Abstract:
A lighting fixture includes a housing formed from walls that are connected by corner posts that are inserted into the ends of the walls eliminate light leaks and external fasteners. The corner posts include barbs or screw holes for receiving screws from the inside of the walls. The housing can be used as a retrofit for a recessed lighting fixture where the housing can surround the lighting fixture and attach thereto. The assembly can then be mounted by a suitable support.

Description:
FIELD OF THE INVENTION 
     The present invention is directed to a surface mounted luminaire. The invention is particularly directed to a housing that can be attached to a recessed luminaire so that the luminaire can be mounted to a surface and to retrofit the luminaire. 
     BACKGROUND OF THE INVENTION 
     Various methods of constructing luminaires and housing for luminaires are known. One common method is to form walls from various panels that are connected by screws or other fasteners. These assemblies typically result in light leaks at the corners of the assembly. 
     U.S. Pat. No. 3,235,989 to Brooks discloses the general concept of a frame for an illuminated sign where the frame is formed from four panels connected together by L-shaped brackets. The brackets are attached to the frame panels by screws and bolts. 
     U.S. Pat. No. 3,863,372 to Stilling discloses a sign box where the frame is assembled from panels and L-shaped gusset members. The gusset members have two legs with a plurality of teeth for engaging a recess in the side panels to secure the panels together. 
     U.S. Pat. No. 4,267,657 to Kloke discloses an illuminated sign where the side panels of the frame are assembled using an L-shaped corner piece. The corner piece includes legs having a plurality of teeth to engage the inner surfaces of the corner panels. 
     U.S. Pat. No. 4,449,166 to Sharp discloses a lighting fixture and air flow support system including a surrounding frame for forming an air supply. The frame includes side panels that are connected together by an L-shaped corner piece. The corner piece is received in the open ends of the respective panels and secured by screws passing through the walls of the side panels. 
     U.S. Pat. No. 4,630,386 to Wilson discloses a reversible picture frame where the frame is constructed from side panels connected together by an L-shaped corner member having teeth for engaging the surfaces of the frame. 
     U.S. Pat. No. 4,851,971 to MacLagan discloses a transparency illuminator having a frame formed from four panels where the panels are connected together by L-shaped corner members 86 as shown in FIG. 4. 
     U.S. Pat. No. 6,592,237 to Pledger discloses a panel frame for providing ventilation to a lighting fixture. The panel frame as shown in FIG. 8 includes four panels coupled together by lugs 40 extending from one end of each of the panels. The lugs engage dimples 50 to connect the panels together. 
     WO 95/30979 discloses an illuminated display sign having an outer frame formed from panels coupled together by an L-shaped bracket. 
     JP 54-115574 discloses a housing formed from extruded panels that are coupled together by L-shaped clip members 9. The panels include grooves that engage the coupling member 6. 
     JP 2009-123545 discloses a picture frame having a lighting device inside the frame. The frame includes four extruded panels coupled together by an L-shaped corner member. 
     DE 32 43 8883 discloses a corner connection for a lighting fixture. The lighting fixture includes corner members for connecting a plurality of panels together for assembling a plurality of lighting fixtures together. 
     While various prior assemblies are generally suitable for their intended use, there is a continuing need for improved lighting assemblies and luminaires. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a surface mounted luminaire. The invention is particularly directed to a housing for a luminaire that does not exhibit light leaks in the corners of the housing. 
     The housing of the luminaire is formed by side walls having an opening at each end. An L-shaped corner post is inserted into the open ends to secure the walls together. 
     One feature of the invention is to provide a housing having walls connected together by a corner post where the corner post has barbs or hooks that connect to walls. 
     Another feature of the invention is to provide a luminaire formed from side walls and a corner post where the corner posts are coupled to the walls by screws, rivets, barbs, hooks, or other fasteners. 
     A further feature of the invention is to provide a retrofit assembly for a recessed luminaire to adapt the recessed luminaire to for surface mounting. 
