Patent Publication Number: US-9404639-B2

Title: Recessed lighting assembly with integrated interface module

Description:
RELATED MATTERS 
     This application claims the benefit of the earlier filing date of U.S. provisional application No. 61/971,459 filed Mar. 27, 2014. 
    
    
     FIELD 
     An embodiment of the invention relates to a compact recessed lighting system that includes an integrated interface module that allows for easy connections and interchangeability with associated parts of the recessed lighting system. Other embodiments are also described. 
     BACKGROUND 
     Recessed lighting systems are typically installed or mounted into an opening in a ceiling or a wall. Recessed lighting systems generally consist of various components of different shapes and sizes. For example, different styles of trims, reflectors, and light source modules may be used to accommodate different needs of consumers. 
     Although current recessed lighting systems come in a variety of shapes and sizes, switching between different components can be tedious and cumbersome. In particular, current recessed lighting systems require the removal of numerous screws and fasteners to change a single component of the system. Further, changing a single component, such as a trim, may require replacement of other components in the system so that the proper connections are established and efficient distribution of light may be accomplished. Thus, there is a need for a recessed lighting system that enables efficient interchangeability between different components. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment of the invention in this disclosure are not necessarily to the same embodiment, and they mean at least one. 
         FIG. 1  shows an exploded view of a recessed lighting system according to one embodiment. 
         FIG. 2A  shows an overhead view of a light source module according to one embodiment. 
         FIG. 2B  shows an overhead view of the light source module with a set of electrical contacts according to one embodiment. 
         FIG. 3  shows an example heat sink according to another embodiment. 
         FIG. 4A  shows a view of a first example trim with an upper opening of the first example trim in the foreground. 
         FIG. 4B  shows a view of the first example trim with a lower opening of the first example trim in the foreground. 
         FIG. 4C  shows a view of a second example trim with an upper opening of the first example trim in the foreground. 
         FIG. 4D  shows a view of the second example trim with a lower opening of the first example trim in the foreground. 
         FIG. 5  shows a cutaway side view of the integrated interface module according to one embodiment. 
         FIG. 6  shows a bottom view of the integrated interface module. 
         FIG. 7  shows a view of an electrical contact according to one embodiment. 
         FIG. 8  shows a top view of the integrated interface module. 
         FIG. 9A  shows a view of a reflector insert with a round upper opening of the insert in the foreground. 
         FIG. 9B  shows a view of the reflector insert with a square lower opening of the insert in the foreground. 
     
    
    
     DETAILED DESCRIPTION 
     Several embodiments are described with reference to the appended drawings are now explained. While numerous details are set forth, it is understood that some embodiments of the invention may be practiced without these details. In other instances, well-known circuits, structures, and techniques have not been shown in detail so as not to obscure the understanding of this description. 
       FIG. 1  shows an exploded view of a recessed lighting system  1 . The recessed lighting system  1  may include a trim  2 , a lens  3 , a reflector insert  4 , an integrated interface module  5 , a light source module  6 , a set of electrical contacts  7 , and a heat sink  8 . Although shown in  FIG. 1  with a single trim  2 , lens  3 , reflector insert  4 , light source module  6 , and heat sink  8 , in other embodiments different styles and/or sizes of trims  2 , lenses  3 , reflector inserts  4 , light source modules  6 , and/or heat sinks  8  may be used. As will be described in further detail below, the recessed lighting system  1  has a more efficient design that reduces the number of components and increases the efficiency of changing/replacing such components in comparison to traditional lighting systems. Each element of the recessed lighting system  1  will be described by way of example below. 
