Patent Publication Number: US-2016245468-A1

Title: Deck light with interchangeable housings

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to the art of low voltage deck lighting. 
     BACKGROUND 
     Various styles of light fixtures have been provided over the years to illuminate outdoor decks, stairways, and the like. For example, such light fixtures are often mounted to a deck structure (e.g., a support post or railing) as a downwardly-directed sconce. By illuminating an area of the surface of the deck, these lights provide pleasing aesthetics and also assist a person who is walking on the deck at night. Deck lights come in a variety of styles and shapes. 
     Common deck lighting systems have three primary components: a power source, electrical wiring, and the individual lighting fixtures. The power source may be a multi-tap transformer that is mounted in a box in the garage or utility closet, plugs into a standard 120 VAC outlet, and provides outputs at multiple voltages. For example, a common multi-tap transformer has AC outputs at 12V, 13V, 14V, and 15V, where the higher voltages are often used to overcome voltage loss from high wattage loads or long cable runs. The transformer box may also have control circuitry and be used as a control panel for collectively controlling the multiple lighting fixtures. For example, the box can include a timer that turns all of the lights on or off at specified intervals. 
     Deck light fixtures typically include integral wiring that extends from the housing a sufficient length for connection to a trunk line extending from the transformer. If a homeowner decided to change the light fixture (such as to achive a new “look”), this would involve the arduous task of not only removing the light fixture from the deck structure, but also removing the associated wiring for that fixture. The replacement fixture is then installed. 
     SUMMARY 
     One aspect of the present invention provides a deck light comprising a back plate having a light source, the back plate configured for attachment to a fixed support structure. A front housing configured for removable coupling to the back plate is also provided. The front housing directs escape of light from the light source in a predetermined direction. One of the back plate and the front housing has a circular opening and another of the back plate and the front housing has a circular flange receivable in the circular opening. An interconnect arrangement is carried by the circular opening and the circular flange, the interconnect arrangement being configured to removably couple the front housing to the back plate. 
     In accordance with a preferred embodiment, the circular opening is defined in the front housing and the back plate includes the circular flange. For example, the interconnect arrangement may comprise at least one radial protrusion on the circular flange and a corresponding slot defined in the circular opening through which the protrusion passes during coupling of the front housing to the back plate. 
     Embodiments are contemplated in which the front housing includes a main cowling to which an adapter plate is attached, the circular opening being defined in the adapter plate. For example, the adapter plate may be generally configured to match the peripheral dimensions of the main cowling. Preferably, the front housing further comprises a lens. 
     According to another aspect, the present invention provides a deck light comprising a back plate configured for attachment to a fixed support structure, the back plate carrying at least one LED. Electrical wiring extends to the back plate for connection to an external power source. A front housing configured for removable coupling to the back plate is also provided, the front housing directing escape of light from the light source in a predetermined direction. The front housing includes a main cowling to which an adapter plate is attached, a circular opening being defined in the adapter plate. The back plate has a circular flange receivable in the circular opening. An interconnect arrangement is carried by the circular opening and the circular flange, and is configured to removably couple the front housing to the back plate. 
     According to another aspect, the present invention provides a method of interchanging a first front housing portion of a deck light with a second front housing portion. One step of the method involves providing a deck light having a back plate attached to a fixed support structure, the back plate carrying at least one LED as a light source. The back plate has a circular flange with at least one interconnect feature configured to removably couple with a corresponding interconnect feature of the first front housing and the second front housing. Another step of the method involves removing the first front housing at least in part by rotation of the first front housing with respect to the back plate in a first rotational direction. According to another step, the second front housing is then coupled at least in part by rotation of the second front housing with respect to the back plate in a second rotational direction. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended drawings, in which: 
         FIG. 1  shows a deck light in accordance with an embodiment of the present invention wherein a front housing is separated from a back plate installed on a deck support post; 
         FIG. 2  is a front elevational view of the embodiment of  FIG. 1  showing coupling of the front housing to the back plate installed on the deck support post; 
         FIGS. 3-5  are exploded views illustrating use of various styles of front housings to a common back plate in accordance with the present invention; and 
         FIG. 6  is a back elevational view of the back plate with a front housing coupled thereto. 
       Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations. 
       FIG. 1  shows a deck light fixture  10  in accordance with an embodiment of the present invention. As can be seen, fixture  10  generally includes a back plate  12  to which a front housing  14  can be coupled. Front housing  14  is interchangeable, meaning that it can have a variety of sizes, shapes, and functions as necessary or desired in a particular case. As a result, the homeowner can change the front housing over the years to provide a “new” light fixture while the infrastructure stays in place. 
