Patent Publication Number: US-9429307-B1

Title: Compact system for connecting an electrical supply to a lighting system

Description:
FIELD OF THE TECHNOLOGY 
     The present technology relates to lighting systems and more particularly to a system for connecting an electrical supply to a lighting fixture. 
     BACKGROUND 
     Installation of conventional lighting fixtures in cramped spaces is often challenging due to fixture size and awkward electrical connections. With conventional technology, a connection between an electrical supply and a lighting fixture housing can be unwieldy due to jutting connectors extending beyond available space. 
     Improved technology for connecting lighting fixtures to electrical supplies is needed. Need exists for a lighting connection system that is compact. Need exists for a lighting connection system that is low profile. Need exists for a lighting connection system that is suited for deployment in a plenum that is shallow or otherwise space restricted. Need exists for a lighting connection system that is economical or cost effective. Need exists for a lighting connection system that is installed readily, quickly, or economically. Need exists for a lighting connection system that is quick-connect or quick-disconnect. A capability addressing one or more such needs, or some other related deficiency in the art, would support illumination systems in multiple applications and deployment scenarios. 
     SUMMARY 
     A connector can provide a lighting system with connectivity to an electrical supply. 
     In one aspect, a lighting fixture can comprise a housing in which a light source is disposed. The housing can comprise a lower portion, an upper portion, and a side portion. The light source can be disposed between the lower portion of the housing and the upper portion of the housing. The side portion of the housing can extend between the upper and lower portions of the housing and about the housing. Thus, the side portion can span either the entire distance from the lower portion to the upper portion or a fraction of the entire distance. Light can emit from the lower portion of the housing into an area to be illuminated. Connectivity to the electrical supply can be provided via the side portion of the housing, resulting in a compact or low profile lighting system. 
     The foregoing discussion of lighting system connection is for illustrative purposes only. Various aspects of the present technology may be more clearly understood and appreciated from a review of the following text and by reference to the drawings and the claims that follow. Other aspects, systems, methods, features, advantages, and objects of the present technology will become apparent to one with skill in the art upon examination of the following drawings and text. It is intended that all such aspects, systems, methods, features, advantages, and objects are to be included within this description, covered by this document, and protected by the accompanying claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates, in perspective view, a representative lighting system that comprises an electrical connection system according to some example embodiments of the present technology. 
         FIG. 2  illustrates the electrical connection system for connecting a light housing to an electrical supply, with the connection in a partially connected state, according to some example embodiments of the present technology. 
         FIG. 3  illustrates the electrical connection system with the connection in a fully connected state according to some example embodiments of the present technology. 
         FIGS. 4A and 4B  (collectively  FIG. 4 ) illustrate two perspective, cut-away views of the electrical connection system with the connection in a fully connected state according to some example embodiments of the present technology. 
         FIGS. 5A and 5B  (collectively  FIG. 5 ) illustrate two perspective views of a bracket coupled with a conduit fastening system of the electrical connection system according to some example embodiments of the present technology. 
         FIGS. 6A, 6B, 6C, and 6D  (collectively  FIG. 6 ) illustrate orthonormal and perspective views of the bracket of the electrical connection system according to some example embodiments of the present technology. 
         FIGS. 7A, 7B, 7C, and 7D  (collectively  FIG. 7 ) illustrate orthonormal views of the lighting-fixture side of the electrical connection system according to some example embodiments of the present technology. 
     
    
    
     Many aspects of the technology can be better understood with reference to the above drawings. The elements and features shown in the drawings are not necessarily to scale, emphasis being placed upon clearly illustrating the principles of example embodiments of the present technology. Moreover, certain dimensions may be exaggerated to help visually convey such principles. 
     DESCRIPTION OF EXAMPLE EMBODIMENTS 
     A lighting system can be connected to an electrical supply. The connection can facilitate or support deployment of the lighting system in a cramped space, for example in a shallow overhead plenum. The lighting system can comprise a housing for a light source. One or more sides of the housing can extend about the light source, for example circumferentially around the light source or otherwise laterally enclosing the light source. The connection to the electrical supply can be provided at a side of the housing, resulting in a low profile and/or a compact format. 
     The present technology can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the technology to those having ordinary skill in the art. Furthermore, all “examples,” “embodiments,” “example embodiments,” or “exemplary embodiments” given herein are intended to be non-limiting and among others supported by representations of the present technology. 
     Connection technology for lighting systems will now be described more fully with reference to  FIGS. 1-7 , which describe representative embodiments of the present technology and illustrate various elements and views of a representative lighting system. 
