Systems, methods, and devices for providing a torsion spring bracket assembly for use in cylindrical luminaire housings

A mounting bracket assembly includes a mounting base and a plurality of arms extending down from the mounting base. A first arm of the plurality of arms includes a first pair of inwardly facing hooks coupled to the first arm and defining a first torsion spring receiver area. The first arm of the plurality of arms includes a first spring coil ramp disposed along a bottom end of the first arm and extending radially inward from the first arm at a first angle. A second arm of the plurality of arms includes a second pair of inwardly facing hooks coupled to the second arm and defining a second torsion spring receiver area. The second arm of the plurality of arms includes a second spring coil ramp disposed along a bottom end of the second arm and extending radially inward from the second arm at a second angle.

TECHNICAL FIELD

The present disclosure relates generally to lighting solutions, and more particularly to systems, methods, and devices for providing a torsion spring bracket for use in surface cylinder fixtures.

BACKGROUND

Torsion springs typically require sufficient space to expand and hold a trim in place. Due to surface cylinder housing construction, there typically is not enough free space available for torsion spring expansion. Another challenge to the use of torsion springs in surface cylinder housings is the removal of the trim assembly that is attached or held in place with torsion springs. In many cases, as the trim assembly is being pulled through the opening of the surface cylinder housing, the spring coil for the torsion spring can hit the edge or lip portion of the surface cylinder housing, making removal more difficult.

The drawings illustrate only example embodiments and are therefore not to be considered limiting in scope. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Additionally, certain dimensions or positionings may be exaggerated to help visually convey such principles. In the drawings, reference numerals designate like or corresponding, but not necessarily identical, elements.

SUMMARY

The present disclosure relates to systems, methods, and devices for providing a torsion spring bracket for use in surface cylinder fixtures. In an example embodiment, a mounting bracket assembly includes a mounting base and a plurality of arms extending down from the mounting base. A first arm of the plurality of arms includes a first pair of inwardly facing hooks coupled to the first arm and defining a first torsion spring receiver area. The first arm of the plurality of arms includes a first spring coil ramp disposed along a bottom end of the first arm and extending radially inward from the first arm at a first angle. A second arm of the plurality of arms includes a second pair of inwardly facing hooks coupled to the second arm and defining a second torsion spring receiver area. The second arm of the plurality of arms includes a second spring coil ramp disposed along a bottom end of the second arm and extending radially inward from the second arm at a second angle.

In another example embodiment, a light fixture module includes a housing and a mounting bracket assembly coupled to and positioned within the housing. The mounting bracket assembly includes a mounting base and a plurality of arms extending down from the mounting base. A first arm of the plurality of arms includes a first pair of inwardly facing hooks coupled to the first arm and defining a first torsion spring receiver area. The first arm of the plurality of arms also includes a first spring coil ramp disposed along a bottom end of the first arm and extending radially inward from the first arm at a first angle. A second arm of the plurality of arms includes a second pair of inwardly facing hooks coupled to the second arm and defining a second torsion spring receiver area. The second arm of the plurality of arms also includes a second spring coil ramp disposed along a bottom end of the second arm and extending radially inward from the second arm at a second angle.

In another example embodiment, a light fixture includes a housing, a mounting bracket assembly coupled to and positioned within the housing, and a light module including a light engine, wherein the light module is coupled to the mounting bracket assembly. The mounting bracket assembly includes a mounting base and a plurality of arms extending down from the mounting base. A first arm of the plurality of arms includes a first pair of inwardly facing hooks coupled to the first arm and defining a first torsion spring receiver area. The first arm of the plurality of arms also includes a first spring coil ramp disposed along a bottom end of the first arm and extending radially inward from the first arm at a first angle. The mounting bracket assembly includes a second arm of the plurality of arms including a second pair of inwardly facing hooks coupled to the second arm and defining a second torsion spring receiver area. The second arm of the plurality of arms also includes a second spring coil ramp disposed along a bottom end of the second arm and extending radially inward from the second arm at a second angle.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Example embodiments disclosed herein are directed to a luminaire having a cylinder housing designed to receive an LED light module or for use with an LED light module. For example, the cylinder housing (hereinafter referred to as a “surface cylinder housing”) may be a surface-mounted, a wall-mounted, a pendant-mounted, or a cable-mounted housing usable in a corresponding luminaire. The example embodiments provide the capability to use torsion spring assemblies to install and remove the LED light module from within the surface cylinder housing that is usable in a corresponding surface-mounted, wall-mounted, pendant-mounted, or cable-mounted luminaire.