       FIG. 2A  shows an overhead view of the light source module  6  according to one embodiment. As shown in  FIG. 2A , the light source module  6  may be any electro-optical device or combination of devices for emitting light. For example, the light source module  6  may have as a single light source  27  a light emitting diode (LED), organic light-emitting diode (OLED), or polymer light-emitting diode (PLED) installed on a carrier structure as shown (e.g., a printed circuit board or flex circuit). In some embodiments, the light source module  6  may have multiple light sources  27  (e.g., LEDs, OLEDs, and/or PLEDs) as shown in  FIG. 2A . The light source module  6  receives electricity from a power source  12  as shown in  FIG. 2B  such that the light source module  6  may emit a controlled beam of light into a room or a surrounding area. In one embodiment, the light source module  6  may include a set of electrical leads  28  positioned in its carrier structure, for receiving electricity from the power source  12  via the electrical contacts  7  as shown in  FIG. 2B . The electrical leads  28  of the light source module  6  may be soldering points that are traditionally coupling areas for wires that are directly soldered to the light source module  6  and directly connect the light source module  6  with the power source  12 . The power source  12  (which may include an electronic power supply circuit) is designed to ensure that the appropriate voltage and current are fed to the light source module  6  to enable the emission of light by the one or more light sources  27  within the light source module  6 . In these embodiments, the power source  12  may be attached or fixed to a junction box or another structure (not shown) of the recessed lighting system  1 , apart from the heat sink  8 , the integrated interface module  5 , the light source module  6 , and the trim  2 . In contrast to traditional lighting systems that receive electricity through wires directly connected between the light source and the power source, the light source module  6  receives electricity from the power source  12  via the electrical contacts  7 . As will be described further below, the electrical contacts  7  make contact with the electrical leads  28 , but do not maintain a permanent or rigid connection (like a solder joint.) Accordingly, the light source module  6  may be easily replaced without the need to cut wires or de-solder applied connections. 
     In one embodiment, the recessed lighting system  1  includes one or more heat sinks  8  to dissipate heat generated by the light source module  6 . As shown in  FIG. 1 , the heat sink  8  may include a set of pins or strands  9  protruding from and/or affixed to a heat sink base  10 . However, in other embodiments, the heat sink  8  may have a different shape or design. For example,  FIG. 3  shows an example heat sink  8  according to another embodiment. In this embodiment, a set of fins  11  are coupled to a heat sink base  10 , and the power source  12  for powering the light source module  6  may be inserted within a center section of the set of fins  11 . In this example embodiment, the heat sink  8  may dissipate heat from both the light source module  6  and the power source  12 . In other embodiments, the power source  12  may be positioned separately from the heat sink  8  and other components of the recessed lighting system  1  shown in  FIG. 1 . For example, the power source  12  may be located in a junction box (not shown) or a frame (not shown), which supports the recessed lighting system  1  in a hole or structure in which the recessed lighting system  1  is installed. Although the heat sinks  8  shown in  FIG. 1  and  FIG. 3  are shown as passive components that cool the light source module  6  by dissipating heat into the surrounding air, active heat sinks (e.g., fans) may also be used. 
     The heat sink  8  may be composed of any thermally conductive material. For example, the heat sink  8  may be made of aluminium alloys, copper, copper-tungsten pseudoalloy, AlSiC (silicon carbide in aluminium matrix), Dymalloy (diamond in copper-silver alloy matrix), E-Material (beryllium oxide in beryllium matrix), and/or thermally conductive plastics or ceramics. 
     In one embodiment, the recessed lighting system  1  may include a lens  3 . The lens  3  may be formed to converge, diverge, or otherwise modify (e.g., filter) light emitted by the light source module  6 . The lens  3  may be a simple lens comprised of a single optical element or it may be a compound lens comprised of an array of simple lenses (elements) with a common axis. In one embodiment, the lens  3  also provides a protective barrier for the light source module  6  and shields the light source module  6  from moisture or inclement weather. The lens  3  may also assist in the diffusion of light and increase the uniformity of light over the surface of the recessed lighting system  1 . The lens  3  may be made of any at least partially transparent material, including glass and hard plastics. In one embodiment, the lens  3  and the trim  2  are contained in a single indivisible unit to work in conjunction to focus and adjust light emitted by the light source module  6 . In other embodiments, the lens  3  and the trim  2  are separate, divisible elements as shown in  FIG. 1 . In these embodiments, the lens  3  may be removably coupled to the integrated interface module  5  as will be described in greater detail below. 