     Turning now to  FIG. 1 , this figure is a perspective view illustration of an example lighting system  100  that comprises an example electrical connection system  125  in accordance with some embodiments of the present technology. The illustrated lighting system  100  provides an example of a lighting fixture incorporating the electrical connection system  125 . As will be discussed in further detail below with reference to subsequent figures, the electrical connection system  125  comprises a two-part, male-female electrical connector disposed within and protected by a mechanical connector. 
     In the illustrated embodiment, the lighting system  100  comprises a plaster frame  101  with accompanying hangar bars  105  to facilitate overhead mounting, for example recessed in a ceiling. Installation personnel can utilize a mechanical adjustment system  115  to tailor the system  100  according to installation specific mechanical and optical parameters. Other embodiments may be deployed in different overhead applications, mounted to a vertical surface, or otherwise deployed, without limitation. As will be discussed in further detail below, the example electrical connection system  125  is side oriented to facilitate installation, mounting, or deployment in cramped spaces, such as in shallow plenums. 
     In some example embodiments, the lighting system  100  may not include a plaster frame. To mention a representative example without limitation, the present technology can be readily utilized in remodel construction applications where a plaster frame does not exist. 
     In addition to mounting facilities, the illustrated lighting system  100  comprises a housing  120  for a light source (hidden from view in  FIG. 1 ). In various embodiments, the light source may comprise one or more light emitting diodes (LEDs), one or more incandescent lamps, one or more fluorescent bulbs, compact fluorescent light sources, or some other appropriate lighting technology. Beyond the illustrated plaster frame application, the housing  120  can be deployed in various other lighting applications. 
     As illustrated, the housing  120  is mounted with a reflector  110  that delivers light to an area to be illuminated, such as into a workspace, office, home, or studio, for example. In various embodiments, the reflector  110  may comprise one or more optical surfaces that may be diffusely reflective or specularly reflective, for example. In some example embodiments, the reflector  110  is funnel shaped so that the reflective surface tapers out towards the area to be illuminated. In some embodiments, the reflector  110  can be or comprise a lower part of the housing  120 . 
     The housing  120  may be viewed as having a lower end and an upper end, with the reflector  110  at the lower end and a cover  225  at the upper end. Those skilled in the art will appreciate that such upper and lower designations are used without implying that the housing  120  would necessarily be installed with the cover  225  up and the light emitting end down. For example, in a wall-mount scenario, a structure other than the plaster frame  101  might be utilized, and the cover  225  might be horizontal to the light emitting end. And in some other embodiments, the housing  120  may be mounted so that light emits skyward. Accordingly, in some installations, the lower end of the housing  120  may be at a higher elevation than the upper end of the housing  120  or the two ends may be at substantially equal elevations. 
     The illustrated lighting system  100  comprises an example electrical supply system  102 . As illustrated, the example electrical supply system  102  comprises a junction box  135  in which an alternating current (AC) supply line (not illustrated) is connected or terminated during installation. The supply line may carry 110 VAC (volts alternating current), for example. A power supply  140  is mounted adjacent the junction box  135  and converts the incoming AC electricity into an appropriate format for delivery to the light source. In the example of a light emitting diode based light source, the power supply  140  may comprise a driver that supplies direct current (DC) electricity or pulsed electricity, for example. In some example embodiments (not illustrated), a driver or other electrical power supply system is mounted at the upper end of the housing  120 . In various embodiments, the electrical supply system  102  can receive and/or deliver a wide variety of forms of electricity, including high voltage, low voltage, AC, DC, pulsed voltage, etc. as may be useful for applications involving compact fluorescent lamps (CFLs), LEDs, incandescent lights, and other light sources, to mention a few representative examples without limitation. 
     A conduit  130  houses and carries electrical lines (not visible in  FIG. 1 ) that extend from the power supply  140  to the housing  120  and conduct electricity for powering the light source. The conduit  130  is typically flexible, for example metallic interlock conduit, with the metallic composition providing electrical conductivity for an electrical ground. That is, ground current, if present, may flow along the conduit  130  via the conduit&#39;s metal composition. Other embodiments may utilize other conduits or tubes for housing electrical lines. Such conduits may be rigid in some embodiments and flexible in other embodiments and may be either conductive or nonconductive. A conduit composed of electrically insulating material may carry a dedicated ground wire in addition to wires forming an electrical supply circuit, for example. 
