Patent Publication Number: US-11047554-B2

Title: Adjustable trim collar for a light fixture

Description:
TECHNICAL FIELD 
     Embodiments of the technology relate generally to light fixtures and more particularly to a light fixture trim that is easily adjustable. 
     BACKGROUND 
     Light fixtures (or luminaires) often include multiple components, such as a housing and a light module containing a light source. Light fixtures that are recessed often include a trim, also referred to as a trim assembly or finishing section. Recessed light fixtures are typically installed in a ceiling and the trim can perform light reflecting or altering functions, as well as provide an aesthetically pleasing appearance for the recessed light fixture. 
     Some recessed light fixtures have trims called directional trims that are configured to reflect light from the light fixture in a particular desired direction, such as towards a wall or display. In certain situations, the housing for the light fixture must be installed in a particular orientation so that when the directional trim is installed in the light fixture at a later time, the directional trim is in the proper orientation. However, a problem encountered with the installation of recessed light fixtures with directional trims is that in some instances, the housings for the recessed light fixtures are installed in an incorrect orientation for the directional trim that will be installed at a later time. In other words, existing directional trims have attachment mechanisms, such as torsion springs with brackets, that only fit within the light fixture housing in certain orientations. When the recessed light fixture housing is installed in the wrong orientation, the existing directional trims will also have the wrong orientation when inserted into the incorrectly installed recessed light fixture housing. When these problems are encountered, the housing must be removed and reinstalled in the correct orientation in order for the later inserted directional trim to have the correct orientation. Such removal and reinstallation of a housing for a recessed light fixture can be time consuming and expensive. 
     SUMMARY 
     The present disclosure relates generally to light fixtures, and more particularly to an adjustable trim that can be used with a light fixture. In one example embodiment, a luminaire comprises a housing, at least two mounting members configured to attach to the housing, a trim assembly attached to the at least two mounting members, and a light module configured to couple to a top flange of the trim assembly. The trim assembly further comprises a bottom flange, a reflector, and an adjustable collar mounted between the top flange of the trim assembly and the light module. The reflector can comprise a downlight reflector portion and a kicker reflector portion. The housing can comprise a plaster ring or frame and receivers for receiving the mounting members. The adjustable collar and the mounting members can be detached from the top flange of the trim assembly so that the adjustable collar and the mounting members can be attached at alternate attachment points on the top flange thereby altering the orientation of the trim assembly when inserted into the luminaire housing. 
     In another example embodiment, a trim assembly comprises a top flange with a plurality of attachment points, a bottom flange, a trim body disposed between the top flange and the bottom flange, and an adjustable collar mounted to a top side of the top flange. A pair of mounting members can be attached to the trim assembly. The orientation of the trim assembly can be modified by detaching the adjustable collar and the mounting members from the top flange and reattaching the adjustable collar and the mounting members at alternate attachment points on the top flange. 
     These and other aspects, objects, features, and embodiments will be apparent from the following description and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
         FIG. 1  illustrates a light fixture that includes an adjustable trim collar according to an example embodiment of the present disclosure; 
         FIG. 2  illustrates the trim assembly of the light fixture of  FIG. 1  according to an example embodiment; 
         FIG. 3  illustrates an exploded view of the trim assembly of  FIG. 2  according to an example embodiment; and 
         FIG. 4  illustrates another exploded view of the trim assembly of  FIG. 2  according to an example embodiment. 
     
    
    
     The drawings illustrate only example embodiments and are therefore not to be considered limiting in scope. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Additionally, certain dimensions or placements may be exaggerated to help visually convey such principles. In the drawings, the same reference numerals used in different drawings designate like or corresponding but not necessarily identical elements. 
     DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS 
     In the following paragraphs, example embodiments will be described in further detail with reference to the figures. In the description, well-known components, methods, and/or processing techniques are omitted or briefly described. Furthermore, reference to various feature(s) of the embodiments is not to suggest that all embodiments must include the referenced feature(s). 
