Abstract:
A recessed down-light fixture having a housing with a light source aperture, a control gear assembly containing control gear, and a guidance system that allows the control gear assembly to slide and align with the light source aperture. The aperture enables passage of a light source through a barrier such as a ceiling. The housing includes a latching or locking device for release and passage of components through the aperture for maintenance or re-lamping. The control gear assembly, or internal wiring compartment, includes a stop that secures the shuttle in a position above the aperture. The control gear assembly can then be detached and pass through the aperture, providing access to electrical components and splices within the assembly. A trim ring having a concealable surface is mounted around the aperture to increase the structural integrity of the aperture, allow for plastering and painting, and to provide a finished appearance.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to a down-light and specifically to a recessed down-light fixture mounted above a light source aperture in a ceiling where part of said down-light fixture moves out from behind the ceiling to provide access to a compartment within the fixture. 
       BACKGROUND OF THE INVENTION 
       [0002]    A recessed light or down-light is a light fixture that is recessed into a cavity or a plenum above a ceiling within a room or space. When installed, the down-light allows light from a lamp or other light source to shine through a light source aperture in the ceiling surface, concentrating the light in a downward direction as a broad floodlight or narrow spotlight. The down-light interior is typically difficult to reach for inspection, repair, adjustment, or replacement of lamps since the ceiling forms a physical barrier between the room side and the ceiling cavity side. 
         [0003]    Numerous ceiling frames for lighting down-lights are known in the art. Down-lights designed for recessing in a ceiling have been available for many years and designs and styles vary. Large light source apertures for down-lights are typically required in order to facilitate access for replacement of the light source and repair or replacement of any ballast, power supply, or other driver components. Larger light source apertures also facilitate inspection of electrical connections from below the ceiling without requiring special tools, difficult procedures, or complex designs. As the physical size of lamps and other light sources has significantly decreased over time, and the output and efficiency of said sources has significantly increased, there is current consumer demand in the market for recessed light fixtures with greatly reduced light source aperture sizes. To meet this demand new technologies are needed. 
         [0004]    Regardless of trends toward smaller light sources, which have greater visual and aesthetic qualities and desirability, the light source aperture must remain of such a size as to allow for access to the above indicated components. The minimum size of the light source aperture is typically dictated by both electrical codes and national safety standards as related to the ability to conduct inspection and repair. In most down-light designs, the light source aperture is typically large enough for manual access to internal components. 
         [0005]    A large trim ring has been a common solution to the need for accessibility for servicing and inspection of electrical components. Larger trim rings, however, often result in an appearance that is undesirable for consumers. They also add additional bulk and weight, which typically requires extra installation and finishing labor. 
         [0006]    Another solution has been to utilize a smaller light source aperture where access to components is made possible above the ceiling, often requiring access panels located on the floor above. Remote access to power supplies and ballasts has been yet another common means of accommodating a smaller light source aperture. This approach relocates the necessary means of access to a less visible location away from the down-light, which invariably requires additional electrical wiring, construction and installation work, with increased costs as a result. 
         [0007]    Some technological solutions that allow for a smaller light source aperture are evident in the patent literature. U.S. Pat. No. 6,402,350 discloses a down-light where a transformer housing can be pulled through an access point. A problem associated with the &#39;350 patent lies in the difficulty of accessing the transformer housing by hand. Another problem with the &#39;350 patent is the relative proximity of the compartment that houses the control gear to the heat producing light source, which can negatively affect the performance and lifespan of the control gear. U.S. Pat. No. 6,036,337 discloses a rotatable lamp assembly; however, the design does not, and is not, intended to improve access to components within the fixture. The side walls of the assembly of the ‘ 337  device have tracks on which the fixture can rotate. The &#39;337 fixture only moves along the tracks in a rotational manner to alter the projection of light and provide different types of lighting. 
