Further, a statement that a particular embodiment (e.g., as shown in a figure herein) does not have a particular feature or component does not mean, unless expressly stated, that such embodiment is not capable of having such feature or component. For example, for purposes of present or future claims herein, a feature or component that is described as not being included in an example embodiment shown in one or more particular drawings is capable of being included in one or more claims that correspond to such one or more particular drawings herein.

Example embodiments of replaceable baffles for light fixtures will be described more fully hereinafter with reference to the accompanying drawings, in which example embodiments of replaceable baffles for light fixtures are shown. Replaceable baffles for light fixtures may, however, be embodied in many different forms and should not be construed as limited to the example embodiments set forth herein. Rather, these example embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of replaceable baffles for light fixtures to those of ordinary skill in the art. Like, but not necessarily the same, elements (also sometimes called components) in the various figures are denoted by like reference numerals for consistency.

Terms such as “first”, “second”, “outer”, “inner”, “distal”, “proximal”, “top”, “bottom”, “on”, and “within” are used merely to distinguish one component (or part of a component or state of a component) from another. Such terms are not meant to denote a preference or a particular orientation, and are not meant to limit embodiments of replaceable baffles for light fixtures. In the following detailed description of the example embodiments, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.

FIG. 1shows a cross-sectional side view of a light fixture100in accordance with certain example embodiments.FIG. 2shows an exploded bottom-front-side perspective view of the light fixture100ofFIG. 1. Referring toFIGS. 1 and 2, the light fixture100can include one or more of a number of components. For example, as shown inFIG. 1, the light fixture100in this case includes a housing140, a baffle120, a trim150, at least one light source160, and one or more mounting features180. A light fixture can also include one or more other components (e.g., a power source, a lens) that are not shown or described herein.

Each mounting feature180can be used to mount the light fixture100to a structure and/or feature. Examples of a structure and/or feature can include, but are not limited to, a ceiling, a wall, a rafter, an I-beam, a girder, a pole, a stud, plywood, and drywall. A mounting feature180can include one or more of a number of features and/or components, including but not limited to, a bracket, a spring clip, a torsion spring, a protrusion, a recess, a fastening device (e.g., a screw, a bolt, a rivet), and a detent.

In this case, there are two identical mounting features180that are disposed on the outer surface of a wall142of the housing140equidistantly with respect to each other. The mounting features180in this case are friction blades. A mounting feature180can be integrated with a component (e.g., the housing140) of the light fixture100. Alternatively, a mounting feature180can be permanently coupled to or removably coupled to a component of the light fixture100. For example, in this case, both mounting features180are removably coupled to a wall142of the housing140of the light fixture100.

The one or more light sources160of the light fixture100are used to emit light. A light source160can be one or more of a number of different types of light sources, including but not limited to light-emitting diode (LED) light sources, organic LEDs, fluorescent light sources, organic LED light sources, incandescent light sources, and halogen light sources. When the light sources are LEDs, those LED light sources can include any type of LED technology, including, but not limited to, chip on board (COB) and discrete die.

The trim150can be a decorative portion of the light fixture100that is visible to users and provides an aesthetic quality to the light fixture100. The trim150can be a separate component that is coupled to another component (e.g., the housing140) of the light fixture100. Alternatively, as in this example, the trim150can be an integrated extension of the housing140. Specifically, in this case, the trim150is an outward extension of the distal end of the wall142of the housing140. The trim150in this case is substantially planar so that the trim150abuts against a surface (e.g., a ceiling tile, drywall) when the light fixture100is installed.

In some cases, as shown inFIG. 1, there can be a receiving feature149disposed between the trim150and the distal end of the wall142of the housing140. The receiving feature149is configured to receive part (e.g., the flange129) of the baffle120(discussed below) so that the baffle120appears continuous with the trim150. In some cases, the receiving feature149can also couple (directly or indirectly) to the trim150, in addition to merely receiving. The receiving feature149can include one or more of any of a number of features. Examples of such features can include, but are not limited to, a recess (as in this case), a slot, a protrusion, a detent, an aperture, and a tab.