     Another feature of the invention is to provide a housing for a luminaire having an adjustable mounting bracket that can be moved along the length of the housing to a selected position. 
     The various features of the invention are basically attained by providing a lighting assembly comprising a lighting fixture adapted for mounting in a ceiling to define a recessed lighting fixture. The lighting fixture has a first end wall, a second end wall, and a reflector extending between the end walls and defining a downwardly open chamber. A top member is coupled to the first and second end walls and a lamp base for supporting a lamp in the open chamber for directing light in a downward direction with respect to the lighting fixture. A mounting member is adapted for mounting the lighting fixture to a ceiling. A housing surrounds the lighting fixture and a coupling member for coupling the lighting fixture to the housing. The housing has a first end wall, a second end wall, a first side wall and second side wall. The first and second side walls extend between the end walls. The housing has a top surface adapted for surface mounting to a ceiling. 
     The features of the invention are also attained by providing a surface mounted lighting assembly comprising a lighting fixture having a first end wall, a second end wall, a ballast channel and at least one reflector. The ballast channel extends between the end walls, top face, and a lamp base for supporting at least one lamp for directing light in a downward direction with respect to the lighting fixture. The lighting fixture is a self-contained assembly adapted for use as a recessed lighting fixture. A housing has a first end wall and a second end wall, a first side wall and a second side wall. The first and second side walls are coupled to the end walls and define an internal cavity. The lighting fixture is positioned within the housing and are coupled thereto for supporting the lighting fixture within the housing. 
     The features of the invention are also attached by providing a method of retrofitting a recessed lighting fixture to a surface mount lighting fixture. The method comprises the steps of providing a lighting fixture adapted for mounting in a ceiling in a recessed position. The lighting fixture has a first end wall, a second end wall, a reflector extending between the first and second end walls, and is adapted for supporting a lamp holder for receiving a lamp. The lighting fixture is positioned in a housing and couples the lighting fixture to the housing. The housing has a first end wall, a second end wall, a first side wall and a second side wall. The first and second side walls extend between the end walls. The housing has an open top end adapted for surface mounting to a ceiling and an open bottom end. 
     These and other aspects of the invention will become apparent from the following detailed description of the invention which, in connection with the annexed drawings, disclose various embodiments of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following is a brief description of the drawings, in which 
         FIG. 1  is a bottom perspective view of the luminaire in a first embodiment of the invention; 
         FIG. 2  is a top view of the luminaire of  FIG. 1 ; 
         FIG. 3  is an enlarge perspective view of the corner of the luminaire of  FIG. 1 ; 
         FIG. 4  is an exploded view of the luminaire showing the housing and the lighting fixture; 
         FIG. 5  is a perspective view of a corner post in one embodiment of the invention; 
         FIG. 6  is a partial perspective showing the assembly of the walls to the corner post using screws; 
         FIG. 7  is a perspective view of the housing in the assembled condition; 
         FIG. 8  is a perspective view of the corner of the luminaire showing the walls connected to the corner post by inwardly bent tabs; 
         FIG. 9  is a perspective view of the corner showing the walls connected to the post by screws and tabs; 
         FIG. 10  is a perspective view of the corner showing the walls connected to the post by tabs that are bent along a horizontal line of the walls; 
         FIG. 11  is a perspective view of the corner showing the walls connected to the corner posts by rivets; 
         FIG. 12  is a top view of the wall sections in one embodiment of the invention; 
         FIG. 13  is a side view of the wall of  FIG. 12 ; 
         FIG. 14  is an end view of the wall of  FIG. 12  showing the reflector coupled to the wall; 
         FIG. 15  is a top view of the coupling bracket; 
         FIG. 16  is an end view of the bracket of  FIG. 15 ; 
         FIG. 17  is an exploded view of the assembly in another embodiment of the invention; 
         FIG. 18  is a top perspective view of another embodiment showing the mounting support; 
         FIG. 19  is a partial cross-sectional view showing the support connected to the side walls of the luminaire; 
         FIG. 20  is a top view of the corner bracket; 
         FIG. 21  is an end view of the corner bracket of  FIG. 20 ; 
         FIG. 22  is a top view of the corner post in another embodiment of the invention; 
         FIG. 23  is a side view of the corner post of the embodiment of  FIG. 22 ; 
         FIG. 24  is a top view of the corner post in a further embodiment of the invention; and 
         FIG. 25  is a side view of the corner post of  FIG. 24 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is directed to a luminaire assembly that can be mounted to a surface or suspended from a ceiling surface. The invention is particularly directed to a housing for a luminaire that can be adapted for a recessed lighting fixture for surface mounting the luminaire. 