     Turning now to  FIGS. 2 and 3 ,  FIG. 2  is an illustration of the example electrical connection system  125  for connecting the light housing  120  to the electrical supply system  102 , with the connection in an example partially connected state, in accordance with some embodiments of the present technology. Meanwhile,  FIG. 3  is an illustration of the example electrical connection system  125  with the connection in an example fully connected state in accordance with some embodiments of the present technology. 
     As discussed above with reference to  FIG. 1  and as shown in  FIG. 2 , the electrical lines  215  run through the conduit  130  to provide electricity for the light source that is in the housing  120 . The electrical connection system  125  comprises an electrical connector  205  encased by a mechanical connector  201  that couples the conduit  130  to the housing  120 . 
     In the illustrated embodiment, the electrical connector  205  has a two-part, plug-and-socket configuration that supports quick connection and disconnection of the electrical supply circuit. The electrical connector  205  is typically installed on the electrical lines  215  during manufacture of the lighting system  100 , but alternatively may be field installed. 
     In some embodiments, a manufacturer can supply the housing  120  with a male connector on a pigtail segment of the electrical lines  215 . Thus, as shipped, a segment of connectorized electrical lines can dangle from the housing  120 . Similarly, the manufacturer may provide other elements of the electrical supply system  102  with a mating female connector on another segment of electrical lines. In this manner, acquirers may purchase lighting system elements that are compatible with one another and may configure lighting systems flexibly according to customer preferences and installation parameters. Thus, the electrical connection system  125  and the electrical connector  205  can support interchangeability of lighting system components. Additionally, field personnel can wire (and unwire) the lighting system  100  readily, efficiently, and economically; including during installation, trouble shooting, maintenance, service, upgrade, or other field operation or procedure. 
     As one alternative to the illustrated electrical connector  205 , the electrical connections can be made using lever nuts, push-in connectors, or other appropriate electrical connection technology known in the art. 
     In the illustrated example embodiment, the mechanical connector  201  houses and provides mechanical and environmental protection for the electrical connector  205  and associated electrical lines  215 . In addition to mechanical and environmental protection, the illustrated mechanical connector  201  provides an electrical ground between the conduit  130  and the housing  120 . In other words, the mechanical connector  201  provides an electrical path to conduct ground current as needed. The ground path can comprise metal-to-metal contact of adjoining elements, for example. 
     In the illustrated example embodiment, the mechanical connector  201  comprises a bracket  200 . The bracket  200  attaches on one side to the conduit  130  via a clamp  245 . Opposite the clamp  245 , the bracket  200  attaches to the housing  120  at an aperture  290 . The bracket  200  comprises two apertures  230  and an adjacent bent lip  275  facing the housing  120 . In the illustrated embodiment, the apertures  230  comprise slots but in other embodiments may take other appropriate forms. 
     In the illustrated embodiment, the bracket  200  bends over a cover  225  of the housing  120 , and two fasteners  210  attach to the cover  225  adjacent the aperture  290 . In some example embodiments, the fasteners  210  comprise threaded screws that engage corresponding threaded holes in the cover  225  of the housing  120  and have corresponding lock washers, O-rings, polymer inserts, or other appropriate retaining elements. 
     To make up the mechanical connection, an installer can loosen the fasteners  210  to provide a gap  212  under the fastener heads, as illustrated in  FIG. 2 . The installer can insert the bent lip  275  of the bracket  200  into the gap  212 , with the fasteners  210  in the corresponding apertures  230  of the bracket  200 . The installer can finger tighten one or both fasteners  210  so that the fastener heads capture the bent lip  275  of the bracket  200  as the gap  212  closes. 
     In some embodiments, the gap  212  under the fastener heads can be set at the factory so that the bent lip  275  of the bracket  200  is captured upon insertion, without necessarily tightening the fasteners  210  to close the gap  212 . For example, the gap  212  can be set so that in order to insert the bent lip  275  into the gap  212 , the installer would tilt the bracket  200  up (relative to the orientation shown in  FIG. 2 ) and finesse the leading edge of the bent lip  275  into the gap  212 . Once the installer maneuvers the bracket  200  into this gap  212 , the installer can allow the bracket  200  to tilt back to its relaxed, operating orientation (for example the angular position illustrated in  FIGS. 2 and 3 ). In this orientation, the fastener heads capture the bent lip  275  and retain the bracket  200  with the gap  212  factory-set. 
     With the bracket  200  captured by the fasteners heads, whether via finger tightening or by finessing into a preset gap  212 , the installer can tighten the fasteners  210  using a screwdriver or other appropriate tool hand tool. So tightened, the fasteners  210  retain the bracket  200  in an operational configuration, for example as illustrated in  FIG. 3 . 
