Abstract:
A light fixture ( 50, 250, 350 ) is formed from a plurality of parts that are substantially snap engageable, thereby simplifying assembly and requiring few or no tools. In one embodiment, the fixture ( 50, 250, 350 ) is installable from below through a ceiling orifice and supportable by the ceiling alone, without requiring permanent attachment to an existent support beam. In another embodiment, the fixture is provided with hanger supports for attachment to ceiling hangers. The light fixture includes a reflector ( 70 ) having an ellipsoidal geometry with improved lighting efficiencies. Also provided is a firebox ( 500 ) that houses a light fixture therein.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Application 60/403,698 filed Aug. 15, 2002, and U.S. Provisional Application 60/468,206 filed May 6, 2003. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates to light fixtures in general, and in particular to a down light fixture having a reflector with an ellipsoidal geometry and improved lighting efficiencies and is formed mostly from pieces that are snapped together.  
       BACKGROUND OF THE INVENTION  
       [0003]     Recessed lighting fixtures can be fairly complicated in both their manufacture and installation. A single lighting fixture is usually formed from several parts that are fixed or semi-permanently connected and presented to a consumer as an installable unit. Furthermore, such lighting fixture is usually not airtight and has an adequate or acceptable lighting efficiency.  
         [0004]     In most situations, a consumer purchases a specific lighting fixture to match a specific environment or decor. In addition, the selection of lighting fixtures, particularly when adding to an existing ceiling, is usually limited by the type or adequacy of ceiling support, since certain lighting fixtures require a permanent attachment to a structural support beam of some kind already situated within the ceiling. Furthermore, the ability to vary the appearance of the lighting fixture once installed is usually very difficult, requiring the disassembly or complete removal of the fixture from the ceiling. Thus, there are a variety of limitations a consumer must consider when purchasing a lighting fixture currently on the market.  
         [0005]     From a manufacturing perspective, complicated assemblies usually translate into increased costs to the consumer as a result of elaborate machinery and/or increased labor costs. Problems with permanent or semi-permanent connections are difficult to rectify, and lighting fixtures that employ such connections become vulnerable if one integral component breaks down or fails. In addition, lighting fixtures that are installable in a variety of environments must be equipped with the means to achieve such installation, which usually requires an assortment of fasteners and mounting assemblies. Thus, lighting fixtures that require permanent or semi-permanent connections, that are not easily varied in their appearance, and that must be adapted for installation in a variety of environments provide the consumer with a product that is unnecessarily expensive, complicated in construction and aesthetically and functionally limited.  
         [0006]     Furthermore, most existing down light fixtures are manufactured with hemispherical or spherical reflector cans that offer adequate lighting efficiencies.  
         [0007]     In addition, due to certain municipal requirements or the like, certain light fixtures must be made air right because any holes in the ceilings result in energy loss through the loss of heating and/or cooling escaping through such ceiling openings. Accordingly, it is beneficial to have an airtight light fixture to avoid energy losses normally associated with non-air tight structures.  
         [0008]     There is a need, therefore, for a light fixture that is simple and inexpensive to manufacture, easy to install and operate and variable in its presentation, is preferably airtight and has a reflector can with improved lighting efficiencies.  
       SUMMARY OF THE INVENTION  
       [0009]     A down light fixture is formed from a plurality of parts that are substantially snap or slide engageable. In one embodiment, the fixture is installable from below through a ceiling orifice and supportable by the ceiling alone, without requiring permanent attachment to an existent support beam. In another embodiment, the fixture is provided with hanger supports for attachment to ceiling joist hangers. The light fixture preferably includes an airtight can adapted to receive a lighting unit and a reflector insertable into said can, said reflector having an ellipsoidal geometry with improved lighting efficiencies. Also provided is a firebox that houses said light fixture. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]      FIG. 1  is a perspective view of one embodiment of the light fixture of the present invention.  
         [0011]      FIG. 2  is an exploded view thereof.  
         [0012]      FIG. 3  is an exploded view of the reflector assembly.  
         [0013]      FIG. 4  is an exploded view of the lighting assembly of the invention.  