In certain example embodiments, the trim150or other portion of the housing140can include one or more alignment features158. Such alignment features158can be used to indicate the proper orientation of the baffle120relative to the housing140when the baffle120is about to become coupled to the housing140. Examples of an alignment feature158can include, but are not limited to, a hash mark, a protrusion, and a recess.

In this case, the alignment feature158is a hash mark disposed on the bottom surface of the trim150. An alignment feature158can be located on any other surface of the trim150and/or any other surface of the housing140. An alignment feature158can be visible to a user or hidden from a user when the baffle120is disposed in the cavity141of the housing140. The alignment feature158can be useful because the coupling features145of the housing140and the coupling features125of the baffle120are not visible to a user once the baffle120is inserted into the cavity141of the housing140.

An alignment feature158can be mechanical (e.g., a sort of coupling of the alignment feature158is required in order to proceed in coupling the baffle120to the housing140), visual (e.g., the alignment feature158only offers guidance as to how the baffle120needs to be oriented relative to the housing140to begin coupling baffle120to the housing140), or a combination thereof. In some cases, as in this example, the alignment feature158works in conjunction with a corresponding alignment feature (e.g., alignment feature128) of the baffle120.

The housing140of the light fixture100houses one or more components (e.g., the baffle120, the light sources160, the power source) of the light fixture100. Specifically, the housing140can include one or more walls142that form one or more cavities (e.g., cavity141), inside of which one or more components of the light fixture100can be disposed. For example, cavity141formed by certain walls142toward the bottom of the housing140has disposed therein the baffle120. This portion of the cavity141can have, at least in part, a conical shape.

In certain example embodiments, the housing140includes one or more coupling features145that detachably couple to one or more complementary coupling features125of the baffle120. The coupling features145can be disposed on an inner surface of one or more walls142that form the cavity141. In this case, there are two identically-configured coupling features145that are each in the form of an elongated slot that has a spiral shape for approximately ¼ turn (covering approximately 90° when looking into the cavity141from the bottom).

At the proximal end of the slot can be a feature (e.g., an opening) to receive the coupling features125of the baffle120when the baffle120is about to be coupled to or decoupled from the housing140. At the distal end of the slot can be another feature (e.g., a detent) to hold the coupling features125of the baffle120in place when the baffle120is coupled to the housing140.

When the housing140has multiple coupling features145disposed on the inner surface of a wall142, those coupling features145can have any of a number of configurations and/or positions relative to each other. For example, one coupling feature145can have a configuration (e.g., shape, size) that is the same as, or different than, the configuration of the rest of the coupling features145. As another example, the multiple coupling features145can be positioned equidistantly from each other within the cavity141. Alternatively, at least one of the coupling features145can be offset relative to one or more of the other coupling features145. In any case, the number, configuration, and position of the coupling features145are designed to complement the number, configuration, and position of the coupling features125of the baffle120, as described below.

The baffle120is a component of the light fixture100that is configured to control effects of light emitted by the light sources160of the light fixture100. The baffle120can have one or more walls122that can form any of a number of shapes (e.g., pyramid, cube, cylinder). In this case, the baffle120has a single wall122that forms a conical shape. In certain example embodiments, the shape formed by the wall122of the baffle120complements, at least in part, the shape of the cavity141formed by the walls142of the housing140.

The inner surface of the wall122of the baffle120forms a cavity121. Further, the inner surface of the wall122of the baffle120can have any of a number of optical features124that are specifically designed to control the light emitted by the light sources160in a certain desired way. Examples of such optical features124can include, but are not limited to, a color (e.g., soft white, gray), a type of material (e.g., a reflective material or coating), ribbing, and etchings. The top end of the baffle120can have an opening that allows the light sources160, or at least light emitted by the light sources160, to be projected into the cavity121formed by the walls122of the baffle120.

