Patent ID: 12196394

DETAILED DESCRIPTION

Reference in the specification to “one embodiment” or “an embodiment” of the present invention, as well as other variations thereof, means that a particular feature, structure, characteristic, and so forth described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrase “in one embodiment” or “in an embodiment”, as well any other variations, appearing in various places throughout the specification are not necessarily all referring to the same embodiment.

Retrofitting a fluorescent light fixture with an LED panel can include removing the entire fluorescent light fixture, e.g., lens, bulbs, ballasts, and housing components such as ballast cover, etc. The added time and expense associated with such complete removal in the case of retrofitting can become extremely burdensome. Accordingly, there is a need for an LED panel system that can be easily retrofitted into existing ceiling-mounted light fixtures with minimal time and expense that replicate the appearance and electrical efficiency of modern LED panels.

For the methods and structures of the present disclosure, a luminaire retrofit kit design is proposed that has installation features, such as assembly and retaining mechanisms, that can facilitate installation of the luminaire inside a traditional fluorescent fixture and thus helps save install time and costs. The assembly mechanism is fixed, and the retaining mechanism can be adjusted (slide) as needed.

Prior to the methods and structures of the present disclosure, a retrofit luminaire used to be installed in the traditional fluorescent housing using a metal mounting frame. The metal mounting frame consists of four individual rectangular metal bars. These four metal bars are added in sequence between the traditional fluorescent housing and the ceiling grid. These metal bars have features on end of each rectangular metal bars to engage onto the other bars and thus make the closed mounting frame. The metal mounting frame has installation features, such as two keyhole slots, and the Luminaire has corresponding features such as two mounting bolts (one of each end of the luminaire). The luminaire is temporarily hung on the mounting frame by aligning the mounting bolt on luminaire with the keyhole slots and sliding it in. Then after the electrical connections are made, the luminaire is pushed towards the ceiling and fully mounted using the retaining mechanism. This is a tedious and time-consuming process of fully installing the luminaire in the traditional fluorescent housing which adds significant labor costs.

As will further be described herein, the deficiencies of the aforementioned method are overcome by the retrofit system of the present disclosure that includes an assembly mechanism structure and retaining mechanism structure, which can help to lower the cost of installation, saves on the installation time, and is easy and quick to install.

The driver structures and methods that are provided herein are now described with more detail with reference toFIGS.1-32.

Referring toFIGS.1and2, in one embodiment, the luminaire retrofit kit100includes an assembly mechanism150and a retaining mechanism200.FIG.1illustrates the assembly mechanism150attached to the housing50of a light emitting diode (LED) based luminaire for the luminaire retrofit kit of the present disclosure.FIG.2illustrates a retaining mechanism attached to the housing of a light emitting diode (LED) based luminaire for the luminaire retrofit kit of the present disclosure.

Referring toFIGS.1,3and4, the assembly mechanism structure150is one of the design features for the luminaire retrofit kit that provides key design features for easy and quick installation. The assembly mechanism structure150includes a rod151, a tether cable152and a housing bracket153.

The rod151provides an engagement point for the assembly mechanism structure150to the pre-installed fluorescent base housing300.FIG.5illustrates one embodiment of a pre-installed fluorescent base housing300, andFIG.6illustrates a magnified view of the slot302and opening301that are typical of a fluorescent base housing300. As will be described herein, the rod151that is on the end of the tether cable152that is opposite the end of the tether cable152that is connected to the luminaire housing300is inserted into the opening301in the fluorescent base housing300during the retrofit installation of the light emitting diode (LED) luminaire.

Referring toFIGS.1,3and4, in some embodiment, the rod151may be composed of rigid material, such as a metal or rigid plastic. The dimensions of the rod151are selected to allow for the rod151to an opening301in the fluorescent base housing300.

For example, the rod151may be composed of a metal, such as aluminum or steel. The rod151may include an opening therethrough. The opening through the rod151may provide for the tether cable152to be passed therethrough. In some embodiments, the portion of the tether cable152that extends through the opening of the rod151may be engaged to the rod151by a fastener156In some examples, the fastener156may be an aviation cable terminal, in which the terminal engages the end of the tether cable152that extends through the opening of the rod151. The diameter of the terminal is larger than the diameter of the opening through the rod151. The terminal may be an end stop, ball stop, and the terminal may be installed using swage methods.