FIGS. 1A-Dpresent various views of a torsion spring bracket assembly100in accordance with an example embodiment. Referring now toFIGS. 1A-D, the example torsion spring bracket assembly100includes a mounting base105and one or more arms110extending away from the mounting base105. The example base105is planar or substantially planar and includes a top surface and opposing bottom surface. The top surface includes a pair of mounting posts107extending up orthogonally from the top surface of the mounting base105. In certain example embodiments, each mounting post107is threaded and designed to be positioned through a ceiling member of a surface cylinder housing to couple the torsion spring bracket assembly100to the surface cylinder housing, as described below. The mounting base105can also include one or more apertures extending through the surface of the mounting base105for removably coupling additional components, such as LED drivers.

In one example embodiment, the assembly100includes two arms110aand110bthat extend orthogonally or substantially orthogonally down from the base105. The base105can include a pair of tabs109that extend out from the base along the same plane and the arms110aand110bcan be attached and extend down from these tabs109. In such a case, the tabs109are considered part of the base105. In alternative embodiments, each arm110a,110bextends angularly out from the bottom side of the base105. The angle can be in the range of 0.1-30 degrees off of vertical in this alternative embodiment. In certain example embodiments, each arm110a,110bis disposed on an opposing side of the base105. In addition, the arms110aand110bextend along parallel planes in certain example embodiments.

Each arm110a,110bhas a flat or substantially flat planar surface that includes a first end coupled to the base105and a distal second end. A pair of flange members115,120can extend out from the first arm110ain an area adjacent to the arm's second end and another pair of flange members125,130can extend out from the second arm110bin an area adjacent to that arm's second end. In certain example embodiments, each respective pair of flange members115,120and125,130are positioned along opposite longitudinal edges of the respective arm110a,110b. In certain example embodiments, each flange member115-130is coupled to and extends angularly from the respective arm110a,110b. The angle the flange members115-130are positioned with respect to the respective arm110a,110bcan generally correspond to the radius of curvature of the inner surface of the surface cylinder housing that the assembly100is coupled to and can range from 0-45 degrees in certain example embodiments. In certain example embodiments, the flange members115-130are integrally formed with their respective arms110a,110b.

Each flange member115-130can have a first end, a distal second end and a substantially planar surface disposed between the first and second ends. In certain example embodiments, the second end of each flange member115-130is adjacent to the second end of the respective arm110. Positioned along the first end of each flange member115-130is a torsion spring receiver hook135,140,145,150. In alternative embodiments, each hook135,140,145,150is coupled and extends from the respective arm110and eliminates the need for the flange members115-130. Each hook135,140,145,150can include a first member142extending angularly out from the first end of the respective flange member115-130and a second member144extending angulary or orthogonally from the first member. In one example embodiment, the first member142is positioned at an angle of about 45 degrees from vertical with respect to its respective flange member115-130. In other example embodiments, the angle of the first member142ranges from 1-90 degrees from vertical. Each pair of hooks135,140and145,150face inward toward each other in certain example embodiments. An opening is defined by the ends of the second members144of each pair of hooks that leads to a torsion spring receiver area that is defined by the arm110respective flange members115,120or125,130and the inner edges of the respective pairs of hooks135,140or145,150.

The torsion spring bracket assembly100ofFIGS. 1A-1Dmay be used to attach a light module, such an example light module shown inFIG. 4.FIG. 4is a perspective view of an example LED light module301with torsion springs that can be installed into the torsion spring bracket assembly100. Referring toFIGS. 1A-Dand4, the LED light module301includes a light engine320and a trim315coupled to the light engine320. In certain example embodiments, the trim315is removably coupled to the light engine320. Torsion springs302can be positioned and coupled to opposing sides of the light engine320, either directly or through the use of a bracket (as shown). Each example torsion spring302includes a spring coil305and shafts310extending away from the spring coil305. Each shaft310can include a hook-shaped feature312at the distal end of the shaft310.

In general a user can install the light module301into the assembly100within a surface cylinder housing by squeezing the two ends of respective shafts310together and inserting the shafts310through the opening defined by the ends of the corresponding second members144and inserting the shafts310into the torsion spring receiver area. By squeezing the two ends312of the shafts310together, the spring coil305is twisted tighter, resulting in a force that attempts to cause the ends312to retract or move away from one-another while in the torsion spring receiver area. When the shafts310contact the inner edges of the hooks135,140,145,150, while continuing to retract, it can cause the torsion spring302to help lift the light module301into the surface cylinder housing and maintain the light module301within the surface cylinder housing.