In certain example embodiments, the baffle120includes one or more coupling features125disposed on the outer surface of the wall122of the baffle120. Each coupling feature125of the baffle120is configured to detachably couple to one or more complementary coupling features145of the housing140. In this case, there are two identically-configured coupling features125that are each in the form of a horizontally-extending protrusion. More details about the coupling features125are provided with respect toFIGS. 3A-3Dbelow.

When the baffle120has multiple coupling features125disposed on the outer surface of the wall122, those coupling features125can have any of a number of configurations and/or positions relative to each other. For example, one coupling feature125can have a configuration (e.g., shape, size) that is the same as, or different than, the configuration of the rest of the coupling features125. As another example, the multiple coupling features125can be positioned equidistantly from each other around the wall122of the baffle120. Alternatively, at least one of the coupling features125can be offset relative to one or more of the other coupling features125. In any case, the number, configuration, and position of the coupling features125are designed to complement the number, configuration, and position of the coupling features145of the housing140.

With the configuration of the coupling features125(tab extensions) of the baffle120and the coupling features145(spiral-shaped slots) of the housing140, the baffle120can be coupled to the housing140by inserting the coupling features125of the baffle120into the coupling features145of the housing140, and subsequently rotating the baffle120in a clockwise direction (when viewed from below) by about ¼ turn. Similarly, the baffle120can be decoupled from the housing140by rotating the baffle120by about ¼ turn in a counter-clockwise direction, and subsequently lowering the baffle120away from the housing140. In this case, the baffle120can be coupled to and decoupled from the housing140by hand, without the use of tools (e.g., screwdriver, wrench).

At the distal end of the wall122of the baffle120can be disposed a flange129. The flange129of the baffle120can be visible to users. The flange129can be a separate component that is coupled to the distal end of the wall122of the baffle120. Alternatively, as in this example, the flange129can be an integrated extension of the wall122of the baffle120. In any case, the flange129is configured in such a way as to integrate with the trim150while disposed within the receiving feature149of the housing140. For example, the flange129in this case is substantially planar so that the flange129is disposed within and abuts against the receiving feature149of the housing140when the baffle120is coupled to the housing140. In this way, the flange129of the baffle120appears continuous with the trim150.

In certain example embodiments, the flange129or other portion of the baffle120can include one or more alignment features128. Such alignment features128can be used to indicate the proper orientation of the baffle120relative to the housing140when the baffle120is about to become coupled to the housing140. In this case, the alignment feature128is a hash mark disposed on the bottom surface of the flange129. An alignment feature128can be located on any other surface of the flange129and/or any other surface of the baffle120. An alignment feature128can be visible to a user or hidden from a user when the baffle120is disposed in the cavity141of the housing140. As explained above, the alignment feature128can be useful because the coupling features145of the housing140and the coupling features125of the baffle120are not visible to a user once the baffle120is inserted into the cavity141of the housing140.

As with an alignment feature158discussed above, an alignment feature128can be mechanical (e.g., a sort of coupling of the alignment feature128is required in order to proceed in coupling the baffle120to the housing140), visual (e.g., the alignment feature128only offers guidance as to how the baffle120needs to be oriented relative to the housing140to begin coupling baffle120to the housing140), or a combination thereof. In some cases, as in this example, the alignment feature128works in conjunction with a corresponding alignment feature (e.g., alignment feature158) of the trim150.

FIGS. 3A-3Dshow various views of a baffle320in accordance with certain example embodiments. Specifically,FIG. 3Ashows a bottom-front-side perspective view of the baffle320.FIG. 3Bshows a cross-sectional side view of the baffle320.FIG. 3Cshows a top view of the baffle320.FIG. 3Dshows a side view of the baffle320.

Referring toFIGS. 1 through 3D, the baffle320ofFIGS. 3A-3Dcan be substantially the same as the baffle120ofFIGS. 1 and 2. For example, the baffle320has a single wall322that forms a conical shape. The inner surface of the wall322of the baffle320forms a cavity321. The top end of the baffle320can have an opening that allows the light sources (e.g., light sources160), or at least light emitted by the light sources, to be projected into the cavity321formed by the walls322of the baffle320. Further, the inner surface of the wall322of the baffle320can have any of a number of optical features324that are specifically designed to control the light emitted by the light sources in a certain desired way.