         [0014]      FIG. 5  is an exploded view of the junction box of the present invention.  
         [0015]      FIG. 6  is a cross-sectional view of the light fixture of the invention taken through its longitudinal axis.  
         [0016]      FIG. 7  is a side elevation of the light fixture of the invention.  
         [0017]      FIG. 8  is an elevation view of the light fixture installed in a ceiling.  
         [0018]      FIG. 9  illustrates the lighting unit of the invention.  
         [0019]      FIG. 10  illustrates the movement of the lighting unit during installation of the fixture.  
         [0020]      FIG. 11  is a perspective view of an alternative embodiment of the light fixture of the present invention.  
         [0021]      FIG. 12  is an exploded perspective view thereof.  
         [0022]      FIG. 13  is an assembled side view thereof shown in cross-section.  
         [0023]      FIG. 14  is an exploded perspective view of an alternative embodiment of the light fixture of the present invention.  
         [0024]      FIG. 15  is an assembled side view thereof shown in cross-section.  
         [0025]      FIG. 16  is a perspective view thereof shown with hanger attachments for installation of the light fixture of the invention.  
         [0026]      FIG. 17  is an exploded perspective view of one embodiment of a firebox of the present invention for housing a light fixture of the present invention.  
         [0027]      FIG. 18  illustrates a light fixture housed in the firebox of  FIG. 17 .  
         [0028]      FIG. 19  is a perspective view of the firebox thereof shown without the insulation.  
         [0029]      FIG. 20 . is a perspective view of the firebox of the invention with insulation retainers. 
     
    
     DETAILED DESCRIPTION  
       [0030]     The following detailed description is of the best mode or modes of the invention presently contemplated. Such description is not intended to be understood in a limiting sense, but to be an example of the invention presented solely for illustration thereof, and by reference to which in connection with the following description and the accompanying drawings one skilled in the art may be advised of the advantages and construction of the invention. In the various views of the drawings, like reference characters designate like or similar parts.  
         [0031]      FIGS. 1-10  illustrate a first embodiment of a light fixture  50  of the present invention, which generally comprises a can  60 , a reflector  70 , a ceiling plate  80  that serves as a decorative trim member, a lighting unit  90  ( FIGS. 9-10 ) and a junction box  100 . The light fixture  50  is preferably airtight, so it can be installed in a variety of locations, and it is mostly assembled using slidable and/or snap-fit connections. The fixture is particularly suited for both new construction and as a retrofit for existing installations.  
         [0032]     The junction box  100  houses the lighting unit  90  ( FIGS. 4 and 5 ) and is attached to a ballast  110  at the rear thereof and to the can  60  at the front thereof. The ballast  110  attaches to the junction box  100  via the slidable engagement of pins  112  ( FIG. 2 ) on the ballast  110  with slots ( FIGS. 4 and 5 ) at the rear of the junction box  100 . The junction box  100  is provided with removable panels  104  to accommodate wiring and the like, each panel  104  being provided with removable cutouts  105  for wiring access. The junction box  100  is also provided with a junction box cover  107  and a wiring compartment cover  108 , which are each capable of snapping onto the junction box  100 .  
         [0033]     The ballast  110  being both part of and mounted outside of the junction box  100  is unique in the industry for new work installations. The ballast is usually outside of the function box so it runs cooler and therefore more efficiently. However, because the ballast  110  of the invention is outside of the junction box  100  (yet slidably attached thereto), versus standard installations where it is attached to a framing kit (not shown), servicing the fixture  50  of the present invention is easily performed by removing entire fixture  50  from the ceiling without first having to remove the ballast  110  inside the ceiling to service the unit. This capability eliminates the need for a framing kit, unless it is specified by contractor.  
         [0034]     The interlock between the can  60  and the junction box  100  allows such parts to slide together easily to become a single unit. This is unique in the industry and provides two options to install the fixture  50 , either in new or retrofit installations. It is possible to pre-install the fixture  50  before the ceiling is constructed or after the ceiling is in place. For example, when the lighting inspector inspects wiring he doesn&#39;t have to pull out entire ceiling and can inspect fixture splices in highly accessible manner. It also simplifies the servicing and cleaning process.  