     Referring to  FIG. 1 ,  FIGS. 1-7  show a first embodiment of the invention including a luminaire assembly  10  having a housing  12  and a light fixture  14 . As shown in  FIG. 1 , the light fixture  14  is mounted within the housing  12 . 
     The housing  12  as shown in  FIG. 2  includes side walls  16  and end walls  18  connected together to form a rectangular housing. The light fixture  14  is received within the opening of the housing  12  and coupled to the housing. The housing  12  in the embodiment shown has an open bottom end and an open top end defined by the side walls  16  and the end walls  18 . A coupling member  64  is coupled to the housing along a top edge for coupling to the top wall of the light fixture as shown in  FIG. 3 . The light fixture can be attached to the coupling member  64  by screws or other fasteners. 
     The light fixture  14  in the embodiment shown includes an outer housing  24  having a top wall  26 , end walls  28  and side walls  30 . As shown in  FIG. 1 , reflectors  32  are provided within the housing  24  for directing light in a downward direction. The light fixture  14  is preferably an assembled unit containing a ballast within the center cover  15 , and suitable electrical wiring and lamps within the lens  17 . In a preferred embodiment of the invention, the lighting fixture  14  is a recessed luminaire as known in the art that is adapted for mounting in a ceiling on various T-bar supports or other supporting structure. The recessed lighting fixture is preferably constructed so that the open bottom end lies flush with the bottom surface of the ceiling panel. 
     In one embodiment of the invention, the assembly  10  is adapted for retrofitting recessed lighting fixtures  14  for surface mounting or suspending from a ceiling. The housing  12  is constructed to enclose the lighting fixture  14  and to support the lighting fixture. The assembly  10  can then be attached to a ceiling or other surface directly or through various support structures. 
     The housing  12  is preferably constructed from side walls  16  and end walls  18  that are connected together by a corner post  34  as shown in  FIG. 5 . In the embodiment of  FIG. 5 , the corner post  34  is an extruded aluminum member having a substantially L-shape formed by two perpendicular legs  36 . Each leg  36  includes inwardly extending ribs  38  defining a longitudinal groove or slot  40 . 
     Referring to  FIGS. 12 and 13 , the side walls  16  are shown. In a preferred embodiment of the invention, the side walls  16  and end walls  18  are substantially the same except for the longitudinal length. Thus, the end wall  16  is shown for clarity although it will be understood that the end and side walls are constructed in a similar manner. Referring to  FIG. 14 , side wall  16  has an outer wall  42  defining the height of the housing with a top end  44  and a bottom end  46 . As shown in  FIG. 14 , the top end  44  extends inwardly perpendicular from the plane of the outer wall  42 . The bottom end  46  also extends inwardly perpendicular from the outer wall  42  a distance corresponding to the width of the top end. The top end  44  has a downwardly extending portion  48  and an inwardly extending flange  50 . The bottom end  46  has an upwardly extending lip  52 . As shown in  FIG. 14 , the ends of the side and end walls define a channel for receiving the legs of the corner post. 
     As shown in  FIG. 15 , the upwardly extending lip  52  has a dimension to mate with the outer edge of the reflector  32  to connect the reflector to the bottom end of the side wall. As shown in  FIG. 14 , the reflector in the embodiment illustrated has a curved portion  54  terminating with an outwardly extending portion  56 . An upwardly extending portion  58  extends from the outer edge of the outwardly extending portion  56 . A downwardly extending hook portion  60  extends at an incline with respect to the upwardly extending portion  58  for hooking onto the lip  52  and supporting the reflector and luminaire. 
