Abstract:
A recessed lighting system is provided. The recessed lighting system a universal light module to emit light through a light transmissive cover, a plurality of trims wherein each trim has the same means for attaching to the light module and the same size opening that aligns with the light transmissive cover of the module, but have different flange widths; and a plurality of different size recessed lighting fixture housings that each include an annular cavity to receive the light module attached to one of the trims. Each of the cavities is differently sized and is coupled to the trims using support brackets on the trims.

Description:
FIELD 
     An embodiment relates to a recessed lighting fixture system that has a universal light module allowing different sized trims and different recessed lighting housings to fit with the light module. Other embodiments are also described. 
     BACKGROUND 
     Recessed lights are light fixtures that are typically installed or mounted into a hollow opening of a ceiling or a wall. When installed, the light from the recessed fixtures appears to shine from a hole in the ceiling, concentrating the light in a downward direction as a broad floodlight or narrow spotlight. Recessed lighting systems generally consist of a trim, a light module, and a housing. 
     The housing is a casing that is mounted to support members in the building and lines up with a hole in the ceiling. The light module is inserted into the housing and is sturdily coupled to the housing. Electrical connections are also made between the light module and the rough wiring in the building. Thereafter, the trim is coupled to the combined light module and housing unit to provide a finished look. 
     Although current recessed lighting systems come in a variety of shapes and sizes, switching between sizes requires the purchase of a new trim, a new light module and a new housing as these systems are specifically designed to interoperate with only similar sized parts. This lack of interchangeability leads to increased costs for consumers who must purchase new components to make a trim size change and for manufacturers who must produce and store every combination of trim, light module, and housing to meet consumer&#39;s needs. Thus, there is a need for a recessed light module system that provides interchangeability between different sized components. 
     SUMMARY OF THE INVENTION 
     There is a need for a recessed lighting system that allows consumers to purchase a single light module that is compatible with multiple trims and housings. 
     An embodiment of the invention is a recessed lighting system, in which a single type or size light module (a “universal” light module), can itself be fitted with any one of several different size trims. Each of the trims has a different size flange, but the same aperture size. The combination of any one of the trims and the universal light module are sized to fit within the cavity of any one of multiple different sized housings, using a set of brackets on the trim and a set of brackets in a cavity of the housings. By using a universal light module that can work with and fit within multiple standard size housings, and can be fitted with any one of multiple different size or type trims, the recessed lighting system described herein may advantageously allow manufacturers and distributors to carry and store a limited amount of components. 
     The above summary does not include an exhaustive list of all aspects of the present invention. It is contemplated that the invention includes all systems and methods that can be practiced from all suitable combinations of the various aspects summarized above, as well as those disclosed in the Detailed Description below and particularly pointed out in the claims filed with the application. Such combinations have particular advantages not specifically recited in the above summary. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment of the invention in this disclosure are not necessarily to the same embodiment, and they mean at least one. 
         FIG. 1  shows an exploded view of several different recessed lighting systems that have in common a universal light module. 
         FIG. 2  shows a housing of the recessed lighting system. 
         FIG. 3  shows an example light module coupled to a trim of the recessed lighting system. 
         FIG. 4  shows a front view of the light module. 
         FIG. 5  shows a back face of three different size trims. 
     
    
    
     DETAILED DESCRIPTION 
     Several embodiments are described with reference to the appended drawings are now explained. While numerous details are set forth, it is understood that some embodiments of the invention may be practiced without these details. In other instances, well-known circuits, structures, and techniques have not been shown in detail so as not to obscure the understanding of this description. 
       FIG. 1  shows an exploded view of several recessed lighting systems  1 . Each recessed lighting system  1  includes a housing  2 A,  2 B, or  2 C, a light module  3  (common to all of the systems), and respective trim  4 A,  4 B, or  4 C. As shown, the multiple housings  2 A,  2 B, and  2 C and the multiple trims  4 A,  4 B, and  4 C are differently sized, but the single light module  3  can fit with any combination of housing  2  and trim  4 . Each of the elements of the recessed lighting system  1  will be explained by way of example below. 