         [0035]     The lighting unit  90  ( FIGS. 9 and 10 ), which comprises a lighting socket  91  and socket holder  92 , is slidably engaged with the interior sidewalls  106  of the junction box  100  ( FIG. 5 ). The socket holder  92  is comprised of two parts (see  FIG. 4 ) that sandwich the socket  91  and snap together, eliminating the need to screw in the socket  91 , which is currently standard industry operating procedure. A socket hinge  93  and junction box pin  94  are attached to the lighting socket  91  for pivoting of the lighting socket  91  within the junction box  100 . Specifically, the socket holder  92  is initially angled downward under the influence of gravity for easy insertion of a lamp element  95  therein and for changing of lamps thereafter (re-lamping), particularly when the lighting socket  91  is already installed in a ceiling  200  ( FIG. 8 ). This functional design is unique to the industry. Subsequent to insertion of the lamp element  95 , attachment of the ceiling plate  80  to the can  60  as described below causes the ceiling plate  80  to push against the junction box pin  94 , which causes the socket holder  92  to rotate about the socket hinge  93  and thereby reorient the lighting socket  91  and lamp element  95  into a substantially horizontal position ( FIG. 6 ). Thus, as the reflector  70 , which has an ellipsoidal geometry, is shaped in a fairly close relation to the lamp unit  95  ( FIG. 6 ), which results in the lighting unit  90  producing an overall efficiency of greater than approximately 84%, it is beneficial that the socket holder  92  is capable of pivoting away from the reflector  70  for easy manipulation of the lamp unit  95  relative to the reflector  70  and the socket  91 . This eliminates the need to have holes in the fixture  50  for the insertion and removal of lamp elements  95 . Accordingly, pin-based CFL (compact fluorescent lamps) lamps, which have to be snapped into sockets, can now be snugly fitted without error, which is particularly important with horizontally-positioned lamps where servicing and removal are difficult.  
         [0036]     The can  60  has a first closed end  62  positionable in a ceiling  200  and a second free end terminating in a flange  64  ( FIG. 2 ). The flange  64  is preferably circumferentially dimensioned so that it will not pass through a ceiling orifice  210  ( FIG. 8 ) through which the light fixture  50  is installed. At least one retaining member  65 , and preferably a plurality of retaining members  65  for retaining the can  60  in a ceiling location  200  are disposed on the can  60  and preferably around the flange  64  as shown in  FIGS. 1-3  and  7 - 8 . The can  60  is inserted from its first end  62  through a ceiling orifice  210  from below the ceiling  200  until the rear surface of the flange  64  abuts the exposed surface of the ceiling  200 .  
         [0037]     Prior to or after insertion of the can  60  through a ceiling orifice  210 , the reflector  70  is snapped into the can  60 . Due to its ellipsoidal geometry, which creates the form factor of the reflector  70  and achieves superior light output efficiencies, the reflector  70  is uniquely designed to maximize the light output and efficiency. Such ellipsoidal geometry is preferably achieved using injection molded technology. Current tests reveal a lighting efficiency of approximately 84%.  
         [0038]     As shown in  FIGS. 2 and 3 , the ceiling plate  80  is provided with at least one tab  82 , and more preferably, a plurality of tabs  82  extending inwardly from a peripheral rim  84 . Due to the thinness of the can flange  64 , the clearance between the tabs  82  and rear surface of the ceiling plate  80  is relatively small. The peripheral edge of the can flange  64  has a series of arcuate sections  67  and planar sections  66 , with the front surface of the flange  64  being entirely planar. The rear surface of the flange  64  is formed with ramped portions  68  with the thickness of the flange  64  varying from approximately 2 mm to approximately 1 mm along such ramped portions  68 .  