         [0008]    U.S. Pat. No. 8,376,594 discloses a down-light having an assembly disposed in a housing, where a carriage moves along track and the socket can move horizontally or vertically. The &#39;594 patent does not disclose a means for moving the electrical components into a position aligned with the light source aperture. U.S. Pat. No. 5,291,381 relates to a lighting fixture with a mounting system in which the components are not detached from the fixture (or the mount) and, therefore, cannot fall to the floor when being removed or installed and cannot be misplaced. The &#39;381 patent does not disclose a means for repositioning components during removal from the fixture. 
         [0009]    Thus, it is readily apparent that there is a need for a small light source aperture recessed down-light fixture that provides easy access for servicing of components behind the ceiling barriers. Also needed is a down-light fixture that can increase the lifespan of the control gear by distancing control gear components from the heat produced by the light source, but still allow all critical components to be accessible for servicing and inspection. 
       SUMMARY OF THE INVENTION 
       [0010]    The present disclosure describes a down-light having components that can be separated during removal from behind a barrier such as a drywall ceiling and the like. Separating the components of the down-light during removal allows for a smaller light source aperture in the barrier. With currently available technologies, a light source aperture large enough to remove both the light source and electrical components simultaneously is typically required. The present disclosure describes a light source and electrical components that can be easily removed through the light source aperture in sequence as separate parts. This separation is accomplished through the use of a sliding shuttle adjacent to the light source. After the light source is removed, the shuttle is shifted to position the control gear assembly over the light source aperture. The control gear assembly can then be detached from the shuttle and removed through the light source aperture from behind the barrier. 
         [0011]    It is accordingly a primary object of the present disclosure to provide a recessed down-light with a wiring compartment, also herein referred to as a control gear assembly, which can be removed through a small light source aperture from behind a barrier such as a ceiling or wall. The down-light includes an operatively connected light source and a control gear assembly that removably attaches to a mobile shuttle allowing these components to be positioned over the light source aperture. The control gear assembly detaches from the shuttle and can be pulled downward through the light source aperture; thereby enabling access to electrical components for inspection, repair, and replacements. 
         [0012]    One advantage of the present disclosure is that it allows the control gear, including the ballast, or power supply, to sit in a location at a significant distance from the heat producing light source. The components inside the control gear enclosure are typically sensitive to heat, and prone to permanent damage or failure if operated at elevated temperatures. In situations where the control gear includes any kind of thermal protection devices, elevated temperatures often cause the fixture unintentionally turn on and off, in what is known in the industry as “nuisance tripping.” 
         [0013]    Ceiling cavities typically have the highest temperatures within any given room, as heat rises, so the elevated ambient temperatures add to the heat that the control gear itself produces. These elevated temperatures can cause the control gear to run at close to, or even above, its maximum recommended operating temperature. Proximity to a heat source like a hot lamp may often provide extra thermal energy that can cause components to fail. 
         [0014]    Proximity of both the lamp and the control gear to the light source aperture is a common design feature in the light fixture industry. The design of the present disclosure, however, offers a unique advantage by allowing the distance between the control gear and the light source to be increased or decreased by varying the horizontal fixture length and shuttle location behind the ceiling. The ability to adjust the distance between the control gear and the light source allows the operating temperatures of sensitive components within the control gear assembly to be optimized, while maintaining accessibility to these components. Further, the present disclosure allows for changes in distance between sensitive components and the light source without increasing the vertical height of the recessed fixture housing, which could require an undesirable reduction in ceiling height. 
         [0015]    The control gear assembly is removably attached to the shuttle and moves with the shuttle when attached, whereas the light source is not directly attached to the shuttle other than being tethered by a wire or electrical cable. The light source is removable without moving the shuttle. Independent movement between components and the shuttle allows the light source and various electrical components to pass through the light source aperture for easy access, rather than requiring a more difficult to reach and larger access behind the barrier. Further, since the light source does not have to be accessed from behind the barrier, a large light source aperture and trim ring are not required. Rather, a smaller light source aperture with a more aesthetically designed trim ring than would normally be required can be used. A smaller light source aperture obviates the need for a larger, less aesthetically appealing trim ring while complying with all required codes and standards for accessibility of internal components and connections behind the barrier. 