     The housing  2  may have an optional housing box  5 , a can (not shown), electrical wires  6  used to bring electrical AC power (e.g., 120 VAC, 240 VAC) to the module  3 , and support braces  7 , in accordance with well-known or conventional techniques. In one embodiment, the housing  2  acts as a heat barrier to block heat emitted by the light module  3  from reaching possibly flammable items inside a ceiling or crawl space (e.g. insulation) in which the housing  2  has been installed via its support braces  7 . The housing  2  may be formed of metals, polymers, metal alloys, and/or heat insulating materials. 
     As shown in  FIG. 2 , the housing box  5  for each housing  2  may be a polygon that defines a cavity  8  therein. However, the housing box  5  may be any suitable shape, including an ellipsoid, cone, or cylinder. The cavity  8  is to receive therein the light module  3 . The housing box  5  includes retention brackets  9  on the walls of the cavity  8  for receiving complementary support brackets  29  of the trims  4 , in order to couple the light module  3  and its trims  4  to the housing  2 . The retention brackets  9  may be any device/component for receiving support brackets  29  of the trims  4  (see  FIG. 1 ) to firmly hold the weight of a combined trim  4  and light module  3 , up against a housing  2 . For example, the retention brackets  9  may be slots formed in a sidewall that defines the cavity  8  as shown in  FIG. 2 , or they may be the hard, flat sidewall itself against which the support bracket  29  is held by friction. 
     The cavity  8  that is formed in the housing  2  may be larger in diameter than the light module  3  such that the light module  3  can easily fit into the cavity  8  without coming into direct contact with the walls of the cavity  8 . In some embodiments, the diameter of the cavity  8  is substantially larger than the diameter of the light module  3 . The size of the cavity  8  may be pursuant to popular industry specifications for recessed lighting cans. For example, the cavity  8  may be about four inches in diameter in compliance with Underwriters Laboratories (UL) 1598 or consistent with a “4-inch recessed lighting can.” As shown in  FIG. 1 , the trims  4  may be designed to couple the light module  3 , which may be of a single type or size, to multiple types or sizes of housings  2 . For example, as shown in  FIG. 1  housings  2 A,  2 B, and  2 C have different size cavities  8 , but the single sized light module  3  fits inside all these housings  2 A,  2 B, and  2 C with corresponding different sized trims  4 A,  4 B, and  4 C. In some embodiments, the light module  3  is substantially smaller than the cavity  8  of the smallest housing  2 . For example, in one embodiment, the module  3  has a diameter substantially smaller than that of the cavity  8  of any standard 4-inch recessed light can. 
     The cavity  8  is open on a bottom end to allow light from a light module  3  coupled therein to illuminate an outside environment (e.g. a room). The bottom end of the cavity  8 , which is open, may be surrounded by a thin ring  11 , e.g., made of rubber or other suitable material, to allow for a better seal with the trims  4  when the light module  3  is secured within the cavity  8 . The light module  3  may be a LED module that is a replacement or retrofit for an incandescent bulb socket in the cavity  8 , and as such may be the primary or sole light source within the cavity  8 . 
     The electrical wires  6  of the housing  2  provide electricity to the light module  3 . The electrical wires  6  may include two or more hot lines that deliver electricity and one or more lines that ground the housing  2  and the light module  3 . In one embodiment, a main line from a circuit breaker is run directly to a junction box  12  on the housing  2 . The electrical wires  6  connect to the main line via the junction box  12 . The junction box  12  may regulate current through an embedded circuit to supply a stable voltage within the operating parameters of the light module  3  or the junction box  12  may be simply an electrical splitter. The electrical wires  6  may include a plug connector that allows for easy connection with a complimentary connector of the light module  3 . For example, the plug connector may be a keyed connector or interlocking connector. 
     The housing  2  may include one or more support braces  7 . Although shown running parallel alongside the width of the housing box  5 , the support braces  7  may be positioned in any fashion along the housing box  5 . The support braces  7  couple the housing box  5  to the structure of a building. For example, the support braces  7  may couple the housing box  5  between studs in the ceiling of a house. In this embodiment, the mounting braces  7  are sixteen inches long, designed to fit within standard wooden framing in ceilings or walls. In some embodiments, the length of the support braces  7  are adjustable to fit within non-standardized structures. The support braces  7  may be coupled to the structure using any known device or method for coupling. For example, the support braces  7  may be secured to the frame of a house with any combination of resins, clips, screws, bolts, or clamps. In one embodiment, the housing box  5  is moveable along the support braces  7  to allow the housing box  5  to slide along the mounting braces  7  to place the light module  3  in the optimum position according to the consumer&#39;s preferences. 