     The example embodiments described herein relate to a recessed light fixture with a trim assembly that can be easily adjusted for varying orientation within a light fixture housing. However, it should be understood that the example embodiments described herein are representative and the disclosure can be applied to other types of light fixtures, such as surface mounted light fixtures and pendant light fixtures. 
     In certain example embodiments, the example light fixtures are subject to meeting certain standards and/or requirements. For example, the National Electric Code (NEC), the National Electrical Manufacturers Association (NEMA), the International Electrotechnical Commission (IEC), the Federal Communication Commission (FCC), and the Institute of Electrical and Electronics Engineers (IEEE) set standards as to electrical enclosures (e.g., light fixtures), wiring, and electrical connections. As another example, Underwriters Laboratories (UL) sets various standards for light fixtures, including standards for heat dissipation. Use of example embodiments described herein meet (and/or allow a corresponding device to meet) such standards when required. 
     Any light fixture components (e.g., housings or trim assemblies), described herein can be made from a single piece (e.g., as from a mold, injection mold, die cast, 3-D printing process, extrusion process, stamping process, or other prototype methods). In addition, or in the alternative, a luminaire (or components thereof) can be made from multiple pieces that are mechanically coupled to each other. In such a case, the multiple pieces can be mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to epoxy, welding, fastening devices, compression fittings, mating threads, and slotted fittings. One or more pieces that are mechanically coupled to each other can be coupled to each other in one or more of a number of ways, including but not limited to fixedly, hingedly, removeably, slidably, and threadably. 
     A coupling feature (including a complementary coupling feature) as described herein can allow one or more components and/or portions of an example trim assembly or other component of a light fixture to become coupled, directly or indirectly, to another portion of the example trim assembly or other component of a light fixture. A coupling feature can include, but is not limited to, a snap, Velcro, a clamp, a portion of a hinge, an aperture, a recessed area, a protrusion, a slot, a spring clip, a tab, a detent, and mating threads. One portion of an example trim assembly can be coupled to a light fixture by the direct use of one or more coupling features. 
     In addition, or in the alternative, a portion of a light fixture can be coupled using one or more independent devices that interact with one or more coupling features disposed on a component of the trim assembly or other component of a light fixture. Examples of such devices can include, but are not limited to, a pin, a hinge, a fastening device (e.g., a bolt, a screw, a rivet), epoxy, glue, adhesive, tape, and a spring. One coupling feature described herein can be the same as, or different than, one or more other coupling features described herein. A complementary coupling feature (also sometimes called a corresponding coupling feature) as described herein can be a coupling feature that mechanically couples, directly or indirectly, with another coupling feature. 
     Terms such as “first”, “second”, “top”, “bottom”, “side”, “distal”, “proximal”, and “within” are used merely to distinguish one component (or part of a component or state of a component) from another. Such terms are not meant to denote a preference or a particular orientation, and are not meant to limit the embodiments described herein. In the following detailed description of the example embodiments, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. 
     Referring now to  FIG. 1 , an example light fixture  100  comprising a trim assembly with an adjustable collar is illustrated. The example light fixture  100  is a recessed fixture for installation in a ceiling. The primary components of the example light fixture  100  comprise a housing, a light module  120 , and a trim assembly  140 . The housing can comprise a plaster ring  105 , mounting member receivers  107  and  108 , and butterfly brackets  109  and  110 . The butterfly brackets  109  and  110  are attached to the plaster ring  105  and are configured to mount behind a ceiling so that the light module  120  and trim assembly  140  can be positioned in an aperture in the ceiling. In alternate embodiments, other types of housings can be employed that may or may not use plaster rings and butterfly brackets. For example, in one alternate embodiment, the housing can comprise a cylindrical shaped can that attaches to a plaster frame that rests on the back side of the ceiling. The mounting member receivers  107  and  108  in the example shown in  FIG. 1  are attached to the plaster ring  105  and are configured to receive torsion springs  155  and  156  that are attached to the trim assembly  140  via brackets. However, in alternate embodiments, other types of mounting members and receivers can be employed. Lastly, the example housing shown in  FIG. 1  includes a junction box  112  and conduit  113 . 
