Patent Publication Number: US-7722208-B1

Title: Recessed luminaire trim assembly

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
   None. 
   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   None. 
   REFERENCE TO SEQUENTIAL LISTING, ETC. 
   None. 
   BACKGROUND 
   1. Field of the Invention 
   The present invention pertains to recessed light fixtures. More particularly, the present invention pertains to a recessed luminaire trim assembly which utilizes a biasing spring to minimize seams between reflector surfaces. 
   2. Description of the Related Art 
   Recessed lighting fixtures have become extremely popular for both residential and commercial uses. Most recessed downlights have a trim or reflector with is generally circular cross-sectional shape. Additionally, the trim or reflector may also have a flange which extends radially from a lower peripheral edge of the reflector. The flange and reflectors have typically had circular cross-sectional shapes, in part, because the circular cross section may be formed integrally of a single piece of material without seams. 
   Architects desire to utilize alternative shapes for the reflectors and the flanges to match the recessed lighting fixtures to the architecture of the buildings being designed. However, when polygonal shapes are utilized for reflectors and flange designs, multiple seams are formed where the reflector elements meet one another and where the flange elements meet one another. When these seams are not tight, there is an aesthetically unpleasant appearance and hindrance of optical performance of the luminaire. This has been a primary problem with implementation of these polygonal shapes in recessed lighting. 
   It is preferable to minimize the width of seams between reflector surfaces and flanges so as to allow an aesthetically pleasing use of polygonal cross-sections with the reflectors and flanges. 
   SUMMARY OF THE INVENTION 
   An recessed luminaire trim assembly, comprises an outer trim, an inner reflector portion having a polygon shaped cross-section defined by a plurality of reflectors and a plurality of seams defined between each of the plurality of reflectors, a flange extending outwardly from a peripheral edge of the inner reflector, a spring connected to the outer trim, the spring having at least one leg engaging the inner reflector portion and tightening the plurality of seams. The inner trim has a generally square shaped cross-section. The spring comprises a first leg and a second leg for engaging the plurality of reflectors defining the plurality of seams. The spring is located at each of the plurality of seams. The inner reflector portion having four reflectors. The spring has a first portion and a second portion, each of the first and second portion having a leg. The spring closing the each of the seams at each of the corner of the flange. The leg extending inwardly from the spring and closing seams at the reflectors and the flanges. The trim assembly further comprises a biscuit connecting each of the seam at each corner of the flange. The outer trim further comprises a plurality of sidewalls. The spring engages two sidewalls. 
   A trim assembly, comprises an outer trim having a plurality of sidewalls defining a lower opening and an upper opening, a miter spring disposed at each sidewall of the lower opening, at least one leg extending inwardly from each of the spring, a plurality of reflectors positioned within the outer trim, wherein each of the plurality of reflectors is engaged by the at least one leg of the miter spring. The miter spring receives the outer trim. The at least one leg is a first leg and a second leg. The miter spring places a force on the plurality of reflectors to close seams disposed between the plurality of reflectors. The trim assembly further comprises a flange extending from each of the plurality of reflectors. The trim assembly further comprises a biscuit positioned between the flanges. The miter spring provides a force on the flanges and closing seams between the flanges. The trim assembly further comprises a fastener connecting the plurality of reflectors and the outer trim. The trim assembly further comprises an inner trim. The inner trim has a polygon shaped cross-section. The inner trim has a square shaped cross-section. 
   A trim assembly comprises a trim spring having at least one leg, a plurality of reflectors defining an opening, a seam located between each of the plurality of reflectors, the trim spring connected to a first stationary portion of the trim assembly, a leg of the trim spring engaging a reflector surface of the plurality of reflectors, wherein the seam is minimized due to the force of the leg on the reflector surface. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
       FIG. 1  is a perspective view of a recessed luminaire trim assembly; 
       FIG. 2  is an exploded perspective view of trim assembly of  FIG. 1 ; 
       FIG. 3  is a perspective view of the inner trim of the trim assembly of  FIG. 1 ; 
       FIG. 4  is a bottom view of the inner trim of the trim assembly of  FIG. 1 ; 
       FIG. 5  is a perspective view of a trim spring utilized with the trim assembly of  FIG. 1 ; and, 
       FIG. 6  is an opposite perspective view of the trim spring of  FIG. 4 . 