         [0039]     Initially, the ceiling plate  80  is brought into overlapping alignment with the can flange  64  so that the ceiling plate tabs  82  are situated adjacent to the planar sections  66  of the can flange  64  and not securely fastened to the flange  64 . Then, the ceiling plate  80  is rotated clockwise, so that the tabs  82  slide onto the ramped portions  68  along the rear surface of the can flange  64  until the tabs  82  encounter stops  69  ( FIG. 3 ) formed by the ends of the ramped portions  68 , and thus becomes securely fitted to the can flange  64 . Removal of the ceiling plate  80  from the can flange  64  is accomplished by a counter-clockwise rotation of the ceiling plate  80  with respect to the can flange  64 .  
         [0040]      FIGS. 1-3  and  7 - 8  illustrate the retaining members  65  used to fasten the can  60  to the ceiling  200 . The primary component of a retaining member  65  is a movable flag-like member (flag)  65   a  threaded on a threaded fastener  65   b , which threaded fastener  65   b  has been passed through the can flange  64 . The flag  65   a  is positioned between a short post  65   c  and a tall post  65   d  ( FIG. 2 ). Initially, the flag  65   a  is positioned directly over the short post  65   c  as shown in  FIGS. 3 and 7  and lies adjacent the can  60 . Initially, the flag  65   a  is also positioned such that it does not extend beyond the peripheral edge of the can flange  64 . There is a tight engagement between the flag  65   a  and fastener  65   b  so that the flag  65   a  turns with the fastener  65   b  when the flag  65   a  is not abutting one of the posts  65   c,d  or the can  60 . Counter-clockwise (fastening) rotation of the threaded fastener  65   b  via the flange  64  causes the flag  65   a  to rotate counter-clockwise with the fastener  65   b  until the flag  65   a  abuts the larger post  65   d  and extends beyond the periphery of the can flange  64 . Continued rotation of the threaded fastener  65   b  while abutting the larger post  65   d  causes the flag  65   a  to thread or move downwardly along the fastener  65   b  and the larger post  65   d  until the flag  65   a  engages the ceiling  200 . Clockwise rotation of the fastener  65   b  causes the flag  65   a  to rotate with the fastener  65   b  clockwise until such flag  65   a  abuts the shorter post  65   c . Continued clockwise rotation of the threaded fastener  65   b  causes the post-abutting flag  65   a  to thread or move upwardly until the flag  65   b  clears the shorter post  65   c , at which point the flag  65   a  continues a clockwise rotation with the fastener  65   b  until the flag  65   a  clears the periphery of the can flange  64  and lies adjacent the can  60  as shown in  FIGS. 3, 7  and  8 .  
         [0041]     The light fixture design enables the fixture  50  to be installed in one of two ways. The first is the “new construction” method, whereby the junction box  100  is wired up before the ceiling  200  itself is installed. Subsequently, the can  60  is attached to the junction box  100  by simply sliding the two pieces  60 ,  100  together ( FIG. 3 ). The second or “retro-fit” method is done after the ceiling  200  is installed, and the fixture  50  is inserted in one piece.  
         [0042]     The light fixture  50  is initially assembled to the extent shown in  FIG. 1 , but without attachment of the lamp unit  95  or the ceiling plate  80 . Such partially assembled light fixture  50  is then inserted through an orifice  210  in the ceiling  200  until the can flange  64 , and more particularly the rear surface thereof, abuts the exposed surface of the ceiling  200 . The can flange  64  is dimensioned to prevent complete or over insertion of the light fixture  50  through the ceiling orifice  210 . Once the flange  64  has been positioned against the exposed surface of the ceiling  200 , the threaded fasteners  64   b  are tightened until the flags  65   a  abut posts  65   d , thereby extending beyond the periphery of the ceiling orifice  210 , and continued tightening of the fasteners  65   b  causes the flags  65   a  to move downward until such flags  65   a  clamp the unexposed surface of the ceiling  200  as shown in  FIG. 8 , thereby securing the can  60  and the junction box  100  to the ceiling  200 . Once the can  60  and junction box  100  have been secured to the ceiling  200 , a lamp unit  95  is inserted into the downwardly-angled socket  91  ( FIG. 9 ), after which the ceiling plate  80  is rotatably and securely engaged with the can flange  64  through the movement of tabs  82  along ramped portions  68  as previously described. Attachment of the ceiling plate  80  to the can flange  64  causes the ceiling plate  80  to impact against the junction box pin  94  ( FIG. 9 ), which causes the socket  91  and lamp unit  95  to rotate into a position shown in  FIG. 6 . Later removal of the ceiling plate  80  from the secured light fixture  50  is as easy as rotating the ceiling plate  80  in the opposite direction so that tabs  82  become aligned with the planar portions  66  of the can flange  64 . Later withdrawal of the fixture  50  from the ceiling  200  through a ceiling orifice  210  is also as easy as rotating the threaded fasteners  65   b  until each flag  65   a  lies adjacent to the can  64  and no longer extends beyond the periphery of the ceiling orifice  210 .  