       FIG. 3  shows an example of the light module  3  coupled to a trim  4 . The light module  3  is comprised of a light source  13  and a power supply  14 . The light source  13  may be any device or combination of devices for emitting light. For example, the light source  13  may be a light emitting diode (LED), organic light-emitting diode (OLED), and polymer light-emitting diode (PLED). As shown in the bottom of  FIG. 4 , the light module  3  may include an integrated lens  15  and a reflector (not shown) for focusing, multiplying, or adjusting light emitted by the light source  13 . For example, multipliers may be used which control the omni-directional light from “A” style bulbs. In comparison, other optical elements may be used to provide a diffused light. In one embodiment, the lens  15  also provides a protective barrier for the light source  13  and shields the light source  13  from moisture or inclement weather. In one embodiment, the lens  15  and the light source  13  are contained in a single indivisible unit. 
     Referring to  FIG. 3 , in one embodiment, the light source  13  includes one or more heat sinks  16  to cool the light source  13 . Although the heat sinks  16  are shown as passive components that cool the light source  13  by dissipating heat into the surrounding air, active heat sinks (e.g. fans) may also be used. In one embodiment, the heat sink  16  is defined by a set of fins surrounding an outside casing of the light source  13 . The heat sink  16  may be composed of any thermally conductive material. For example, the heat sink  16  may be made of aluminium alloys, copper, copper-tungsten pseudoalloy, AlSiC (silicon carbide in aluminium matrix), Dymalloy (diamond in copper-silver alloy matrix), an E-Material (beryllium oxide in beryllium matrix). 
     The power supply  14  is a device that supplies or regulates electrical energy to the light source  13 , and thus powers the light source  13  to emit light. The power supply  14  may by any type of power supply, including power supplies that deliver an alternating current (AC) or a direct current (DC) voltage to the light source  13 . The power supply  14  may receive electricity from an external source through electrical wires  17 . In one embodiment, the power supply  14  receives electricity from the housing  2  via the electrical wires  6 . In this embodiment, the electrical wires  17  of the power supply  14  are connected to the electrical wires  6  of one of the housings  2 . In one embodiment, the electrical wires  17  of the power supply  14  include a plug connector that allows for easy connection with a complimentary connector of the housing  2 . For example, the plug connector may be a keyed connector or interlocking connector. 
     Upon receiving electricity, the power supply  14  may regulate current or voltage through an embedded circuit to supply a stable voltage or current within the operating parameters of the light source  13 . The power supply  14  may transfer electricity to the light source  13  through complimentary electrical connectors (not shown) on each unit  13  and  14 . 
     In one embodiment, the light source  13  and the power supply  14  are directly coupled together along a set of surfaces. This direct coupling allows for dissipation of heat from the light source  13  through the power supply  14 . The light source  13  and the power supply  14  may be coupled together using, for example, any combination of resins, clips, screws, bolts, or clamps. In one embodiment, a thermal paste may be applied between the adjoining surfaces of the light source  13  and the power supply  14  to further assist in the transfer and dissipation of heat. In one embodiment, the power supply  14  may include a heat sink  18  to dissipate the heat generated by the power supply  14 , and the absorbed heat generated by the light source  13 . In one embodiment, the heat sink  18  is defined by a set of thermally conductive fins surrounding an outside casing of the power supply  14  and similar to those on the light source  13 . 
     In one embodiment, the light source  13  and the power supply  14  are similarly sized such that the units can be easily, compactly, and efficiently coupled together. For example, the light source  13  and the power supply  14  may be generally cylindrically shaped with similar diameters. In this embodiment, heat sink fins on both the light source  13  and the power supply  14  may be aligned such that cooling air can efficiently pass through/over the fins and dissipate heat. In another embodiment, the light source  13  and the power supply  14  are a single indivisible unit. 