   

   DETAILED DESCRIPTION 
   It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings. 
   Furthermore, and as described in subsequent paragraphs, the specific mechanical configurations illustrated in the drawings are intended to exemplify embodiments of the invention and that other alternative mechanical configurations are possible. 
   Referring now in detail to the drawings, wherein like numerals indicate like elements throughout the several views, there are shown in  FIGS. 1-6  various aspects of a recessed luminaire trim assembly. The trim assembly provides a plurality of reflectors forming a polygonal shape with miter springs which minimize seams between reflective surfaces and flanges. The combination of the reflectors and springs allow for an aesthetically pleasing polygon trim shape while minimizing the seam effects associated with reflector and flange seams. 
   Referring initially to  FIG. 1 , a perspective view of the polygon trim assembly  10  is depicted. In the present disclosure, the polygon is referred to as a square, however alternative shapes may be utilized as will be understood and explained further herein. Therefore the term square trim should be considered exemplary and not limiting. The square trim assembly  10  fits within a recessed lighting fixture and provides the appearance of a square fixture trim rather than the typical circular trim utilized in many recessed down lights. The square trim assembly  10  comprises an outer trim  12  and an inner trim  30  ( FIG. 2 ). The outer trim  12  is defined by a plurality of outer trim sidewalls  14 . The outer trim  12  is generally box like in shape with an upper opening  16  and a lower opening  18 . The upper opening  16  allows light from a lamp or source (not shown) disposed within a fixture assembly to pass from the upper portion of the fixture through the trim assembly  10  to the room or space beneath the recessed fixture in order to provide illumination. The sidewalls  14  are substantially rectangular in shape wherein each sidewall  14  comprises upper and lower parallel edges with vertically extending side parallel edges between the upper and lower edges. The vertical edges are shorter than the upper and lower parallel edges. Thus, each sidewall  14  comprises a rectangular shape although alternative shapes may be utilized. Along the upper edges of the sidewalls  14  are outer trim upper walls  20 . Each of the upper walls  20  bends and extends inwardly horizontally from the upper edges of the outer trim sidewalls  14 . The upper opening  16  is partially defined by the innermost edge of each trim upper wall  20 . Located within each upper wall  20  are fasteners  22  which are utilized to connect the outer trim  12  to the reflectors  32  described further herein. The fastener  22  may be various constructs including a rivet, screw, nail or other known device which attaches two parts. Each of the outer trim upper walls  20  has a longitudinal length which is substantially equal in order to define the exemplary square shaped box of the trim assembly  10 . Alternatively however, the outer trim  12  need not be a square box in shape but could alternatively be rectangular or other polygonal shapes which may require the use of reflectors with seams to connect the various sides of the polygonal shape, as will be understood further herein. Extending from the sidewalls  14  are leaf springs  24  which are fastened to the sidewall  14  and are utilized to engage a housing or enclosure of the recessed fixture. 
   The trim assembly  10  further comprises an inner trim  30  which is positioned within the outer trim  12 . The inner trim  30  comprises a plurality of reflectors or reflective surfaces  32 . The reflective surfaces  32  are shown located within the outer trim  12 . Within the outer trim  12 , the reflector surfaces  32  extend at an angle inwardly beyond the outer edge of the upper opening  16 . The inset reflectors  32  design insures that the user, when looking upwardly through the square trim assembly  10 , will not see the edge of the outer trim  12  but instead will only see the reflective surfaces  32 . Accordingly, the outer trim  12  may have a plurality of finishes including black or other painted color and need not be a reflective surface which, in general, may be more expensive to manufacture. Additionally, a lens may be positioned over the opening  16  if desired. The outer trim  12  comprises a plurality of apertures  23  along the upper wall  20 . The apertures  23  may receive a clip for retaining a lens over the aperture  16 . 