         [0043]     It should be appreciated that the light fixture  50  of the present invention is secured directly to the ceiling  200  via retaining members  65   a , and does not require attachment to a support beam or the like, which support beam may or may not be present in a desired lighting location. It should also be appreciated that the thinness of the flange  64  and the relative thinness of the ceiling plate tabs  82  and peripheral edge  84  of the ceiling plate  80  allows the ceiling plate  80  to securely engage the flange  64  and lie flush against the exposed ceiling surface  200  after engagement.  
         [0044]     It should also be appreciated that most of the components that form the lighting fixture  50  are snap engageable or slidably engageable. In fact, it is only during the rotation of the retaining members  65   b  in the embodiment described above that an external tool is required. The ease with which the entire lighting fixture snaps together also allows for variations in the aesthetic (viewable) components, such as the ceiling plate  80  and any other components visible from below the ceiling  200 .  
         [0045]      FIGS. 11-13  illustrate an alternative embodiment of a light fixture  250  of the present invention, wherein the can  261  and junction box  262  are molded as a single unit  260  and are preferably formed from polycarbonate, although other materials may be used. The junction box  262  is attached to a ballast  310  at the rear thereof via the slidable engagement of the ballast pins  312  ( FIG. 12 ) with slots (not shown) provided at the rear of the junction box  310  in the same manner as discussed in connection with the engagement of the ballast  110  and junction box  100  of  FIGS. 1-10 . A self-ventilating “louvered” system (vents  264 ) is provided above the lamp unit  295  and socket  291  to release heat and prevent heat build-up, thereby improving light output efficiency. The lamp socket  291  is secured between the socket holder  292  plate and a back plate  293 , which clip together. The combined can/junction box  260  has knockouts  304  molded into both sides of the junction box  262  for electrical connections. A baffle  255  clips into the can  261  using cantilever clips  256 , making it removable. The ceiling ring  280  has a low profile and clips into the baffle  255 . This snap-in ceiling ring  280  insures simpler removal from the ceiling. A reflector  270  is secured to the can  261  by screws (not shown), which is an industry safety advancement, because it enables safe cleaning of the reflector  270  without the possibility of electric shock. Ellipsoidal geometry (see  FIG. 12 ) is used to create the form factor of the reflector  270 , achieving superior light output efficiencies on the order of approximately 84%. The junction box  262  also has hinged lids  263 ,  265 ,  267  for ease of wiring, whereas top lid  267  is provided for access to the lighting socket  291 . The can  261  also has a plurality of holes  266  (four holes being shown for purposes of illustration) on top for fastening a framing kit (not shown) thereto.  
         [0046]     The light fixture  250  of  FIGS. 11-13  is installed as a single unit through a ceiling orifice and is attached to a ceiling through the use of retaining members as described in connection with  FIGS. 1-10  or through the use of a framing kit attachable to the can  261  via holes  266 . A critical feature of the light fixture  250  of this embodiment is the ellipsoidal geometry of the reflector  270 , which produces light output efficiencies that are superior to spherical-type reflectors. As with the first described embodiment of  FIGS. 1-10 , mostly all of the components of the light fixture  250  snap or slide together or are engageable together without the use of tools or the like.  