     In one embodiment, referring to  FIG. 4 , a front end of the light source  13  for emitting light includes a light opening  19  and a locking surface  20  that surrounds the light opening  19 . The locking surface  20  may be rounded at the outer and inner peripheries as shown, and may include one or more slots  21  formed along the outer periphery of the surface  20 , for receiving and engaging complimentary elements of a trim  4 . As seen in  FIG. 3 , the slots  21  may be beveled to form an isosceles trapezoid or similar shape. The beveled shape of the slots  21  provides an easier connection with the trims  4  that prevents deformation of the slots  21  and complimentary elements of the trims  4  during engagement and disengagement. The slots  21  may be uniformly distributed around the light opening  19 . For example, there may be four slots  21  located at 0°, 90°, 180°, and 270° around the light opening  19 . However, in other embodiments the slots  21  may be non-uniformly distributed to, for example, account for weight distribution inconsistencies of the light module  3 . In other embodiments, the slots  21  may be replaced with other devices for coupling the light module  3  to the trims  4 . For example, the light module  3  may include a threaded structure for engaging a complimentary threaded structure of the trims  4  or a set of clamps for coupling with the trims  4 . 
     In one embodiment, a respective trim  4  is associated with each of the different housings  2 ; a single type and size light module  3 , which is is substantially smaller than the cavity  8  of the smallest housing  2 , can be fitted to any one of the different trims  4 , within the associated housing  2 . This compatibility between multiple housings  2  and a single light module  3  allows a retailer to carry a single light module  3  that can be used with multiple housings  2  (and their associated trims  4 ). 
     The trim  4  serves a primary purpose of covering the hole in the ceiling or wall in which the housing  2  and the light module  3  reside. The trim  4  accomplishes this by attaching to the border surface  20  of the light module  3 , allowing light to pass through an annular aperture  23  of the of the trim  4 , and then laying flush with and covering from view the edge of the hole in the surrounding ceiling or wall section. In doing so, the trim  4  helps the recessed lighting system  1  appear seamlessly integrated into the ceiling or wall. The size and design of the trim  4  may depend on the size of the hole in which the housing  2  has been fitted and that it must conceal as well as the aesthetic decisions of the consumer. 
     The trim  4  may form an uninterrupted thermal path with the light module  3 . The trim  4  may be formed of any thermally conductive material that assists in dissipating heat from the light module  3 . For example, the trims  4  may be made of aluminum alloys, copper, copper-tungsten pseudoalloy, AlSiC (silicon carbide in aluminum matrix), Dymalloy (diamond in copper-silver alloy matrix), and E-Material (beryllium oxide in beryllium matrix). By assisting in the dissipation of heat from the light module  3 , the trims  4  allow for the use of light modules  3  with increased power. For example, the uninterrupted thermal path between the trims  4  and the light module  3  allows dissipation of heat from a 20 W light source  13  for more than eight hours without degradation of the light source  13  or the power supply  14 . 
       FIG. 5  shows a back side of several examples of different sized trims  4 A,  4 B, and  4 C. The trims  4 A,  4 B, and  4 C include an outer flange  24  whose open center section defines the aperture  23 . In one embodiment, the outer flange  24  is separately manufactured from a center piece that contains the aperture  23 , and is bonded or otherwise joined to the center piece. The outer flange  24  is used to cover/hide from view the outside housing  2 , the light module  3 , and the edge of the corresponding hole in the wall or ceiling, while the aperture  23  exposes light emitted from the light source  13  to a room. The aperture  23  of each of the differently sized trims  4  may be essentially identical, e.g., have the same diameter D S ; however, the diameter of the flange  24  is different for each of these differently sized trims  4 . For example, in a set of three trims  4 A,  4 B, and  4 C shown in  FIG. 5 , the diameter D S  of each aperture  23  may be about two inches, while the outside diameters D A , D B , and D C  of the flanges  24  are about 4 inches, 6 inches, and 7 inches, respectively. 
     The trim  4  may include a flat border surface  25  that surrounds the aperture  23  and is surrounded by several tabs  26  and coupled to the flange  24 . The border surface  25  of the trim  4  may have an outer diameter that is about equal to or slightly smaller than the diameter of the locking surface  20  of the light module  3  (see  FIG. 4 ) and that has an equal diameter D Y  for each of the trims  4 . In one embodiment, the spacing between the tabs  26  on each of the trims  4  is about identical to the spacing between the slots  21  on the light module  3 . For example, if slots  21  are located at 0°, 90°, 180°, and 270° around the light opening  19  of the light module  3 , the tabs  26  are located at 0°, 90°, 180°, and 270° around the aperture  23 .  FIG. 3  shows the light module  3  coupled to one of the trims  4  using a tab  26  of the trim  4  and an associated one of the slots  21  of the light module  3 . The tab  26  is sized to fit within or pass through the associated slot  21  when the trim  4  and the module  3  are aligned, such that the light module  3  and the trim  4  can be twistably coupled together. As shown in  FIG. 3 , the tab  26  has passed through the slot  21  and has been moved to contact the top surface of a ridge  22  of the light module  3  thereby creating a coupling connection. In one embodiment, the tabs  26  may be beveled to form an isosceles trapezoid or similar type of shape. The beveled shape of the tabs  26  provides an easier connection with the light module  3  that prevents deformation of the tabs  26  and the complimentary section of the ridges  22  of the light module  3 . In one embodiment, the tabs  26  on each of the trims  4 A,  4 B, and  4 C are identically shaped and sized. As described, the light module  3  and the trims  4  are directly coupled together through a simple twisting motion of the light module  3  relative to the trim  4  without the assistance of tools. 