     In the illustrated example configuration, the bracket  200  extends along the side of the housing  120 , adjacent heat sink fins  280  of the housing  120 , past a corner of the housing  120 , and over the cover  225  of the housing  120 . An extension  604  on the bracket  200  buts up to the side of the housing  120  and has an edge  603  that is curved to distribute contact along the housing periphery. In other embodiments, the extension  604  may have a linear edge, for example for contact with a flat side of a rectangular housing. 
     As illustrated, the electrical connection system  125  protrudes or juts from the side of the housing  120 , thereby facilitating mounting in limited access spaces, such as in a shallow overhead plenum or recessed in a wall. In the illustrated embodiment, the electrical connection system  125  (specifically the mechanical connector  201 ) protrudes from the cover side of the housing  120 . However, other embodiments may have the electrical connection system  125  in other locations. For example, in some embodiments, the electrical connection system  125  can be located towards the middle of a side of the housing  120 , at the light emitting end of the side of the housing  120 , or at some other appropriate side location. In various embodiments, one or more housing sides may have a geometry that is flat, oblong, tapered, cylindrical, square, rectangular, planar, or some other appropriate geometric form. 
     Turning now to  FIG. 4 , this figure provides illustrations, specifically two perspective, cut-away views, of the example electrical connection system  125  with the connection in an example fully connected state in accordance with some embodiments of the present technology. 
     The views of  FIG. 4  illustrate in further detail an example of how the fasteners  210  and the bent lip  275  can cooperatively retain the bracket  200  and cover the aperture  290  in the illustrated embodiment.  FIG. 4  additionally illustrates how the conduit  130  and the mechanical connector  201  provide a channel through which the connectorized electrical lines  215  (not illustrated in  FIG. 4 ) extend to supply power for the light source  409 . 
     As illustrated in  FIG. 4 , an example embodiment of the clamp  245  embraces and holds the conduit  130  to the bracket  200 . The illustrated clamp  245  comprises a screw  400 , a jam nut  410 , and an associated coupler  405 , as discussed in further detail below with reference to subsequent figures. 
     Turning now to  FIG. 5 , this figure provides illustrations, in two perspective views, of the example bracket  200  coupled with a conduit fastening system, as part of the electrical connection system  125 , in accordance with some embodiments of the present technology. 
     In the illustrated embodiment, the coupler  405  extends through an aperture in the bracket  200 , wherein the aperture is visible in  FIG. 6  and denoted by reference number  600 . The coupler  405  comprises a shoulder  501  on the conduit side of the bracket  200  and is threaded on the housing side of the bracket  200 . The threads mate with a jam nut  410 . When the jam nut  410  is tightened, the shoulder  501  and the jam nut  410  urge together against the bracket  200 . Thus, the jam nut  410  and the shoulder  501  cooperatively retain the coupler  405  with the bracket  200 . 
     The coupler  405  comprises an aperture  502  that receives an end of the conduit  130  (not illustrated in  FIG. 5 ). Once the conduit  130  is inserted in the aperture  502 , the screw  400  is tightened (for example with a screwdriver or other appropriate hand tool). Tightening the screw  400  advances the screw  400  into the side of the conduit  130 , so that the conduit end is captured as illustrated in  FIG. 4 . Thus, the tightened screw  400  impinges on the conduit  130  and may seat into and deform the conduit  130 . 
     As an alternative to the illustrated coupler  405 , the conduit  130  can be attached to the bracket  200  using a conduit clip or other appropriate fastening facility known in the art. In a representative embodiment, such a conduit clip can be positioned over the end of the conduit  130 , for insertion in the aperture  600  in the bracket  200 . When the conduit clip and the end of the conduit  130  are inserted in the aperture  600 , the conduit clip can squeeze around and grasp the conduit  130  firmly. Additionally, the conduit clip can comprise a strip of material that springs laterally outward in its relaxed state, so that the conduit clip is captured in the aperture  600  of the bracket  200  upon insertion. 
     Turning now to  FIG. 6 , this figure provides illustrations in orthonormal and perspective views of the example bracket  200  of the example electrical connection system in accordance with some embodiments of the present technology. 
       FIG. 6  further illustrates the extension  604  that is generally parallel to the surface  609  of the bracket  200 , with the surface  609  substantially perpendicular to the aperture  600  in the illustrated embodiment. The edge  603  of the extension  604  is curved to follow and contact the side surface of the housing  200 , as discussed above. Thus, the edge  603  and the side surface of the housing may have substantially matching contours. The illustrated geometries are examples; various other configurations, angles, and geometries may be utilized as appropriate. 