   Between each of the reflective surfaces  32  is a seam  34 . Due to the shape of the square trim assembly  10 , the plurality of seams  34  are created by the reflective surfaces  32  at various corner locations in order to provide the polygonal shape. It is highly desirable to minimize the effects or visibility of these seams  34  by forcing the edges of each reflective surface  32  to engage one another thereby minimizing the seam width  34 . The reflectors  32  have a lower flange  36  extending from the lower edges of the reflectors  32  which extend outwardly to hide the outer trim  12  from viewing. Accordingly, when installed, the exemplary flange  36  abuts a ceiling lower surface and appears as a square shape to a user below. As previously indicated, alternative polygonal shapes may be utilized. 
   Referring now to  FIG. 2 , an exploded perspective view of the square trim assembly  10  is depicted. In the exemplary embodiment, the outer trim  12  is exploded from the inner trim  30 . A plurality of reflectors  32 , an upper flange  38  and a lower flange  36  define the inner trim  30 . The reflectors  32  each engage one another defining seams  34 . When the engagement between reflectors  32  is not tight, the seams  34  widen. Such widening is not aesthetically pleasing and may alter the optical performance of the fixture. The reflectors  32  have an upper flange  38  and a lower flange  36 . Each upper flange  38  comprises a tab  39  which engages an adjacent reflector upper flange  38  to retain the upper portions of the reflectors  32  together during construction. The tabs  39  are folded downwardly, from the position depicted, so as to be about 90 degrees to the upper surface of the upper flanges  38 . The upper flanges  38  define a substantially square shaped opening corresponding to the opening  16  so that the opening of inner trim  30  is substantially aligned with the upper opening of the outer trim  12 . Extending from the lower edges of the reflectors  32  is a lower flange  36 . Since the lower flanges  36  extend from the lower edges of the reflectors  32 , seams  40  are also formed on the lowermost surface of the flanges  36  at each corner of the trim assembly  10  at an angle of about forty-five (45) degrees. The seams  40  extend from the seams  34  as best shown in  FIG. 4 . It is also desirable therefore to minimize the seam widths  40  within each of these corners to therefore improve aesthetic appearance of the trim assembly  10  when seen from a room beneath the fixture and trim assembly  10 . 
   Referring now to  FIG. 3 , one of the reflectors  32  is removed to show the curved cross-section of the remaining reflectors  32 . Although the upper opening  16  is defined by a square shape and the lower opening  18  of the inner trim  30  is defined by a square shape, the cross-sections of the reflectors  32  are curved to provide better light control from the reflectors  32 . The reflectors  32  are curved in a concave form when viewed from an interior position of the assembly  10  providing desirable optical performance. The side edges of the reflectors  32  are angled in moving from a smaller upper dimension in the longitudinal direction of the upper flange  38  to a larger dimension in the longitudinal direction of the lower flange  36 . Nonetheless, a cross-sectional view of the exemplary inner trim  30  depicts a square cross-section. 
   Also depicted within  FIG. 3  are a plurality of biscuits  44 . Each flange  36  receives a biscuit  44  at ends of the flange  36 . The biscuits  44  are substantially L-shaped wherein each leg of the biscuit  44  engages one of the reflectors  32 . Specifically, the peripheral edges of the lower flange  36  are rolled, turned or formed with a space wherein the biscuits  44  may be received. Thus, the flanges  36  are frictionally connected and vertical movement, that is movement between horizontal planes, of one flange  36  relative to an adjacent flange  36  is inhibited. In  FIG. 3 , since one of the reflectors  32  is removed, two adjacent biscuits are extending outwardly within the open area wherein the removed reflector  32  should be located. The biscuits  44  provide at least one function in that they maintain each flange  36  at the same elevation so that one flange is not displaced upwardly or downwardly from an adjacent flange  36 , which would be aesthetically unpleasant. 
   Referring now to  FIG. 4 , a bottom view of the inner trim  30  is depicted. As shown from below, the figure depicts the various seams  34 ,  40  of the reflectors  32  and flange  36 . When the inner trim  30  is manufactured, the seams  34  are generally wide due to the movement of the reflector material to a neutral position. However, such seams  34 ,  40  are aesthetically unpleasing when illuminated. From the position depicted, the inner trim  30  requires an external force to close or minimize the seams  34 , 40 . 