         [0016]    Various types of light sources are compatible with the down-light of the present disclosure. These light sources include a lamp, a bulb, a light emitting diode (LED), a metal halide lamp, a halogen lamp, an incandescent lamp, or a fluorescent lamp, and additional ceiling lights known in the art. In one embodiment of the present disclosure, the light source is comprised of light-emitting diodes (LEDs) and a heat sink. Alternative embodiments of the present disclosure include the use of various styles of lamp holders and light sources, such as a reflector-style lamp holder and lamps. 
         [0017]    The trim detail of the present disclosure may, in one embodiment, have a textured surface to promote better adhesion to plaster, spackle or similar filler materials, and paint. This method of installing and finishing the trim ring, where the trim ring is covered with a finishing material to make it unnoticeable, results in a true “trimless” appearance once the fixture installation is completed. 
         [0018]    One object of the invention is to provide a down-light built using a variety of lamps and light sources that is suitable for mounting in a multiplicity of ceiling arrangements or wall conditions. 
         [0019]    Another object of the invention is to provide a down-light that presents a small light source aperture in a ceiling. The smaller light source light source aperture obviates the need for a large trim ring covering the light source aperture. 
         [0020]    A further object of the invention is to provide a down-light configured so that tools are not necessarily required to access the light source, control gear assembly, or shuttle. 
         [0021]    A further object of the invention is to provide a down-light where the control gear assembly is on a sliding shuttle allowing components to be positioned above the light source aperture, thereby providing ready access to all components for inspection, replacement or repair. 
         [0022]    A further object of the invention is to provide a down-light where a thermal protection device is attached to a removable plate attached to the shuttle allowing it to move into view through the light source aperture for inspection, repair, or replacement. 
         [0023]    A further object of the invention is to provide a down-light where a light source, a cable, and associated wiring are attached to and strain-relieved to a removable control gear mounting plate attached to the shuttle. This arrangement allows the control gear assembly to move into view through the light source aperture, separate from the shuttle, and pass through the light source aperture to be accessible for inspection, repair, or replacement. 
         [0024]    A further object of the invention is to provide a down-light where the attachment point for the cable is on a removable control gear assembly. 
         [0025]    Yet another object of the invention is to provide a down-light having a guidance system that leads to the light source aperture for the shuttle to follow. The guidance system, in one embodiment, consists of tracks along a housing configured to allow both the light source and control gear assembly to be positioned over the light source aperture for removal. 
         [0026]    Additional objects and advantages will become apparent, and a more thorough and comprehensive understanding may be had, from the following description and claims taken in conjunction with the accompanying drawings forming a part of this specification. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]    The present invention and the manner in which it may be practiced is further illustrated with reference to the accompanying drawings wherein: 
           [0028]      FIGS. 1A, 1B, 1C, 1D, and 1E  are top perspective views of an exemplary down-light, where an exemplary control gear assembly and shuttle move from an initial point to an exemplary light source aperture before passing through an exemplary barrier, and FIG. 1 F is an exploded view of the shuttle and associated components; 
           [0029]      FIG. 2  is an elevated side view of an exemplary shuttle, with a magnified view of an exemplary track mechanism that the shuttle moves along; 
           [0030]      FIG. 3  is a bottom perspective view of the down-light, showing an exemplary trim ring fastening the down-light to the barrier; and 
           [0031]      FIGS. 4A, 4B, and 4C  are perspective views of an exemplary trim ring showing the various holes and fasteners for adjusting the height and orientation of the trim ring. 
           [0032]      FIGS. 5A, 5B and 5C  show a perspective and exploded view of an alternative embodiment of the light source that includes LEDs and a heat sink. 
           [0033]      FIG. 5D  shows perspective views of an alternative embodiment of the light source that includes LEDs, a heat sink and also including a reflector-style lamp holder. 