     In some example embodiments, the bracket  200  is made of a unitary metallic member that may be painted, powder coated, anodized, galvanized or otherwise surface treated, or left bare. In some embodiments, the bracket  200  is made from a single piece of sheet metal that is bent and punched for economical fabrication. In other embodiments, the bracket  200  may comprise two or more structural members that are fused, glued, welded, fastened, or otherwise joined together using appropriate joining technology known in the art. 
     Turning now to  FIG. 7 , this figure provides illustrations in orthonormal views of the lighting-fixture side of the example electrical connection system  125  in accordance with some embodiments of the present technology. More specifically,  FIG. 7  illustrates an example embodiment of the cover  225  of the housing  120 . 
     The teaching provided herein supports numerous embodiments, some of which will now be further discussed, without limitation. 
     Representative embodiments of a lighting connection system are described herein. In some embodiments, the lighting connection system can comprise a housing and a connector. The housing can be sized to accommodate a light source. The housing can comprise: a first aperture disposed to emit illumination produced by the light source; a first member disposed so that the light source, when installed in the housing, is between the first aperture and the first member; a second member that extends between the first member and the first aperture and that forms at least a portion of a side of the housing; and a second aperture disposed at least partially in the side of the housing. The connector can comprise: a bracket sized to cover the second aperture; a clamp that is operative to attach the bracket to a conduit; and a channel sized to pass an electrical line between the conduit and the housing. 
     In some embodiments of the lighting connection system, the first member comprises at least part of the second aperture. In some embodiments of the lighting connection system, the second aperture is disposed between the first member and the second member. In some embodiments of the lighting connection system, the bracket comprises a projecting edge. In some embodiments of the lighting connection system, the bracket comprises a third aperture sized to receive a fastener that attaches to the first member. In some embodiments of the lighting connection system, the bracket comprises a first region and a second region, and when the bracket is disposed to cover the second aperture, the first region adjoins the first member and the second region adjoins the second member. In some embodiments of the lighting connection system, the bracket comprises a lip that is bent for capture by a fastener that attaches to the first member. 
     Representative embodiments of a lighting fixture are described herein. In some embodiments, the lighting fixture can comprise a housing for a light source and a connector for an electrical supply. The housing can comprise: a lower portion that is mountable adjacent a plaster frame; an upper portion, wherein the light source is disposed between the upper portion and the lower portion; and a side portion extending between the upper portion and the lower portion and about the light source. The connector can protrude from the side portion. 
     In some embodiments of the lighting fixture, the side portion and the upper portion meet to form an edge, and the connector adjoins the edge. In some embodiments of the lighting fixture, the connector comprises a member that adjoins the upper portion of the housing and the lower portion of the housing. In some embodiments of the lighting fixture, the side portion comprises heat sink fins extending between the upper portion and the lower portion. In some embodiments of the lighting fixture, the connector is operable to connect a flexible conduit to the housing. In some embodiments of the lighting fixture, the connector comprises a bent lip. In some embodiments of the lighting fixture, the connector comprises a bracket, and the bracket comprises at least one slot sized according to a fastener that attaches the bracket to the housing. 
     Representative embodiments of a bracket for connecting an electrical supply to a lighting system are described herein. The bracket can comprise: a first flat portion that comprises a first aperture; a second flat portion that extends at an angle relative to the first flat portion and that comprises a second aperture sized to receive a fastener; and a lip operable to be retained by a head of the fastener when the fastener is disposed in the second aperture. 
     In some embodiments of the bracket, the angle is substantially perpendicular. In some embodiments, the bracket further comprises a third flat portion projecting from the first flat portion substantially parallel to the second flat portion. In some embodiments, the bracket further comprises a third flat portion extending from the first flat portion, the third flat portion curved according to a housing of the lighting system. In some embodiments of the bracket, the first flat portion, the second flat portion, and the lip are portions of a unitary member. In some embodiments of the bracket, a piece of sheet metal comprises the first flat portion, the second flat portion, and the lip. 
     Technology for connecting lighting systems to electrical supplies has been described. From the description, it will be appreciated that embodiments of the present technology overcome limitations of the prior art. Those skilled in the art will appreciate that the present technology is not limited to any specifically discussed application or implementation and that the embodiments described herein are illustrative and not restrictive. From the description of the example embodiments, equivalents of the elements shown therein will suggest themselves to those skilled in the art, and ways of constructing other embodiments of the present technology will appear to practitioners of the art.