   Referring now to  FIG. 5 , an active miter spring  50  is depicted in perspective view. The spring  50  is utilized to engage the outer trim  12  and provide a biasing force on the inner trim  30  so as to decrease the widths of the seams  34  as well as the widths of the seams  40  between the flanges  36 . The active miter spring  50  comprises a first portion  51  and a second portion  53 . The first portion  51  is at an angle of about ninety (90) degrees from the second portion  53 . This arcuate distance is utilized because the spring  50  is connected to the outer trim  12  having a square shape with corners of 90 degrees. If alternative polygonal shapes are utilized for the outer trim  12  and the inner trim  30 , the angles between the spring portions  51 ,  53  may be adjusted to compensate for such shape. For example, if an octagonal shape is utilized for the inner and outer trims  30 , 12 , the angle between first and second portions may be about one hundred thirty-five (135) degrees. Alternatively, if a hexagonal shape is utilized for the inner and outer trims  30 , 12 , an angle of one-hundred twenty (120) degrees may be utilized. Various other shapes may be utilized. Each portion  51 , 53  comprises a first spring wall  52  and an adjacent retaining wall  54 . The spring wall  52  and retaining wall  54  define a hem which will be understood by one of skilled in the art to provide a space wherein a lower edge of the outer trim  12  is positioned. Specifically, each active miter spring  50  is located at a corner of the outer trim  12  as depicted in the previous figures. Retaining wall  54  further comprises a dimple  56  which engages a mating recess or aperture  57  ( FIG. 2 ) on each surface of the outer trim side walls  14 . Additionally, a fastener may extend through features  56 ,  57  to retain springs  50  on the outer trim  12 . Extending from the spring wall  52  is a kick leg  58 . Each kick leg  58  extends inwardly so that when the active miter spring  50  is placed along the lower edge of the outer trim  12 , the kick leg  58  will engage an adjacent reflective surface  32  and force the reflector  32  inwardly, thereby reducing seam width between reflectors  32 . Since each spring  50  engages two reflectors  32 , the two adjacent reflectors  32  are forced toward one another to close seams  34 ,  40  therebetween. 
   Referring now to  FIG. 6 , the spring  50  is depicted from the opposite side as depicted in  FIG. 4 . The hem is generally depicted as U-shaped and connecting the spring wall  52  to the retaining wall  54 . The kick leg  58  is stamped and has a rolled end portion  59  so that when the leg  58  engages an adjacent reflective surface  32 , the reflector  32  is not damaged by a sharp edge or large point force. 
   In assembly, the active miter springs  50  are attached to the outer trim  12  at each corner of the lower edge of the outer trim  12 . The dimple features  56  are aligned with mating apertures  57  in order to retain the springs  50  in position on the outer trim  12 . The outer trim  12  is seated between the spring wall  52  and retaining wall  54  so that the retaining wall  54  is positioned along an outer surface of the outer trim  12 . The flanges  36  of inner trim  30  are next fitted with biscuits  44  so that the flanges  36  are aligned within a horizontal plane. Once each corner of the inner trim  30  comprises a biscuit  44 , the inner trim  30  is positioned upwardly through the lower opening of the outer trim  12 . The reflectors  32  engage the legs  58  as the inner trim  30  is positioned within the outer trim  12 . Due to the engagement of the legs  58  and the reflectors  32 , the reflectors  32  are forced inwardly to tightly engage one another. This engagement reduces width of the seams  34  between reflectors  32 . Likewise, the spring force causes tightening of the seams  40  between the flanges  36 . Due to the tightening of theses seams  34 ,  40 , the use of various flange and trim shapes is possible, since seam width and appearance have generally precluded the use of shapes other than circular. Once the inner trim  30  is positioned within the outer trim  12 , the fasteners  22  are positioned through the upper wall  20  and the upper flange  38 . The fasteners  22  may be a plurality of known fasteners, and in the present embodiment are rivets. 
   The foregoing description of structures and methods has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise steps and/or forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the claims appended hereto.