           [0034]      FIG. 6  is a perspective view of an exemplary trim ring showing a concealable surface on the trim detail. 
           [0035]      FIG. 7  is a cross sectional side view illustrating a thin plaster coat on the trim ring. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0036]    At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions, or surfaces consistently throughout the several drawing figures, as may be further described or explained by the entire written specification of which this detailed description is an integral part. The drawings are intended to be read together with the specification and are to be construed as a portion of the entire “written description” of this invention as required by 35 U.S.C. §112. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up”, “down”, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “vertically”, “upwardly”, etc.) simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly” and “outwardly” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate. 
         [0037]    As referenced in  FIGS. 1A-4C , a down-light  10  mounts behind a barrier  50  and passes through the barrier  50  to enable access to a light source  42  and a control gear assembly  34 , which includes the control gear  38  and the plate  36 , the cable  44 . The barrier  50  may include, without limitation, a ceiling, a wall, a door, a cabinet, a shelf, a display unit and a stage. The down-light  10  passes from behind the barrier  50  to enable access for inspection, repair, or replacement. In this manner, accessing the down-light  10  behind the barrier  50  is not necessary, since the internal mechanism of down-light  10  allows critical components to pass from behind the barrier  50 . Another advantage that the down-light  10  allows is that the space in barrier  50  through which the light source  42  passes, herein referred to as a passage point or light source aperture  24 , is maintained at a minimal size. Specifically, the mobility of the light source  42  allows for a smaller light source aperture  24  than would normally be required, without the use of a larger, less aesthetic trim ring. Rather, a smaller trim ring  30  is used around the light source aperture  24  while still complying with all required codes and standards for accessibility of internal components and connections. 
         [0038]      FIG. 1A  illustrates a recessed down-light  10  positioned behind the barrier  50 . The internal mechanism of release allows internal components of the down-light  10  to move from behind the barrier  50  through a small light source aperture  24  (as shown in  FIG. 1B ) to enable access to the light source  42  and associated electrical components. The capacity to move the light source  42  from behind the barrier  50 , rather than accessing the light source  42  behind the barrier  50 , facilitates inspection, maintenance, and replacement of the light source  42  and electrical components; and also allows for use of a smaller light source aperture  24  through the barrier  50 . The down-light  10  is suitable for mounting in a multiplicity of ceiling arrangements, lighting styles, and wall conditions. 
         [0039]    In  FIG. 1B , the light source  42  passes through the light source aperture  24  independently of the other components in the down-light  10  to provide access. The light source  42  is tethered to a cable  44 , so as not to completely separate from the control gear assembly  34 . The light source  42  only connects to the shuttle  12  via the cable  44  and does not connect directly to the shuttle  12 , while the control gear assembly  34  connects to moveable shuttle  12 , while maintaining independent movement through the barrier  50 . The entire unit, including the shuttle  12 , may be surrounded by a housing  20  (as shown in  FIG. 1E ) when installed. The shuttle  12  positions behind the barrier  50 , in a generally nonvisible area. The shuttle  12  forms a mounting frame for a wiring compartment for electrical components of the down-light  10 . 
         [0040]      FIG. 1C  illustrates the shuttle  12  slidably moving above the barrier  50  where the bottom end of housing  20  contains tracks to guide the shuttle  12  to a position over the light source aperture  24 . This process, where the shuttle  12  shifts over, puts the shuttle  12  in a position to where the control gear assembly  34  can be removed through the barrier  50 . In one embodiment, the shuttle  12  takes a substantially trapezoidal shape and is fabricated from a rigid metal material, such as aluminum. However, any number of materials may be used to fabricate the shuttle  12 . A thermal protector  48  may be included to provide a means of safety should the ceiling cavity become too hot. 
         [0041]    A control gear assembly  34  detachably joins within a slot  26  in the shuttle  12  (as shown in  FIGS. 1D and 1E ). The control gear  38  is mounted to a plate  36  that has a substantially rectangular shape. Plate  36  is sized and dimensioned to fit inside the slot  26  formed in the shuttle  12 . The control gear  38  is held into place by plate  36  (as shown in  FIG. 1E ). 