In this example, the baffle320includes two coupling features325disposed on the outer surface of the wall322of the baffle320. Each coupling feature325of the baffle320is configured to detachably couple to one or more complementary coupling features (e.g., coupling features145) of the housing (e.g., housing140). Each coupling feature325includes a horizontally-extending protrusion328that is supported by one or more (in this case, two) vertical supports327. The protrusion328extends beyond the vertical supports327, which allows the protrusion328to movably couple to a complementary coupling feature of the housing, an example of which is shown in detail below with respect toFIGS. 4A and 4B.

In this example, the two coupling features325are identically configured with respect to each other. Further, the coupling features325are positioned equidistantly from each other around the wall322of the baffle320. The number, configuration, and position (in this case, about ¾ up the height of the wall322) of the coupling features325are designed to complement the number, configuration, and position of the coupling features of the housing. The coupling features325of the baffle320can be integrated with (e.g., extruded), or coupled to (e.g., welded), the wall322of the baffle320.

As with the baffle120ofFIGS. 1 and 2, at the distal end of the wall322of the baffle320ofFIGS. 3A-3Dis disposed a flange329. The flange329is configured in such a way as to integrate with the trim (e.g., trim150) while disposed within the receiving feature (e.g., receiving feature149) of the housing (e.g., housing140). The flange329in this case is substantially planar. In this case, the flange329(nor any other part of the baffle320) ofFIGS. 3A-3Ddoes not include an alignment feature.

FIGS. 4A and 4Bshow various views of a subassembly499of a light fixture in accordance with certain example embodiments. Specifically,FIG. 4Ashows a bottom-front-side perspective view of the subassembly499.FIG. 4Bshows a cross-sectional side view of the subassembly499. The subassembly499includes a housing440and a pair of mounting features480coupled to the housing440.

The various components of the subassembly499ofFIGS. 4A and 4Bcan be substantially the same as the corresponding components of the light fixture100ofFIGS. 1 and 2. For example, the pair of mounting features480are identically-configured friction blades that are disposed on (coupled to) the outer surface of a side wall442of the housing440equidistantly with respect to each other.

The trim450in this case is an outward extension of the distal end of the wall442of the housing440. The trim450is substantially planar so that the trim450abuts against a surface (e.g., a ceiling tile, drywall) when the light fixture is installed. The subassembly499also includes a receiving feature449disposed between the trim450and the distal end of the wall442of the housing440. The receiving feature449is configured to receive part (e.g., the flange329) of the baffle (e.g., baffle320) so that the baffle appears continuous with the trim450. The receiving feature449in this example includes a recess that is disposed all the way around the bottom end of the housing440.

The housing440has at least one wall442that forms a cavity441inside of which a baffle (e.g., baffle320) can be disposed. The upper portion of the cavity441has a cylindrical shape, and the bottom portion of the cavity441has a conical shape. There are two coupling features445that detachably couple to one or more complementary coupling features (e.g., coupling features325) of a baffle (e.g., baffle320). The coupling features445in this case are disposed on the inner surface of the upper side wall442that forms part of the cavity441.

The two identically-configured coupling features445are each in the form of an elongated slot that has a spiral shape for approximately ⅓ turn (covering approximately 90° when looking into the cavity441from the bottom). The two coupling features445are positioned equidistantly from each other within the cavity441. The number, configuration, and position of the coupling features445are designed to complement the number, configuration, and position of the coupling features of the baffle.

Example embodiments allow a baffle to be removably coupled to a housing of a light fixture. In some cases, an example baffle can be installed and removed without the use of tools, allowing a user to easily install and/or remove a baffle without removing the light fixture from its installed position and without disassembling other portions or components of the light fixture. In this way, baffles can easily be interchanged to produce a desired lighting effect (e.g., different shade, different focus, different color) of light emitted by the light sources of the light fixture.