Patent Publication Number: US-2016230969-A1

Title: Recessed light fixture

Description:
FIELD OF THE INVENTION 
     The present invention relates to recessed light fixture. More specifically, the present invention is concerned recessed light fixture comprising a housing and a junction box connected by a flexible arm. 
     BACKGROUND OF THE INVENTION 
     Recessed light fixtures are typically mounted between ceiling joists or suspended ceiling support members. They may be installed in new constructions, i.e. when the ceiling joists are still exposed, or in existing buildings, i.e. when the ceiling is already finished with drywall or plaster and lath. 
     Light fixtures for installation in existing buildings typically comprise a housing and a junction box connected by a flexible wire. For installation, the user cuts an opening in the ceiling, inserts the fixture within the opening in the ceiling from below and locks it into position by mounting clips provided on the housing. 
     There is still a need in the art for a recessed light fixture. 
     SUMMARY OF THE INVENTION 
     More specifically, in accordance with the present invention, there is provided a recessed light fixture, comprising a housing; a junction box; and a flexible arm connecting said housing and the junction box together; wherein the flexible arm comprises a plate extending between the junction box and the housing and supporting a cover, the cover comprising at least one flexion line across a width thereof between the housing and the junction box. 
     There is further provided a junction box for a recessed light fixture, wherein one of: i) a top and ii) a side wall of the junction box extends into a plate secured on a free end thereof to a housing of the recessed light fixture, the plate supporting a cover, and the cover comprising at least one flexion line across a width thereof between the housing and the junction box. 
     Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of specific embodiments thereof, given by way of example only with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the appended drawings: 
         FIG. 1A  shows a perspective view of a recessed light fixture assembly according to an embodiment of an aspect of the present invention; 
         FIG. 1B  is a top view of the assembly of  FIG. 1A ; 
         FIG. 1C  is a side view of the assembly of  FIG. 1A ; 
         FIG. 2  shows details of a housing and a junction box of a light fixture assembly according to an embodiment of an aspect of the present invention; 
         FIG. 3A  shows a light fixture assembly according to an embodiment of an aspect of the present invention in a straight configuration; 
         FIG. 3B  shows a light fixture assembly according to an embodiment of an aspect of the present invention in a bent down configuration; 
         FIG. 3C  shows a light fixture assembly according to an embodiment of an aspect of the present invention in a bent up configuration; 
         FIG. 4A  shows a cover of an arm according to an embodiment of an aspect of the present invention; 
         FIG. 4B  shows an arm according to an embodiment of an aspect of the present invention; 
         FIG. 5A  shows a first configuration of a light fixture assembly according to an embodiment of an aspect of the present invention; 
         FIG. 5B  shows a second configuration of a light fixture assembly according to an embodiment of an aspect of the present invention; 
         FIG. 6A  shows a perspective top view of a recessed light fixture assembly according to an embodiment of an aspect of the present invention; 
         FIG. 6B  shows a top view of the assembly of  FIG. 6A ; 
         FIG. 6C  shows a side view of the assembly of  FIG. 6A ; 
         FIG. 6D  shows a bottom view of the assembly of  FIG. 6A ; 
         FIG. 6E  shows a perspective bottom view of the assembly of  FIG. 6A ; 
         FIG. 7  shows steps of installation of a light fixture assembly according to an embodiment of an aspect of the present invention; 
         FIG. 8  shows steps of installation of a light fixture assembly according to an embodiment of an aspect of the present invention; and 
         FIG. 9  shows steps of installation of a light fixture assembly according to an embodiment of an aspect of the present invention. 
     
    
    
     DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     As generally illustrated in  FIG. 1 , the recessed light fixture comprises a housing  10  and a junction box  20  connected together by an arm  30 . 
     The housing  10  typically comprises a top wall  12  and a bottom open end terminating in a flange  13 . The housing  10  comprises at least one retaining member  15  for securing the housing  10  in a ceiling location The housing  10  generally supports a light source, a reflector, a lens, a cooling member lamp socket as known in the art. 
     The junction box  20  comprises a top wall  21 , bottom wall  25 , side walls  26 ,  27  and generally defines an enclosure for connecting wires (not shown) from an electrical power source to the lamp socket in the housing  10 . 
     As illustrated in the figures, the arm  30  extends from the top wall  12  of the housing  10  to the top wall  21  of the junction box  20 . Alternatively, the arm  30  may connect the housing  10  to the junction box  20  through respective lateral walls thereof (not shown). 
     The arm  30  comprises a plate  32  and a cover  34 . The plate  32  may be an extension of the top wall  21  of the junction box  20 , the top wall  21  of the junction box  20  narrowing down into a plate  32  of a reduced width as shown in  FIGS. 1 a  and 1 b    for example, and secured to the top wall  12  of the housing  10  on the opposite end using rivets  37  as seen in  FIG. 6  for example, or using screws, welding, or snaps. 
     For securing the cover  34  on the plate  32  on each end thereof, snaps, screws, welding or rivets  36  through openings  38  as illustrated in the figures (see for example  FIGS. 1 a  and  b   ) may be used. The arm  30  thus formed runs from the top wall  12  of the housing  10  to the top wall  21  of the junction box  20  covering respective openings in the top walls  12 ,  21  thereof, and houses wires running from the housing  10  to the junction box  20 . Although the cover  34  was described hereinabove as secured on the upper surface of the plate  32 , it may be secured on the lower surface of the plate  32  as illustrated for example in  FIG. 6 . Both the plate  32  and the cover  34  are made in a rigid material, such as stainless steel, plastic, aluminum or alloy for example. 
     The material and the thickness of the cover  34  are selected so that flexion lines  60  extending transversally can be provided across a width of the cover  34 , such as embossed lines or lines of a reduced thickness compared to the nominal thickness of the remaining of the cover  34 , allowing repeated flexion of the cover about this at least one embossed line without risking tearing. 
     At locations generally facing or opposite these lines  60  on the cover  34 , the material of the plate  32  may be provided with a flexion area, such as lines  62  of a reduced thickness forming a transverse zone of a reduced thickness compared to the nominal thickness of the remaining of the plate  32  as seen in  FIG. 1   c,  or with precut edge lines  62  as shown in  FIGS. 2 and 6A, 6B  for example. Alternatively, the material of the plate  32  may be selected so as to be rigid and sufficiently flexible so as to be able to follow the flexion of the cover  34  if needed. 
     As a result, the arm is flexible from a straight position between the housing  10  and the junction box  20  ( FIG. 3A ) to positions where the arm is bent so that the junction box  20  and the housing  10  are maintained at an angle one relative to the other, i.e. the top wall of the housing  10  is positioned below the top wall of the junction box  20  ( FIG. 3C ) or above the top wall of the junction box  20  (not shown), or at an angle with the top wall of the junction box  20  ( FIG. 3B ). 
     Besides fastening means generally at ends thereof, i.e. at the housing  10  (see rivets  37  In  FIG. 6  for example) and at the junction box (see rivet  36  in  FIG. 1  for example), the cover  34  and the plate  32  are secured together in the deformation area of the arm  30  formed by the lines  60  and  62  of the cover  34  and of the plate  32  respectively, for example by a retaining clip  63  as shown in  FIGS. 1 and 6 , or by a rivet, welding or a snap for example. Thus the cover  34  is prevented from peeling away from the plate  32  upon bending of the arm  30 . 
     The height of the cover  34  relative to the plate  32  is selected so as to accommodate wires therethrough without pinching or otherwise damaging the wires upon bending of the arm  30 . 
     Provision of oblong openings  38  for connexion between the cover  34  and the plate  32  by rivets  36  as illustrated for example allows accommodating movements of the cover  34  between different positions of the arm  30  as shown in  FIG. 3 . 
     The present arm allows rigidly holding the housing and the junction box at different relative positions as shown in  FIG. 3 . 
     The different embodiments described hereinabove are given as way of examples only and respective features may be used alone or in combination. 
     A recessed light fixture assembly comprising an arm as described herein may achieve airtightness below 2 cubic feet per meter. 
     For installation, a user cuts an opening in the ceiling, inserts the fixture within the opening in the ceiling from below and locks it into position by mounting clips provided on the housing. 
       FIG. 7  illustrates inserting the junction box first ( 112 ), then the housing ( 114 ) through such an opening in the ceiling so as to position the assembly ( 114 ). 
     In case of ceiling configurations where space is limited, flexibility of the arm is necessary for insertion of the junction box and the housing to position the assembly, as illustrated for example in  FIGS. 8 and 9 . 
     The present assembly comprises an arm rigidly connecting the housing to the junction box while allowing flexibility for ease of installation of the assembly when necessary, for example to facilitate the passage of the housing in the ceiling where space is limited, while fully enclosing and sheltering electric wires within the assembly. 
     The scope of the claims should not be limited by the embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.