     In one embodiment, the recessed lighting system  1  may include one or more trims  2 . The trims  2  may be interchangeable such that multiple trims  2  may be separately used with the recessed lighting system  1 . For example, a first trim  2  may be coupled to the integrated interface module  5 . Thereafter, this first trim  2  may be detached from the integrated interface module  5  without the use of tools and a second trim  2  may be installed. The trims  2  serve the primary purpose of covering the exposed edge of the ceiling or wall where a hole is formed in which the recessed lighting system  1  resides, while still allowing light from the light source module  6  to be emitted into a room through its upper and lower openings  15 A and  15 B. In doing so, the trims  2  help the recessed lighting system  1  appear seamlessly integrated into the ceiling or wall. 
     The trims  2  may be made of any material or set of materials. For example, the trims  2  may be made of one or more of aluminum plastic polymers, alloys, copper, copper-tungsten pseudoalloy, AlSiC (silicon carbide in aluminum matrix), Dymalloy (diamond in copper-silver alloy matrix), and E-Material (beryllium oxide in beryllium matrix). 
     In one embodiment, the trims  2  are capable of coupling to the integrated interface module  5  while in other embodiments the trims  2  are capable of coupling to one or more other components of the recessed lighting system  1 . The trims  2  may couple to the integrated interface module  5  using any connecting mechanism, including resins, clips, screws, bolts, or clamps. In one embodiment, the trims  2  may include a ridge  14  for coupling to corresponding elements of the integrated interface module  5  as shown in  FIGS. 4A, 4B, and 4D  and as will be described in greater detail below. 
     As noted above, the recessed lighting system  1  may include multiple trims  2  of different shapes and sizes. Each of these differently shaped and/or sized trims  2  may be capable of being coupled to the same integrated interface module  5 . The size and design of the trims  2  installed with the recessed lighting system  1  may depend on the size of the hole in which the recessed lighting system  1  has been fitted and that the trim  2  must conceal, as well as the aesthetic decisions of the consumer. In these embodiments, the ridge  14  of each of the trims  2  may be uniform while the other elements of the trims  2  may be distinct. 
       FIGS. 4A and 4B  show views of a first example trim  2  according to one embodiment. In particular,  FIG. 4B  shows a view of the first example trim  2  with an upper opening  15 A in the foreground and  FIG. 4A  shows a view of the first example trim  2  with the lower opening  15 B in the foreground. The upper opening  15 A may be surrounded with the ridge  14  for coupling with the integrated interface module  5  while the lower opening  15 B may be surrounded by a flange  16  for concealing the wall or ceiling hole in which the recessed lighting system  1  is installed. As shown in  FIGS. 4A and 4B , the upper and lower openings  15 A and  15 B are both round/circular and the flange  16  of the trim  2  is also round/circular. Turning now to  FIGS. 4C and 4D , a second example trim  2  is shown. In contrast to the first example trim  2  in  FIGS. 4A and 4B , the second example trim  2  in  FIGS. 4C and 4D  has primarily square/rectangular upper and lower openings  15 A and  15 B and a square/rectangular flange  16 . Each of the trims  2  shown in  FIG. 4A-4D  may be similarly attached to the integrated interface module  5  using a similar ridge  14  as will be described in greater detail below. Accordingly, the recessed lighting system  1  may be easily adaptable to function with different style trims  2  based on the preferences and needs of the consumer. 
     In some embodiments, the reflector insert  4  may be used to bridge differences in size or shape between the integrated interface module  5  and the trim  2 . However, the use of the reflector insert  4  may be optional and, as noted above, may be only used when the shapes and/or sizes of the integrated interface module  5  and the trim  2  do not align or do not allow connection, and/or provide a non-ideal connection, which allows the leakage of light. In particular, as shown in the examples of  FIGS. 1, 4C, and 4D , the trim  2  includes a square upper opening  15 A while the front face  18 A of the integrated interface module  5  is round. To accommodate for these differences in shape, the reflector insert  4  may be used, as shown in  FIGS. 9A and 9B , which includes 1) a round upper opening  34 A to accommodate the round front face  18 A of the integrated interface module  5  and/or to accommodate the round light source module  6  and 2) a square lower opening  34 B to accommodate the square upper opening  15 A of the trim  2 .  FIGS. 9A and 9B  show views of an example reflector insert  4  according to the example embodiment described above. In particular,  FIG. 9A  shows a view of the reflector insert  4  with a round upper opening  34 A in the foreground and  FIG. 9B  shows a view of the reflector insert  4  with a square lower opening  34 B in the foreground. The reflector insert  4  may be optionally used in the recessed lighting system  1  to accommodate for differences in integrated interface module  5  and trim  2  designs as described above. By accommodating for these differences, leakages or losses of light may be avoided. In particular, light which would leak out into a periphery of or behind the trim  2  is now properly focused in front of the trim  2 , through the upper and lower openings  15 A and  15 B of the trim  2  and out into a room. Although described in relation to round and square shapes, in other embodiments the reflector insert  4  may accommodate for any set of different shapes or sizes, including triangular shapes, rectangular shapes, elliptical shapes, star shapes, hexagonal shapes, etc. 