     Referring to  FIG. 12 , the inwardly extending flange  50  includes one or more longitudinal slots  60 . In the embodiment shown, the slots  60  are positioned towards the longitudinal ends of the side walls and end walls. The side walls and end walls are angled at about  45  degrees as shown in  FIG. 4  to form a mitered corner between the side walls and the end walls. The downwardly extending portion  48  and the lip  52  as shown in  FIG. 13  include an opening or tab  62 . The coupling tab  62  is cut from the side wall along three sides to form a bendable tab that can be bent inwardly to couple with the corner post. 
     A coupling bracket member  64  shown in  FIG. 4  and  FIGS. 15 and 16  is provided for coupling the light fixture  14  to the housing  12 . As shown in  FIG. 15 , the coupling bracket  64  has a planar configuration with a plurality of screw holes  66 . A side edge  68  includes a bent tab  70  that extends substantially perpendicular to the plate of the coupling bracket  64 . The tab  70  has a dimension to be received within the slots  60 . 
     In one embodiment, the end walls and side walls of the housing  12  include a longitudinal slot  72 . The tab  70  of the mounting bracket  64  has a dimension to be received within the slot  72 . As shown in  FIG. 3 , the tab  70  is inserted into the slot  72  in the end wall so that the tab hooks to the end wall. Screws  74  are then passed through the screw hole  66  and into the top wall of the light fixture for coupling the light fixture to the housing. 
     The side walls and end walls of the housing can be coupled to the corner post by various methods. In the embodiment shown in  FIG. 6 , the side walls  16  and end walls  18  have a bendable tab  76  cut from the inner surface of the wall and a screw hole  78 . The corner post is inserted into the end of the side walls and end walls. The screws  80  are then threaded through the screw holes  78  and into the longitudinal slot  40  for coupling the side walls and end walls to the corner post as shown in the assembly of  FIG. 7 . 
     As shown in  FIG. 8 , the side walls and end walls can also be coupled to the corner post by bending the tabs  76  inwardly into engagement with the longitudinal slot  40 .  FIG. 9  also shows the side walls and end walls connected to the post by screws threaded through the screw holes  78 . In other embodiments, the side walls and end walls can have a tab  82  cut from the respective side wall and end wall that can be bent along a horizontal line parallel to the bottom edge of the side walls and end walls. The tabs  82  are bent inwardly into engagement with the longitudinal slot  40  in the corner post  34  as shown in  FIG. 10 . In another embodiment, a rivet  84  can be inserted through the screw hole  78  to attach the side walls and end walls to the corner post. In preferred embodiments, the side walls and end walls have a suitable hole and/or tab along the top edge and the bottom edge to provide secure coupling to the corner post. In still other embodiments, the top and bottom portions of the side and end walls can have bendable tabs or screws for coupling with the corner posts. 
     The corner post  34  and the mitered ends of the side walls and end walls provide a uniform and closed housing. The corner posts preferably have a longitudinal length corresponding to the height of the side walls and end walls as shown in  FIG. 6 . Preferably, the corner posts do not have openings that allow light to escape between the mitered seam between the side walls and the end walls.  FIG. 17  is an exploded view of the luminaire assembly showing the side and end walls coupled to the luminaire. As shown in  FIG. 17 , inner end walls  19  can be attached to the end walls  18 . The inner end walls  19  can also be formed as end walls of the luminaire. 
     Referring to  FIG. 18 , another embodiment of the invention is shown. The assembly  90  of  FIG. 18  includes a luminaire  92  and housing  94 . The luminaire  92  as in the previous embodiment, is preferably a luminaire suitable for mounting as a recessed assembly within a ceiling or surface so that the open bottom end of the luminaire is flush with the surface of the ceiling. The housing  90  includes side walls  96  and end walls  98 . The side walls  96  and end walls  98  are constructed substantially the same as in the embodiment of  FIGS. 12-14 . 