     As noted above, the trim  4  comes into direct contact with the light module  3  after being coupled together. For example, the border surface  25  of a trim  4  may be in direct contact with the locking surface  20  of the light module  3 , such that the trim  4  and the light module  3  are coupled together. By being formed of thermally conductive materials and being directly connected, the trim  4  may create an uninterrupted thermal path from the light module  3  to the outside atmosphere. Accordingly, the light module  3  may be made smaller as heat dissipation is not only performed by the light module  3  itself, but also by an attached trim  4 . Traditionally, small LED light modules (e.g., 4-6 inches in diameter) were not used by manufacturers because of their poor heat dissipation and overheating issues caused by reduced surface area. For example, overheating may cause color shift and exponential decrease of lime-time if the Tc points of LEDs exceed the manufacturer&#39;s specification. By allowing the trim  4  to act as an additional heat sink, the light module  3  may be smaller in size. For example, the uninterrupted thermal path between the trims  4  and the light module  3  may allow dissipation of heat from a 20 W light source  13  for more than eight hours without degradation to the light source  13  or the power supply  14 . In one embodiment, a thermal paste may be applied between the abutting surfaces of the light module  3  and the trim  4  to further assist in the transfer and dissipation of heat. 
     In one embodiment, the trim  4  further includes one or more mounting blocks  27 . The mounting blocks  27  are protrusions, on the flange  24 , that support mounting arms  28 . The mounting blocks  27  may be symmetrical e.g., in pairs, across the aperture  23  such that they can uniformly support the trim  4  as the latter is coupled to the housing  2 . In one embodiment, the mounting blocks  27  are located between the border surface  25  and an outer perimeter of the flange  24  such that the mounting blocks  27  can be inserted into the cavity  8  while the flange  24  covers the hole in the ceiling or wall containing the lighting system  1 . 
     As seen in the example shown in  FIG. 5 , each mounting arm  28  includes two support brackets  29  that extend from a pivoting joint  30 . In one embodiment, the pivoting joint  30  is fixed at one of the mounting blocks  27  using any known method and device for coupling. For example, the pivoting joint  30  may be coupled to the mounting block  27  using any combination of resins, clips, screws, bolts, or clamps. The support brackets  29  may be v-springs, tension springs, or friction clips. The support brackets  29  are individually bendable about the pivoting joint  30  allowing the support brackets  29  to be bent and inserted into the cavity  8  of the housing  2 . Upon being inserted into the cavity  8  and released, the support brackets  29  engage the complementary retention brackets  9  that are attached to the walls of the cavity  8  (see  FIG. 2 ). The retention brackets  9  may be any device/component for receiving the support brackets  29  and firmly coupling the combined trim  4  and light module  3  to the housing  2 . For example, the retention brackets  9  may be slots formed in a sidewall that defines the cavity  8  as shown in  FIG. 2  or the hard, flat sidewall itself. 
     Traditionally, support brackets  29  or similar devices are located on the light module  3  instead of the trim  4 . However, housings  2  often use different retention brackets  9  that are not compatible with support brackets  29  on a particular light module  3 . By locating the support brackets  29  on the trim  4  as described herein instead of the light module  3 , only the relatively inexpensive trim  4  needs to be changed or replaced to be compatible with the retention brackets  9  of various housings  2 . Thus, a single light module  3  may be used with a variety of different housings  2 . 
     While certain embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that the invention is not limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those of ordinary skill in the art. The description is thus to be regarded as illustrative instead of limiting.