The tether cable152of the assembly mechanism structure may be any flexible rope, wire and/or cable. In one example, the tether cable152can be provided by an aircraft cable. Aircraft cables are stranded wires. As a general rule, Aircraft Cable is ⅜″ and smaller, e.g., being available in 3/16″ and ¼″ sizes, which can each be suitable for the tether cable152. The aircraft cable in 7×7 and 7×19 constructions. Aircraft Cables have a wire core in the same construction as the outer strands. Commercial quality “aircraft grade” cable is made from galvanized steel wire or stainless steel wire. Galvanized aircraft cable provides high tensile strength and adequate corrosion resistance for most commercial applications.

The length L1 of the tether cable152is selected to allow for the retrofit luminaire, e.g., luminaire base50, to be secured to the fluorescent base housing30by engagement of the rod151to the opening301of the fluorescent base housing300. However, the length L1 is also sufficient to allow for the luminaire base50to be manipulated, e.g., moved back and forth, while the rod151is engaged to the opening301, which provides for the retrofit luminaire to be manipulated so that the retaining mechanism200can be engaged to the slot302of the fluorescent base housing300providing that the luminaire retrofit is seated in installation to the fluorescent base housing300.

Referring toFIGS.1,3and4, the end (i.e., bracket end) of the tether cable152that is opposite the end of the tether cable152that is engaged to the rod151is attached to a bracket153. The bracket end of the tether cable152may include an eye loop that engages an opening154in the vertical wall153aof the bracket153. The eye loop may include a fastener156that engages the end of the tether cable152in a closed loop, as depicted inFIG.3. The fastener156may be connected by swage. An eye end, i.e., a terminal having an eye, may be substituted for the loop end.

Referring toFIG.3, the bracket153is the portion of the assembly mechanism structure150that is engaged to the retrofit luminaire, e.g., base50of the retrofit luminaire. The bracket153is composed of a rigid material. For example, the bracket153may be composed of a metal or a rigid plastic. In some embodiments, the bracket153is composed of a metal, such as aluminum or steel. The bracket153may include a vertically orientated riser portion, e.g., a vertical wall153a, and a base153b. The vertical wall153amay be disposed at a substantially 90 degree angle with the base153bto provide that the bracket153has a substantially L-shaped geometry when viewed from a side view perspective. The vertical wall153may include at least one opening154for engagement by the eye loop of the tether cable152, i.e., the bracket end of the tether cable152. The base153bof the bracket153includes at least one fastener opening for engagement of the bracket153to the housing of the retrofit luminaire, e.g., base50of the retrofit luminaire.

FIG.4illustrates engagement of the bracket153to the base of the retrofit luminaire by fasteners157. For example, the fasteners157may be rivets, screws or may be provided by nut and bolt arrangements. As illustrated inFIG.1, the bracket153may be used to engage the tether cable152of the assembly mechanism structure150to the luminaire base50at its perimeter, which includes a lip that is adjacent to a portion of the body that is recessed to provide depth for housing the light engine and components through which the luminaire provides lighting. In some embodiments, the bracket153of the assembly structure150is engaged to the lip of the luminaire base50. As illustrated, four of the assembly mechanism structures150may be engaged to the base50of the luminaire, in which one of the assembly mechanism structures150are positioned at each of the four corners of the rectangular shaped luminaire base50. It is noted that this is only one example of the retrofit luminaire assembly, and it is not intended that the present disclosure be limited to only this example.

In some embodiments, the assembly mechanism structure150helps with assembly of the luminaire, e.g., retrofit light emitting diode (LED) luminaire, inside the traditional fluorescent housing300. The assembly mechanism structures150may be attached, e.g., factory installed, onto the back of the housing for the retrofit light emitting diode (LED) luminaire, e.g., base50of the luminaire. The location of the assembly mechanism structure150are fixed; and the location is optimized based on the installation slot302location on the traditional fluorescent housing300.

During installation, the slim rod151on other end of the tether152is inserted in the hole301of the traditional fluorescent housing200(near the mounting slot302) and pulled back. This helps the luminaire to hang from the traditional fluorescent housing300, which will help to do the next installation step.

FIGS.2and7-31illustrate some embodiments of the retaining mechanism200that can be engaged to the slot302of the fluorescent base housing300to provide that the luminaire retrofit is seated in installation to the fluorescent base housing300. In some embodiments, the retaining mechanism200is a mechanism that helps to fully retain/install the luminaire inside the traditional fluorescent housing300which helps keep the luminaire stay in flush with the ceiling.