Positioned near the bottom of the second end of each arm110is a spring coil ramp180. In certain example embodiments, the spring coil ramp180,185is formed from a portion of the respective arm110. Alternatively, the spring coil ramp180,185is a tab-like member coupled to or near the bottom of the second end of the arm110. Each example spring coil ramp180,185extends angularly inward from it respective arm110. For example, spring coil ramp180extends angularly inward from arm110aand spring coil ramp185extends angularly inward from arm110b. In one example embodiment, each spring coil ramp180,185is angled about 10 degrees from the surface of its respective arm110. In an alternative embodiment, the length and angle of each spring coil ramp180,185is configured such that the inner surface of the end of each respective ramp180,185extends to a point radially equal to or a little less than the lip portion220extending from the wall215of the can housing, as best shown inFIG. 3.

FIG. 2is a cross-sectional view of the torsion spring bracket assembly100ofFIGS. 1A-Dinstalled in a surface cylinder housing200in accordance with an example embodiment. Now referring toFIGS. 1A-2, the example torsion spring bracket assembly100can be installed in a surface cylinder housing, such as the surface cylinder housing200ofFIG. 200. The surface cylinder housing200can have a substantially cylindrical shape and can include a top end205that includes a mounting surface210and an outer wall215generally extending down from the top end205. A lip portion220can extend radially inward from the outer wall215.

The mounting posts107of the assembly100can extend through openings in the mounting surface210to couple the mounting base105to the mounting surface210. On or more types of coupling devices, such as nuts, can be threadably coupled to each post107to couple the mounting base105to the mounting surface210. In addition, an LED driver240or other electrical components can be coupled to the bottom side of the mounting base105. Each arm110can be positioned generally along the outer wall215and extend down towards the lip portion220and the bottom of the surface cylinder housing220.

As shown inFIG. 2, in some example embodiments, the LED driver240is coupled to the torsion spring bracket assembly100, where the torsion spring bracket assembly100may provide an electrical ground path for electricity related to the LED driver240. For example, the torsion spring bracket assembly100may be made from a metal (e.g., aluminum) and, as a conductor, may be used to provide an electrical ground path for the LED driver240and/or other electrical components that are coupled to it.

In some example embodiments, the torsion spring bracket assembly100may serve as a heat conduit to transfer heat from, for example, the LED driver240to the surface cylinder housing200. As shown inFIGS. 2 and 3, because the torsion spring bracket assembly100is in physical contact with the surface cylinder housing200as well as with the LED driver240, the torsion spring bracket assembly100may provide a heat transfer path between the LED driver240and the surface cylinder housing200. For example, the torsion spring bracket assembly100may be made from a metal such as aluminum for efficient heat transfer and may operate as part of a luminaire's heat sink.

FIG. 3is a partial cross-sectional view showing the interaction of the torsion spring coil from a light module301and one of the spring coil ramps185, as the light module301is being removed from the can housing. During removal, after the ends312of the shafts310are moved together to remove the shafts310from the torsion spring receiver area, the light module301, including the light engine320and trim315, are moved downward towards the opening in the can housing. The spring coil305moves down and along an area adjacent to the arm110and as it approaches the bottom of the arm110it can contact the spring coil ramp185if the spring coil305is too close to the wall215of the can housing. Contacting the ramp185forces the spring coil305back towards the center of the opening and away from the lip220of the housing, thereby reducing the possibility the coil305catches on the lip220during removal of the light module301.

In alternative embodiments, the spring coil ramp180,185can be positioned at an angle anywhere between 1-60 degrees. In certain exemplary embodiments, the bottom edge of the spring coil ramp180,185is at substantially the same vertical position as the second end of the flange members115-130.

Although the present disclosure describes the example embodiments, it should be appreciated by those skilled in the art that various modifications are well within the scope of this disclosure. Those skilled in the art will appreciate that the present disclosure is not limited to any specifically discussed application and that the embodiments described herein are illustrative and not restrictive. From the description of the example embodiments, equivalents of the elements shown therein will suggest themselves to those skilled in the art, and ways of constructing other embodiments will suggest themselves to practitioners of the art. Therefore, the scope of the claims presented below is not limited herein.