         [0047]      FIGS. 14-16  illustrate yet another embodiment of a light fixture  350  of the present invention, wherein the reflector  370  and junction box  362  are molded as a single unit  360  and preferably formed from polycarbonate, although other materials may be used. The embodiment of  FIGS. 14-16  is smaller than the embodiment of  FIGS. 11-13 , such that, for example, the embodiment of  FIGS. 11-13  might illustrate an eight-inch can  261 , while the embodiment of  FIGS. 14-16  might illustrate a six- or seven-inch can  361 . The reflector  370  is part of the can  361  instead of a separate part that is fastened inside. Ellipsoidal geometry, is used to create the form factor of the reflector  370 , achieving superior light output efficiencies. The junction box  362  is also a part of the can  361 , such that the can  361 , junction box  362  and reflector  370  are a single unit. A fluorescent lamp socket  391  clips into a polycarbonate (or other material) socket bracket  392 , which slides into the junction box  362  and is held in place by ribs (not shown). The junction box  362  has knockouts  404  molded into both sides for electrical connections, and lids  365 - 367  for easy access to the inside of the junction box  362 . A baffle  355  clips into the can  361  using cantilever clips  356 , making it removable. The ceiling ring  380  has a low profile and clips into the baffle  355  and insures simpler removal from the ceiling. Hanger bar supports  400  are molded into the junction box  362  and are provided instead of a separate framing kit. Steel hanger bars  410  slide in through the supports  400  and are secured using set screws to ceiling joists (not shown).  
         [0048]     The light fixture  350  of  FIGS. 14-16  is preferably installed using the hanger bars  410  and hanger bar supports  400  as part of a new construction. A critical feature of the light fixture  350  of this embodiment is the ellipsoidal geometry of the reflector  370 , which produces light output efficiencies that are superior to spherical-type reflectors. As with the first two described embodiment of  FIGS. 1-13 , mostly all of the components of the light fixture  350  snap or slide together or are engageable together without the use of tools or the like.  
         [0049]      FIGS. 17-20  illustrate a firebox  500  of the present invention that is used to house a light fixture therein. Such firebox  500  may be installed in a ceiling prior to installation of a light fixture therein, or the firebox  500  and a light fixture may be installed as a combined, single unit. For purposes of explanation, the light fixture  350  of the embodiment of  FIGS. 14-16  will be used to illustrate a light fixture contained within the firebox  500 .  
         [0050]     The firebox  510  is preferably fabricated from twenty-four gauge (0.024 in) galvanized sheet metal and provided with triangular protrusions  520  extending from the top of each sidewall to secure insulation when bent ninety degrees inward. One and one-half inch thick mineral wool insulation is provided on all sides  530 ,  532 ,  534 ,  536  and top  538 , and held in place by four galvanized sheet metal retainers  540  riveted (via rivets  542 ) to the firebox front and back walls  512 ,  514 . Since the top of the firebox  510  is open, the upper piece of insulation  538  provides the only upper insulative barrier for a light fixture housed therein. A quarter-inch compressed fiberglass pad  539  on the bottom of the firebox  500  acts as an insulator against the ceiling sheet rock (not shown), and is preferably provided with a hole  541  for accommodating the can or baffle of the light fixture housed within. A light fixture  350  is secured inside the firebox  510  and has a flexible wire housing  351  that connects through a wiring hole  513  in the front  512  of the metal firebox  510  where external wires are connected. Of course, while certain dimensions and materials are discussed herein, it will be understood that other materials and dimensions could be used as desired.  
         [0051]     While the present invention has been described at some length and with some particularity with respect to the several described embodiments, it is not intended that it should be limited to any such particulars or embodiments or any particular embodiment, but it is to be construed with references to the appended claims so as to provide the broadest possible interpretation of such claims in view of the prior art and, therefore, to effectively encompass the intended scope of the invention. Furthermore, the foregoing describes the invention in terms of embodiments foreseen by the inventor for which an enabling description was available, notwithstanding that insubstantial modifications of the invention, not presently foreseen, may nonetheless represent equivalents thereto.