         [0042]    As illustrated in  FIG. 1B , the tabs  40  are on the bottom end of the shuttle  12 . The tabs  40  are defined by protruding members that extend from the shuttle  12 . The tabs  40  serve as a grip for sliding the shuttle  12  into position over the light source aperture to access the control gear assembly  34 . In this manner, the control gear assembly  34  can separate from the shuttle  12  and pass through the light source aperture  24 .  FIG. 1E  illustrates both the control gear assembly  34  and the light source  42  separated from the shuttle  12  and accessible from in front of the barrier  50  for inspection, repair, and replacement. 
         [0043]      FIGS. 1D and 1E  illustrate the shuttle  12  and the shuttle exterior  22  (as shown in  FIG. 1E ) which includes an outer surface  16  and an inner surface  18 . The inner surface  18  acts as enclosure for electrical components. The light source  42  may include, without limitation, a lamp, a bulb, a light emitting diode (LED), a metal halide lamp, a halogen lamp, an incandescent lamp, or a fluorescent lamp, and ceiling lights generally known in the art. The components that comprise the control gear  38  may include, without limitation, wiring, resistors, capacitors, junctions, ballasts, LED drivers, processors, power supplies, transformers and the like. A slot  26  (as shown in  FIG. 1E ) extends along a central section of the shuttle  12 . The slot  26  forms a passage way between the inner surface  18  and the outer surface  16 . 
         [0044]    The shuttle  12  moves along a track that extends along the barrier  50 . The mechanism for moving the shuttle  12  is manual in the preferred embodiment illustrated here; however, in certain embodiments the mechanism for moving the shuttle may be motorized. The shuttle  12  moves between an initial point and the light source aperture  24  in the barrier  50 . The automated functionality of the mechanism for moving shuttle  12  makes it such that no tools are required to access the light source  42 , control gear assembly  34 , or shuttle  12 . 
         [0045]    The shuttle  12  follows the linear track between the initial point and the light source aperture  24 . The linear track terminates at a stop mechanism  49  (as shown in  FIG. 2 ), which is configured to restrict movement of the shuttle  12  beyond the light source aperture  24 . In this manner, the control gear assembly  34  and the light source  42  and standard lamp holder  46  can be positioned directly over the light source aperture  24 . 
         [0046]    The stop mechanism  49  secures the shuttle  12  against the light source aperture  24 , while requiring a force to be applied to allow movement of the shuttle  12  back to the initial point. In one embodiment, the stop mechanism  49  is a ball bearing plunger incorporating a body and a spring loaded ball or pin to regulate movement of the shuttle  12 . In this embodiment, the ball seats into a notch in the shuttle  12 , until such time as sufficient pressure is applied to enable the ball to retract into the shuttle  12 , thereby allowing the shuttle  12  to move freely between the initial point and the light source aperture  24 . 
         [0047]    The light source aperture  24  is positioned in relation to the shuttle  12  to enable passage of the control gear assembly  34  and the light source  42  through the barrier  50 . It is significant to note that the present invention is effective in maintaining a smaller light source aperture  24  because the control gear assembly  34  does not have to be accessed from behind the barrier  50 . Rather, the control gear assembly  34  is shuttled over barrier  50  to the light source aperture  24 . The smaller light source aperture  24  eliminates the need for a larger, unsightly trim ring to cover a large light source aperture in the ceiling. Yet, all required codes and standards for accessibility of internal electrical components and connections behind the barrier  50  are met with the smaller light source aperture  24 . 
         [0048]    In some embodiments, the control gear assembly  34  detachably joins within the slot  26  in the shuttle  12  and has a substantially rectangular shape, which is sized and dimensioned to fit inside the slot  26  formed in the shuttle  12 . The control gear assembly  34  is held into place chiefly through a plate  36 . The plate  36  is located proximate to the outer surface  16  of the shuttle  12 , engaging the inner surface  18  along the longitudinal axis of the slot  26 . 