     In a typical installation process, the housing is first installed in the ceiling. At a later point in time, the light module and trim assembly are inserted into the housing. Often times, the trim assembly may be configured to direct light from the light module in an asymmetric distribution, such as directing more light towards a wall or display. The positions of the mounting members (torsion springs  155  and  156  and attached brackets) and the receivers  107  and  108  only permit the trim assembly to be inserted into the housing in the orientation shown in  FIG. 1  or rotated 180 degrees. Restricting the orientation of the trim assembly to these two positions can be a problem if alternate orientations are desired or if the housing is installed in an incorrect orientation. The adjustability of the trim assembly, as shown in  FIGS. 2-4  and described below, addresses the restricted orientation of conventional trim assemblies. 
     Referring again to  FIG. 1 , the light module  120  can be attached to the trim assembly  140  with one or more clips  150  located along the perimeter of the trim assembly. The clips  150  in the example light fixture  100  are attached so that they rotate outward to permit placing the light module  120  on the trim assembly  140 , and rotate inward to lock the light module  120  into position after being placed on the trim assembly  140 . The light module includes heat sink  125  and a light source (not visible in  FIG. 1 ) disposed on the bottom side of the heat sink. The light source can be any of a variety of lighting technologies including one or more light emitting diodes or one or more organic light emitting diodes. The light source is oriented on the bottom of the light module  120  so that emitted light is directed out of an aperture in the trim assembly. 
     In the example of  FIG. 1 , the trim assembly  140  comprises a bottom flange  142 , a top flange (not visible in  FIG. 1 ), and a trim body  144  located between the bottom and top flanges. As will be described in connection with  FIGS. 2-4  below, the trim body can have a variety of forms. For example, the trim body can comprise one or more reflector portions giving the trim assembly  140  a particular orientation that directs light from the light module in an asymmetric pattern so that more light is transmitted in one direction than another direction. 
     Referring now to  FIGS. 2-4 , illustrations of the trim assembly  140  are provided.  FIG. 2  shows a top perspective view of the trim assembly  140  in an assembled state, whereas  FIGS. 3 and 4  provide exploded views of the trim assembly  140 . Referring to  FIG. 2 , the trim assembly comprises a bottom flange  142 , a top flange  147  (visible in  FIGS. 3 and 4 ), and a trim body  144  between the bottom flange  142  and the top flange  147 . The trim body  144  can comprise a variety of reflector portions. In the example shown in  FIG. 2 , the trim body  144  comprises a downlight reflector portion  146  and a kicker reflector portion  145 . As indicated by the gaps visible in  FIG. 2  between the downlight reflector portion  146  and the kicker reflector portion  145 , the kicker reflector portion  145  is angled further inward towards the interior of the trim assembly  140  so that the kicker reflector portion  145  will bias more of the light exiting the light fixture in a direction away from the kicker reflector portion  145 . The location of the kicker reflector portion  145  gives the trim assembly  140  a defined orientation that should be aligned properly when inserted into a light fixture housing so that the kicker reflector portion  145  properly reflects light. 
     The trim assembly  140  shown in  FIG. 2  also comprises an adjustable collar  148  attached to a top flange  147  (visible in  FIGS. 3 and 4 ) of the trim assembly  140 . An upper reflector  160  is attached to the top side of the adjustable collar  148 . When the light fixture is assembled, a light module is positioned on top of the adjustable collar  148  and the upper reflector  160  and locked into place by fastening devices such as clips  150 . The center of the upper reflector  160  includes a light aperture through which emitted light from the light module exits. The bottom surface of the upper reflector  160  comprises a reflective material to reflect in a downward direction any portions of the emitted light that are emitted at a wide angle. 
     The adjustable collar  148  is attached to the trim assembly  140  via fasteners  152  located on opposite sides of the adjustable collar  148 . While screws are shown as the example fasteners  152  in  FIG. 2 , a variety of fasteners can be used to attach the adjustable collar to the trim assembly. As will be described further in connection with  FIGS. 3 and 4 , mounting members in the form of torsion springs and torsion spring brackets are also secured to the trim assembly  140  by fasteners  152 . 