     As can be seen, back plate  12  has a circular main portion  16  which is suitably attached to a fixed structure of the deck or the like. In this case, for example, main portion  16  is attached to a wooden support post  18  (e.g., a 4×4 support post) of a homeowner&#39;s deck such as using common wood screws  20 . Electrical wiring  22  extends from main portion  16  for interconnection to the wiring system leading back to the transformer. In a preferred embodiment, the lighting fixture receives power in the same manner as prior art systems—i.e., by direct electrical wiring from the transformer or from another lighting fixture connected in parallel. In one example, the lighting fixture operates nominally at 12 VAC, but the input voltage may vary from 9 VAC to 15 VAC. One skilled in the art will appreciate, however, that various solar- or battery-powered systems are contemplated within the scope of the present invention. 
     Main portion  16  carries a suitable light source to provide the desired illumination. While a variety of light sources are contemplated, many preferred embodiments of the present invention utilize light emitting diode (LED) light sources for their longevity and energy efficiency. In this regard, main portion  16  includes a circuit board  24  having a plurality of LEDs, such as those indicated at  26 . Circuit board  24  also carries other circuit components used to ensure proper operation of the LEDs. 
     An annular flange  28  extends around the periphery of main portion  16 , as shown. Flange  28  is configured to be received in a circular opening  30  defined in an adapter plate  32  of front housing  14 . Flange  28  and circular opening  30  have a mating arrangement which allows front housing  14  to be removably coupled to back plate  12 . In this case, for example, a plurality of (e.g., three) radial protrusions  34  are situated at spaced apart locations around flange  28 . Radial protrusions  34  are sized to extend through corresponding slots  36  defined in circular opening  30 . After the protrusions clear the slots, they will be received in an enlarged diameter groove  37  ( FIG. 3 ) which allows rotation of front housing  14  with respect to back plate  12 . 
     Thus, referring now also to  FIG. 2 , the manner in which front housing  14  is coupled to back plate  12  can be explained. Front housing  14  is moved to back plate  12  with front housing  14  in position A. In position A, protrusions  34  can be received through the slots  36 . Once front housing  14  is fully seated on annular flange  28 , it can be rotated to the final position for use (position B). Front housing  14  can be decoupled and removed by reversing this process. 
     Referring now to  FIG. 3 , certain additional details regarding fixture  10  can be seen. For example, a resilient O-ring  38  or other suitable seal may be placed at the interface of flange  28  and opening  30  in order to inhibit water penetration at this location. As can be seen, adapter plate  32  is generally configured to match the peripheral dimensions of a main cowling  40  of front housing  14 . A transparent lens  42  is located, in this embodiment, in the downward-facing opening of main cowling  40  to allow light to escape in this direction. Specifically, lens  42  is captured and retained in this embodiment between main cowling  40  and adapter plate  32 . Adapter plate  32  is suitably attached to main cowling  40  via any suitable means, such as screws  44 . Screws  44  extend through apertures in adapter plate  32  and are received in threaded holes defined in main cowling  40 . 
       FIGS. 4 and 5  illustrate how back plate  14  can be used with a variety of different main cowlings. The adapter plate will be modified depending on the size and shape of the cowling with which it will be used. In  FIG. 4 , for example, the front housing includes an alternative main cowling  140  which is coupled with back plate  12  via a generally square adapter plate  132 . A transparent lens  142  is located in a downward-facing opening of main cowling  140 .  FIG. 5  shows an alternative main cowling  240  which is coupled to back plate  12  via an adapter plate  232 . In this case, light escapes through a series of horizontal openings defined by respective louvers  50  of main cowling  240 . A transparent lens  242  is captured between adapter plate  232  and cowling  240 . 
     Certain additional details of light fixture  10  are shown in  FIG. 6 . As can be seen, back plate  12  defines one or more openings  52  through which suitable fasteners (e.g., wood screws  20 ) can be received for attachment to a support structure. A small removable access plate  56  facilitates passage of electrical wiring into back plate  12  during the assembly process. 
     It can thus be seen that the present invention provides a deck light having interchangeable front housings. Although the invention has been described using preferred embodiments any combination of the features discussed are included within the scope of the invention. Explanation is by way of example only and the disclosure is not meant to be limiting.