     In one embodiment, the reflector insert  4  may be held within the integrated interface module  5  through the use of the lens  2 , which may be coupled to the integrated interface module as will be described in greater detail below. As shown in  FIGS. 9A and 9B , a cavity  17 A may be formed between the upper opening  34 A and the lower opening  34 B. The cavity  17 A may be shaped to focus light from the light source module  6  through the trim  2  and/or the lens  3  and into a room in which the recessed lighting system  1  is installed. The cavity  17 A may form a frusto conical shape; however, in other embodiments the cavity  17 A may be in any other shape that facilitates the focusing of light (e.g., frusto pyramidal). In one embodiment, the front surfaces of the walls of the cavity  17 A may be coated with or may include one or more reflecting elements that assist in the adjustment of light emitted by the light source module  6 . For example, the cavity  17 A may be coated with a shiny enamel or include one or more mirrors or retroreflectors or a microcellular polyethylene terephthalate (MCPET) material to adjust the focus of light emitted by the light source module  6 . In other embodiments, the cavity  17 A may include various other optic elements to assist in the focusing of light emitted by the light source module  6 . 
     Returning to the trims  2 , in addition to concealing a hole in which the recessed lighting system  1  is installed, the trims  2  may be used to focus light generated by the light source module  6 . For example, the trims  2 , as shown in  FIGS. 1, 4A, and 4C , may include a cavity  17 B that is formed between the upper and lower openings  15 A and  15 B. The cavity  17 B may be shaped to direct light. For example, similar to the cavity  17 A, the cavity  17 B may form a frusto conical shape such that the cavity narrows from the lower opening  15 B towards the upper opening  15 A. However, in other embodiments the cavity  17 B may be in any other shape that facilitates the focusing of light (e.g., frusto pyramidal). In one embodiment, the walls of the cavity  17 B may be coated with or may include one or more reflecting elements that assist in the adjustment of light emitted by the light source module  6 . For example, the cavity  17 B may be coated with a shiny enamel or include one or more mirrors or retroreflectors or a microcellular polyethylene terephthalate (MCPET) material to adjust the focus of light emitted by the light module  6 . In other embodiments, the cavity  17 B may include various other optic elements to assist in the focusing of light emitted by the light source module  6 . 
     Turning now to the integrated interface module  5 , the techniques and devices for combining and/or coupling each of the components of the recessed lighting system  1  together will now be described. As will be discussed in greater detail below, the integrated interface module  5  allows components of the recessed lighting system  1  to be combined while reducing the number of fasteners needed to do so, and the overall complexity of changing parts or installing the recessed lighting system  1  into a structure may be simplified. 
     The integrated interface module  5  may be a shell and/or enclosure that 1) prevents the exposure of heat from the light source module  6  to items inside a ceiling or crawl space (e.g., insulation) in which the recessed lighting system  1  has been installed and 2) directs light emitted by the light source module  6  along with a trim  2  and/or reflector insert  4  to generate a more focused beam of light. The integrated interface module  5  may be formed of metals, polymers, metal alloys, and/or other heat insulating materials.  FIG. 5  shows a cutaway side view of the integrated interface module  5  according to one embodiment. As shown in  FIG. 1  and FIG.  5 , the integrated interface module  5  may be a cylindrical structure that defines a cavity  17 C therein. However, in other embodiments, the integrated interface module  5  may be any suitable shape, including an ellipsoid, cone, or polygon that is capable of housing the light source module  6 . 
