Patent Publication Number: US-2016238233-A1

Title: Modular light fixture

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims benefit of U.S. provisional application Ser. No. U.S. 62/115,686, filed on Feb. 13, 2015. All documents above are incorporated herein in their entirety by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to light fixtures. More specifically, the present invention is concerned with modular light fixtures. 
     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 modular light fixtures. 
     SUMMARY OF THE INVENTION 
     More specifically, in accordance with the present invention, there is provided a light fixture unit, comprising a housing comprising opposed side walls, a projector assembly and a junction box being positioned within the housing above the projector assembly, wherein the side walls of the housing comprise openings and an air channel is provided on each side of the d junction box for evacuation of hot air generated within the housing. 
     There is further provided an assembly of at least a first light fixture unit and a second light fixture unit, the first light fixture unit comprising a first housing, a first projector assembly and a first junction box positioned within the first housing above the first projector assembly, the first housing having at least one first sidewall comprising at least one first angled surface within the first housing; the second light fixture unit comprising a second housing, a second projector assembly and a second junction box positioned within the second housing above of the second projector assembly, the second housing having at least one second sidewall comprising at least one second angled surface within the second housing; wherein the first and the second housings are adapted to be secured using a screw connecting the first angled surface and the second angled surface. 
     There is further provided a method for installing a modular assembly of light fixture units, comprising providing light fixture units each comprising a housing having at least one sidewall comprising at least one angled surface within the housing; connecting the light fixture units two by two by the least one sidewall at a top part thereof; positioning a junction box on top of each housing; connecting the light fixture units two by two by the least one sidewall by connecting the angled surfaces; and inserting each projector assembly at the open bottom end of the housing. 
     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 bottom view of a unit according to an embodiment of an aspect of the present invention; 
         FIG. 1B  is a perspective top view of a unit according to an embodiment of an aspect of the present invention; 
         FIG. 2A  shows an exploded view of two units according to an embodiment of an aspect of the present invention side by side; 
         FIG. 2B  shows a first detail of  FIG. 2A ; 
         FIG. 2C  shows a second detail of  FIG. 2A ; 
         FIG. 3A  shows an exploded view of an assembly of the two units of  FIG. 2A  according to an embodiment of an aspect of the present invention; 
         FIG. 3B  shows a first detail of  FIG. 3A ; 
         FIG. 3C  shows a second detail of  FIG. 3A ; 
         FIG. 4A  shows an exploded view of two units according to an embodiment of an aspect of the present invention side by side; 
         FIG. 4B  shows a first detail of  FIG. 4A ; 
         FIG. 4C  shows a second detail of  FIG. 4A ; 
         FIG. 5A  shows an view exploded of an assembly of the two units of  FIG. 4A  according to an embodiment of an aspect of the present invention; 
         FIG. 5B  shows a first detail of  FIG. 5A ; 
         FIG. 5C  shows a second detail of  FIG. 5A ; 
         FIG. 6  is a section view of a unit according to an embodiment of an aspect of the present invention; 
         FIG. 7  shows a perspective view of an assembly according to an embodiment of an aspect of the present invention; 
         FIG. 8  shows a perspective view of an assembly according to an embodiment of an aspect of the present invention; 
         FIG. 9  shows a perspective view of an assembly according to an embodiment of an aspect of the present invention; 
         FIG. 10  shows a perspective view of an assembly according to an embodiment of an aspect of the present invention; 
         FIG. 11  shows a perspective view of a unit according to an embodiment of an aspect of the present invention; 
         FIG. 12  A shows a detail of inner walls of a housing of a unit according to an embodiment of an aspect of the present invention; 
         FIG. 13A  shows a detail of an embossed element in a wall of a housing of a unit according to an embodiment of an aspect of the present invention, as seen from the inside of the housing; and 
         FIG. 13B  shows a detail of an embossed element in a wall of a housing of a light fixture unit according to an embodiment of an aspect of the present invention, as seen from the outside of the housing. 
     