     Referring now to  FIGS. 3 and 4 , exploded views of the trim assembly  140  are shown. The exploded view in  FIG. 3  includes the upper reflector  160 , whereas the upper reflector  160  has been removed from the exploded view shown in  FIG. 4 . The views in  FIGS. 3 and 4  further illustrate how the downlight reflector portion  146  and the kicker reflector portion  145  are arranged to make up the trim body  144 . It should be understood that in alternate embodiments, the trim body  144  can comprise a single component and can have a variety of shapes. 
     The exploded views in  FIGS. 3 and 4  also further illustrate the arrangement of the mounting members and the adjustable collar  148 . In the example of  FIGS. 3 and 4 , the mounting members are torsion spring brackets  154  and  157  with corresponding torsion springs  155  and  156 . The example torsion spring brackets  154  and  157  each have a hole through the horizontal top portion of the bracket through which the fasteners  152  can pass to secure the brackets  154  and  157  to the trim assembly  140 . The torsion springs  155  and  156  attach to the bottom portions of the brackets  154  and  157 . The ends of the torsion springs can be fit into receivers in the housing, such as receivers  107  and  108  shown in  FIG. 1 , thereby securing the trim assembly  140  and the light module to the housing. It should be understood that in alternate embodiments, other types of mounting members, such as friction clips, can be used. 
     The adjustable collar  148  and the top flange  147  work together to provide flexibility in the orientation of the trim assembly  140 . As shown in the example of  FIGS. 3 and 4 , the adjustable collar comprises apertures through which the fasteners  152  pass. Similarly, the top flange  147  comprises apertures through which the fasteners  152  can pass. However, the apertures in the top flange  147  comprise a plurality of attachment points for the adjustable collar  148  and fasteners  152 . For example, the adjustable collar  148  can be rotated to align with different subsets of apertures (attachment points) on the top flange  147 . In the example shown in  FIGS. 3 and 4 , the apertures of the adjustable collar  148  are aligned with a first subset of apertures (attachment points) on the top flange  147 . However, the adjustable collar  148  can also be rotated 90 degrees to align the apertures of the adjustable collar  148  with a second subset of apertures (attachment points) on the top flange  147 . The second subset of apertures on the top flange permits attachment of the adjustable collar  148  and torsion spring brackets  154  and  157  at an alternate 90 degree rotated orientation for the trim assembly  140 , thereby permitting insertion of the trim assembly  140  into a housing in an alternate position. In other embodiments, additional apertures (attachment points) can be located along the top flange  147  to provide additional orientations other than a 90 degree rotated orientation of the trim assembly  140 . For example, additional apertures (attachment points) can be located along the top flange  147  at a variety of positions so that the trim assembly can be rotated 45 degrees, 135 degrees, 270 degrees or some other angular rotation in order to orient the trim assembly  140  in the desired position for insertion into a housing. 
     Once the adjustable collar  148  and the mounting members are attached to the top flange  147  in the desired orientation, a light module can be placed on top of the trim assembly  140  and secured by the clips  150 . After the light module is secured to the trim assembly  140 , the light module and trim assembly can be inserted up into a housing of the light fixture and the mounting members (for example, the torsion springs) can be attached to receivers in the housing. Therefore, the adjustable collar and top flange permit the trim assembly  140  to be installed in a light fixture in a variety of rotated orientations to achieve a desired distribution of emitted light exiting the light fixture. 
     Although particular embodiments have been described herein in detail, the descriptions are by way of example. The features of the example embodiments described herein are representative and, in alternative embodiments, certain features, elements, and/or steps may be added or omitted. Additionally, modifications to aspects of the example embodiments described herein may be made by those skilled in the art without departing from the spirit and scope of the following claims, the scope of which are to be accorded the broadest interpretation so as to encompass modifications and equivalent structures.