     In one embodiment, the integrated interface module  5  may include an open front face  18 A and an open rear face  18 B. The space between the front and rear faces defines the cavity  17 C. Similar to the cavities  17 A and  17 B, the cavity  17 C may be shaped to focus light from the light source module  6 , which is situated along the open rear face  18 B, toward the open front face  18 A and out into a room in which the recessed lighting system  1  is installed via a trim  2 , the reflector insert  4 , and/or the lens  3 . For example, the shape of the cavity  17 C may be defined by a frusto conical shaped wall as shown; however, in other embodiments the cavity  17 C may be in any other shape that facilitates the focusing of light (e.g., frusto pyramidal). In one embodiment, front surfaces of the walls that define the cavity  17 C may be coated with or may include one or more reflecting elements that assist in the adjustment of light emitted by the light source module  6 . For example, the walls for the cavity  17 C may be coated with a shiny enamel or include one or more mirrors or retroreflectors or a microcellular polyethylene terephthalate (MCPET) material to adjust the focus of light emitted by the light module  6 . In other embodiments, the cavity  17 C may contain various other optic elements to assist in the focusing of light emitted by the light source module  6 . 
       FIG. 6  shows a bottom view of the integrated interface module where the rear face is visible in the drawing. As shown in  FIG. 6 , in one embodiment, the integrated interface module  5  may include a set of fastener blocks  20  and a set of guides  22  for receiving the electrical contacts  7 . The electrical contacts  7  may be each formed of an electrically conductive material that facilitates the transfer of electricity from the power source  12  to the light source module  6 . For example, as shown in  FIG. 2B  and  FIG. 7 , the electrical contacts  7  may be strips of metal that create an electrical connection between the power source  12  and the light source module  6 . 
     Referring to  FIG. 7 , in one embodiment, the electrical contacts  7  are each comprised of 1) a base end  21  that may be secured or fastened to the integrated interface module  5  and 2) a finger  23  that simply comes into contact with (to thereby form an electrical connection with) the light source module  6 . The finger  23  may be bent relative to the base end  21  such that the finger is raised in relation to the base end  21  and is able to make firm contact with the electrical leads  28  of the light source module  6 . As seen in  FIG. 6 , the fastener blocks  20  may be holes for receiving screws or other fasteners while the guides  22  may be grooves that are sized to receive the fingers  23  of the electrical contacts  7 . In this embodiment, the fingers  23  may be narrow tabs that facilitate contact with corresponding leads  28  without contacting other elements of the light source module  6  while the base ends  21  may be wider stubs that facilitate coupling to the fastener blocks  20  of the integrated interface module  5 . 
     In one embodiment, a base end  21  of each of the contacts  7  may be secured to a corresponding fastener block  20  through the use of resins, clips, screws, rivets, or any other fastener. The fastener blocks  20  may also facilitate the connection of corresponding wires that deliver electricity to the contacts  7  from the power source  12 . For example, a screw may be used to attach the base end  21  of each contact  7  to the fastener block  20 . In this example wires from the power source  12  may be wrapped around each screw. Accordingly, the wires may deliver electricity to the contacts  7  via the connection as the fastener blocks  20 . 
     As described above, the guides  22  may be grooves that are sized to receive the fingers  23  of the electrical contacts  7 . Although the contacts  7  may be fastened at the base end  21  to the integrated interface module  5 , the fingers  22  may remain unattached from the integrated interface module  5 . By being fastened to the integrated interface module  5  at only one end (i.e., the base end  21 ), the electrical contacts  7  are pivotable/bendable such that a firm but adjustable electrical connection may be established with corresponding electrical leads  28  on the light source module  6 . In one embodiment, the guides  22  provide a barrier to prevent the fingers  23  from being overly depressed/bent while in contact with the leads  28  of the light source module  6 . Accordingly, the guides  23  ensure that the electrical contacts  7  and the leads  28  maintain a firm connection to facilitate the transfer of electricity between the power source  12  and the light source module  6 . Since the electrical contacts  7  only make contact with electrical leads  28  of the light source module  6  instead of a soldered or otherwise more permanent connection, the light source module  6  may be replaced or adjusted within minimal effort. 