         [0049]    As referenced in  FIG. 2 , the stop mechanism  49  of shuttle  12  serves to locate and retain the shuttle  12  in a desired position relative to the light source aperture  24 . The stop mechanism  49  engages the tab  40  on the bottom end of housing  20  of the shuttle  12 . The tab  40  is defined by a protruding member that extends from the bottom end of housing  20  of the shuttle  12 . In some embodiments, there may be a second stop for locating and retaining the shuttle  12  in a desired position. Control gear assembly fastener  28  (shown in  FIG. 1E ) removably attaches the control gear assembly  34  to the shuttle  12 . Mechanical force is utilized to pull the control gear assembly  34  in a downward direction in relation to the shuttle  12 . 
         [0050]      FIG. 1F  shows the control gear assembly  34  separated from shuttle  12  and thermal protector  48 . 
         [0051]      FIG. 2  is an elevated side view of shuttle  12 , with a magnified view of a track mechanism that the shuttle moves along. Illustrated is a stop mechanism  49 , which engages the tab  40 . The shuttle housing  20  is shown in the magnified view adjacent to tab  40  and stop mechanism  49 . 
         [0052]      FIG. 3  illustrates light source aperture  24  surrounded by trim ring  30  (shown in  FIGS. 4A, 4B, 4C and 6 ). The trim ring  30  mounts around the light source aperture  24 , forming a rigid periphery to increase the structural integrity of the light source aperture  24  and also serve as a guide for the light source  42  moving through the light source aperture  24 . The trim ring  30  may include a plurality of holes  32  spaced around the trim ring  30  for receiving fasteners, such as bolts or screws. The fasteners pass through the barrier  50  and the holes  32  to secure the trim ring  30  into place around the light source aperture  24 . The holes  32  can have different heights and spacing to enable adjustments to the trim ring  30 . 
         [0053]      FIGS. 4A, 4B, and 4C  show the trim ring  30  being adjusted around the light source aperture  24  to create variable heights and orientations for the trim ring  30  in relation to the barrier  50 . This adjustability enhances the decorative effect and provides a better fitting for the down-light  10  when integrated into barriers  50  of various thicknesses. In some embodiments, the trim ring  30  has a plurality of holes  32  through which fasteners can pass through for rotatably adjusting the height and orientation of the trim ring  30 . The fasteners can include any bolt, screw, or rod known in the ceiling accessories industry. In one embodiment, the trim ring  30  is an aluminum cover that encircles the light source aperture  24 , from both sides of the barrier  50 . 
         [0054]      FIGS. 5A, 5B and 5C  show an alternative embodiment of the present disclosure that includes the use of LEDs  54  and a heat sink  52 .  FIG. 5D  shows an alternative embodiment that includes a reflector-style lamp holder  47 . 
         [0055]      FIGS. 6 and 7  show an embodiment of the present invention that includes a trim detail, the exposed area of the trim at the visible side of the barrier, having a concealable surface  56 . The concealable surface  56  of the trim detail may have a textured surface that allows for and facilitates its being covered with plaster, spackle or similar filler material and paint. This method of installing and finishing the trim ring  30 , where the trim detail is covered with material to make it unnoticeable, results in a true “trimless” appearance once the fixture installation is completed. In the typical “trimless” installation as disclosed herein, the only visible aspect of the down-light  10 , as seen from below, is light source aperture  24  in the barrier  50  containing the light source  42 . With the “trimless” design, the surrounding region of light source aperture  24  is relatively thin and has a concealable surface  56  which may be roughened, perforated or the like to facilitate binding to the cover material. A concealable surface  56  is useful for embedding in and enhancing the adhesion to a plaster coat  58 , drywall compound or similar materials, and may also be coated with a chemical coating to further enhance the adhesion. 
         [0056]    Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.