    
    
     DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     As shown in  FIGS. 1-6 , a unit  10  according to an embodiment of an aspect of the present invention comprises a housing  12 , a projector assembly  14 , a junction box  16 , and a power converter  18 . 
     The housing  12  is of a parallelepiped shape, and comprises opposed side walls  11  and  15 . The housing may be made in a metal such as steel or aluminium for example. 
     As illustrated in  FIGS. 2, 4 and 5  for example, the projector assembly  14  comprises a light unit  13  and a heat sink  20 . 
     The power converter  18  is used to feed a LED for example. It may be omitted, as some LED light sources can be fed directly from the grid. 
     The junction box  16  is a container for electrical connections as known in the art. 
     As best seen in  FIGS. 3 and 6  for example, the junction box  16  is positioned within the housing  12  on top of the projector assembly  14 , and the LED driver  18  is secured to the inner surface of the top wall  19  of the junction box  16  opposite the projector assembly  14  (see for example  FIG. 3 ), the driver  18  thus being shielded from heat generated by the projector assembly  14  by the junction box  16 . 
     The top wall  19  of the junction box  16  is made in a material with heat conducting capacity, such as aluminum for example, so as to allow transfer of heat generated by the power converter  18  out of the unit. 
     The side walls  11  and  15  of the housing  12  comprise openings  22  to allow air flow and thus further heat evacuation out of the unit. Moreover, air channels  21  are provided on each side of the junction box  16  between the bottom wall  35  of the junction box  16  and its top wall  19  as shown for example in  FIGS. 3-6 , allowing, in combination with the wall openings  22  as best seen in  FIG. 1B  for example, hot air coming from the projector assembly  14  to escape the unit. 
     As best seen in  FIGS. 12 and 13 , the walls  11 ,  15  of the housing  12  comprise connection elements  23  in the form of embossments or cut away elements at a bottom part thereof, and holes  17  on an upper part thereof for example. 
     As best seen in  FIGS. 4 and 5 , the holes  17  on the upper part of the housing allow securing two adjacent units  10   a  and  10   b  by inserting screws  27  generally horizontally, at the top of the units, for example, before the junction box  16  and its top wall  19  is positioned. 
     The connection elements  23  generally provide surfaces  23 A,  23   b  directed inwards of the housing, at an angle of about 45 degrees relative to the surface of the wall of the housing  12  as shown in  FIG. 12  for example, each provided with a hole, at the bottom part of the unit. As best seen in  FIGS. 2, 3 and 13  for example, these angled surfaces  23 A,  23   b  allow securing two adjacent unit  10   a  and  10   b,  already fastened together by the top part thereof as described hereinabove in relation to  FIGS. 4 and 5  for example, together by the bottom part thereof, using screws  25  inserted at an angle from below the angled surfaces  23 A,  23   b,  in conditions when a generally horizontal access is not available. The projector assembly  14  of each unit needs be removed to access these angled surfaces  23 A,  23   b.    
     In case of a cubic housing, the four walls are identical and two units  10   a,    10   b  may be assembled together by securing any one of the walls of their respective housings at the top part thereof and the bottom part thereof as described hereinabove. 
     As shown in  FIGS. 2-5 , two units  10   a,    10   b  may be assembled together by securing together a wall of their respective housing, using screws  25  secured to the connection elements  23  at the bottom of the units (see  FIGS. 2 and 3 ), and screws  27  on the holes  17  at the top of the units (see  FIGS. 4 and 5 ). The connection elements  23  at the bottom of the unit  12  allow inserting the screws  25  diagonally from two sides (see close ups  FIG. 3 ) as the projector assembly  14  is removed from the housing. The screws  27  at the top of the unit can be inserted generally horizontally (see close ups  FIG. 4 ) when the top wall  19  of the junction box  16  is removed from the housing. Thus four screws allow forming an assembly of two units  10   a,    10   b,  which can be easily disassembled. Rivets may also be used. 
     Units  10  may thus be mechanically and electrically assembled, into assemblies of units, with a number of configurations and a range of shape and directions, as shown for example in  FIGS. 7-10 , before straightforward installation within a ceiling, either as a recessed light fixture assembly or suspended light fixture assembly. Such an assembly can be further expended by adding additional units if needed as the walls of the units comprise the necessary connecting features, i.e. connection elements  23  and holes  17  as described hereinabove. A finishing cover plate  30  may further be added for aesthetic purposes, as shown in  FIG. 10  for example. 
     Knock outs  40 , i.e. removable portions on the walls of the unit  10 , may be provided on the walls of the housing  12 , generally at the level of the junction box therein, i.e. on the upper part of the walls of the housing  12  as shown for example in  FIG. 11 . Such knock outs  40  are readily removed to allow passage of wires, thereby allowing directly connecting the junction boxes of different units assembled together into a common junction box, before installing the assembly on the ceiling, thereby allowing supplying power to an assembly of units using a single primary circuit from the building. 
     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.