     In one embodiment, a wall  24  may separate a base end  21  and a finger  23  of a first electrical contact  7  from a base end  21  and a finger  23  for a second electrical contact  7 . The wall  24  prevents the contacts  7  from coming into contact and causing an electrical short circuit. 
     In one embodiment, the integrated interface module  5  may include a set of light module mounting blocks  26 . The light module mounting blocks  26  may be used for coupling the integrated interface module  5  to the light source module  6  and/or the heat sink  8 . For example, the light module mounting blocks  26  may be defined by a set of tabs that include holes for receiving a screw or other fastener. In this embodiment, the light source module  6  and the heat sink  8  may each include a set of holes  29  and  30 , respectively, for receiving corresponding screws or fasteners  31 . Accordingly, the light source module  6  may be sandwiched between the integrated interface module  5  and the heat sink  8 . The fasteners  31  may secure the unified connection between the integrated interface module  5 , the light source module  6 , and the heat sink  8  using the holes  29  and  30 . Although described as holes  29  and  30 , the holes  29  and  30  may be replaced with any device or mechanism that allows the coupling of the integrated interface module  5 , the light source module  6 , and the heat sink  8  as described above. In these embodiments, the fasteners  31  may be clips, screws, bolts, clamps, or any other type of connecting mechanism. By utilizing one set of fasteners (i.e., the fasteners  31 ) to connect multiple components (i.e., the integrated interface module  5 , the light source module  6 , and the heat sink  8 ), the recessed lighting system  1  reduces the number of parts and the overall complexity in comparison to conventional systems. 
       FIG. 8  shows a top view of the integrated interface module  5  in which the front face  18 A of the integrated interface module  5  is pointed outward. In one embodiment, the integrated interface module  5  may include a lip  32  for receiving the lens  3 . The lip  32  may be a ridge that surrounds the open front face  18 A of the integrated interface module  5 . In one embodiment, the diameter/dimensions of the lip  32  are slightly larger (e.g., 1 mm larger) than the diameter/dimensions of the lens  3  and/or the reflector insert  4 . By being only slightly larger, the lip  32  allows the lens  3  and/or the reflector insert  4  to tightly/securely fit with the integrated interface module  5 . In one embodiment, the lens  3  and/or the reflector insert  4  is fastened to the lip  32  through the use of resins, clips, screws, bolts, clamps, or any other type of connecting mechanism. However, in other embodiments, the lens  3  and/or the reflector insert  4  snap fits into the lip  32  and can be removed by a user without the use of tools. For example, the reflector insert  4  may be placed within the cavity  17 C. The lens  3  may thereafter by coupled to the lip  3  such that both the lens  3  and the reflector insert  4  are tightly joined with the integrated interface module  5 . 
     In one embodiment, the integrated interface module  5  may include a channel  33  for receiving a trim  2 . The channel  33  may be defined by a set of walls that form a corresponding set of concentric circles with the front face  18 A of the integrated interface module  5 . In one embodiment, the channel  33  may be sized to receive the ridge  14  of multiple different trims  2 . For example, as described above, multiple trims  2  with openings  15 A and  15 B and flanges  16  of different shapes and sizes may have a uniformly sized and shaped ridge  14 . The ridges  14  for each of the trims  2  may fit snuggly into the channel  33  with applied pressure and without the need for tools. Accordingly, trims  2  may be easily coupled to the integrated interface module  5  by forcing the ridge  14  of a trim  2  into the channel  33 . Similarly, a trim  2  may be removed by forcing/pulling a corresponding ridge  14  from the channel. As described above, the integrated interface module  5  allows the replacement and adjustment of trims  2  of different shapes and sizes without the use of tools and with minimal effort. 
     As described above, the recessed lighting system  1  provides a reduced set of components while ensuring adaptability and easy installation into a structure. In particular, by including an integrated interface module  5  that allows the light source module  6 , the trim  2 , the lens  3 , and the heat sink  8  to be easily replaced with minimal tools and minimal fasteners, the recessed lighting system  1  described herein provides a more efficient and user friendly design in comparison to traditional systems. 
     While certain embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that the invention is not limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those of ordinary skill in the art. The description is thus to be regarded as illustrative instead of limiting.