     In this embodiment, a corner support member  100  is coupled to the side walls and end walls to strengthen the housing. As shown in  FIGS. 20 and 21 , the corner member  100  has a substantially triangular shape with angled longitudinal ends  102 . The angled ends  102  form an angle of approximately 90 degrees for mating with the respective side wall and end wall. As shown in  FIG. 21 , the ends  102  are bent out of the plane of the body  104  and extend parallel to the body  104  to define a tab  106 . The tabs  106  are inserted into the slots  72  to couple the side walls and end walls together. The side walls and end walls are also coupled together by a suitable corner post as in the previous embodiment. The body  104  of the corner member includes a plurality of holes  108  that are adapted for receiving screws or other fasteners. The screws or fasteners can extend through the body and into the luminaire housing for coupling the luminaire to the housing. 
     In the embodiment of  FIG. 18 , the assembly includes a mounting or hanger structure  110  for suspending the assembly. The hanger  110  has a bottom wall  112  with a width to extend between the opposite side walls as shown. An upwardly extending side wall  114  extends perpendicular from the bottom wall. An inwardly extending flange  116  extends perpendicular from the side wall  14 . The bottom wall includes a hole  118  and the flange  116  includes a hole  120  for receiving a support rod  122 . The rod  122  can be solid or hollow for supplying wiring to the luminaire. The rod  122  is adapted for coupling to the hanger  110  and the a bracket or other support surface to suspend the lighting assembly  90 . The rod can also extend through the hanger and attach directly to the luminaire to support the luminaire and housing. The end walls of the housing can be attached to the top surface of the luminaire by screws extending downwardly through the lip of the end walls as shown in  FIG. 18 . 
     Referring to  FIG. 19 , the bottom wall  112  of the hanger has an outer end  124  with a downwardly extending lip  126 . The lip  126  has a downwardly extending portion  128  and an outwardly extending portion  130  parallel to the plane of the bottom wall and an upwardly extending flange  132  to define a hook-shaped end. The hook-shaped end as shown in  FIG. 19  hooks onto the downwardly extending lip  134  of the side wall. In this manner, the lip  126  hooks onto the side wall to support the assembly. A coupling plate  136  is attached to the end of the bottom wall  112  by screws  138 . The plate  136  has a length to overlie the lip  126  and the top surface  140  of the side wall to securely couple the hanger  110  to the side wall. The screws  138  can be loosened to allow the hanger to slide along the longitudinal length of the side walls to adjust the position of the hanger with respect to the side wall. The screws are then tightened to securely position the hangers in the desired location. 
     In the previous embodiment, the corner posts are connected to the side walls and end walls by screws, rivets or tabs. In another embodiment, the corner posts can be connected by hooks on the corner posts. Referring to  FIGS. 22 and 23 , the corner post  142  has a substantially L-shape as in the previous embodiment. Each leg  144  has an inwardly extending hook portion  146  at the top and bottom edges. The hook portion  146  has an inclined surface  148  to slide into the respective side wall and end wall and an end surface  150  perpendicular to the plane of the respective leg to hook into a slot  152  in the side wall  154 . 
     In another embodiment shown in  FIGS. 24 and 25 , a similar corner bracket  154  is shown. The bracket  154  includes inwardly extending hook portions  156  in the same manner as the embodiment of  FIG. 22 . In this embodiment, the outer corner of the L-shaped corner post has a curved profile  158  and a lip  160 . In this embodiment, the side walls are not mitered and have the ends cut perpendicular to the plane of the side walls. The side walls are snapped onto the corner post so that the ends of the side walls abut the lip  160  to form a smooth outer corner. 
     The housing of the invention is particularly suitable for retrofitting a recess luminaire for surface mounting. One aspect of the invention provides a method for retrofitting a recessed lighting fixture or luminaire. The housing is assembled around the luminaire so that the luminaire is supported by the housing. 
     While various embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made without departing from the scope of the invention as defined in the appended claims.