The retaining mechanism includes a track bracket201, and at least one retaining clip assembly210b,210c,210d,210e. The track bracket201connects the retaining mechanism to the luminaire housing50. The track brackets201are attached to the back of the luminaire (either factory or field installed). The design of the retaining mechanism200is such that the retaining clip assembly210a,210b,210c,210d,210eis snapped (or inserted) inside the extruded profile of the track bracket201that is connect to the luminaire. The location of the retaining mechanism200is optimized based on the location of the installation slot302of the traditional fluorescent housing300. These retaining mechanism200can be adjusted by sliding the retaining clip assembly210a,210b,210c,210d,210einside the extrusion, i.e., track bracket201, by the customer based on the slot location302in the traditional fluorescent housing300. During installation, of the retrofit light emitting diode (LED) luminaire to the traditional fluorescent housing300, the torsion springs205are compressed and then inserted inside the open slot, e.g., installation slot302, of the traditional fluorescent housing300. After insertion into the slot302, the torsion springs205are released, and the design of the torsion spring205pulls the luminaire, i.e., retrofit light emitting diode (LED) luminaire, towards the traditional fluorescent housing300, and keeps it flush with the ceiling. In some embodiments, the hook on the end of the spring205helps keep the luminaire in the housing. In some embodiments, there are about four retaining mechanisms200per luminaire.

FIGS.7-11illustrate one embodiment of a retaining mechanism200. The retaining mechanism200may include a track bracket201. The track bracket201may be composed of a rigid material, e.g., a plastic or metal. For example, the track201may be composed of an extrusion of a metal, such as aluminum or steel. The extrusion process by which the track201is formed provides that the track201has the same cross-sectional across it's length, i.e., the entirety of the length, but for sections that have been machined. For example, the extrusion may be machined to provide slot openings for insertion of the retaining clip assembly210a,210b,210c,210d,210e, as well as fastener openings through which a fastener may be used engage the track201to the luminaire housing50.

Referring toFIG.7, the track201includes a retaining profile having at two ridges R1, R2, in which at least one of the two ridges R1, R2is for engaging a retention tab203of the retaining clip bracket202. The ridge R1, R2when viewed from a side cross-sectional view is part of an inverted “J” shape when viewed with sidewalls S1, S2of the trench201that the ridges extend into. The trench of the track may also be referred to as a race of the track201. The height of the sidewalls S1, S2is selected to provide a trench199for the track having a sufficient depth for engaging the retention tab203. The width W1separating the ridges R1, R2at the ends of the sidewalls S1, S2of the track201is selected so that the retention tab203can deform into a compressed position as the retention tab203is pushed into the race199of the track201. The width W1is also selected to provide that after the retention tab203is pushed through the opening defined by the space separating the ridges R1, R2, the retaining end (also referred to as shrapnel) of the retention tab203can deflect back to its original geometry that it had prior to being deformed while pressed through the opening to the race of the track201. As will be described below, when the retention tab203deflects, the retaining end can snap into the one of the retaining ridge R1, R2.

Still referring toFIG.7, the race199of the track201is adjacent to a fastener engagement portion198. As noted above, the track bracket201can be connected to the retrofit light emitting diode (LED) luminaire using fasteners, such as screws, and or nut and bolt arrangements. As illustrated inFIG.7, the fastener engagement portion198may included a threaded sidewall. In some embodiments, the track bracket201may also include an extension (retention extension197) that provides additional retention support for the retrofit light emitting diode (LED) luminaire.

FIG.8illustrates one embodiment of a retention clip assembly210athat can be used to engage the track bracket201that is illustrated inFIG.7. For example, the retention clip assembly210amay include a retention clip back202that provides for a retention loop206for the torsion spring205, as well as includes two inner retention tabs203and an outer retention tab204. The aforementioned elements are within a unitary structure that may be composed of a metal, such as steel or aluminum. For example, the aforementioned elements of the retention clip assembly may be formed from sheet metal and stamped. The two inner retention tabs203are for engagement to the inner surfaces of at least one of the ridges R1, R2, once they have been pressed through the opening to the race199of the track201depicted inFIG.7

Referring back toFIG.8, the retention clip assembly210aalso includes a torsion spring205. The torsion spring205depicted inFIG.8may be composed of high carbon spring steel in wire form. The torsion spring205includes a partial loop205afor engagement to the retention loop206of the retention clip back202. The torsion spring205may also include arms205bthat extend from the partial loop in a V-shaped geometry. In some embodiments, the tips of the arms205beach include a hook that is designated by reference number205c. The width of the V-shaped geometry for the arms205bof the torsion spring205, and the deflecting nature of the torsion spring material allows for the torsion spring205to be compressed to width that allows for the arms205bof the torsion spring205to be inserted into the installation slot302of the of the pre-installed fluorescent housing300. By “pre-installed” it is meant that the fluorescent housing300is mounted to the ceiling prior to the retrofit light emitting diode (LED) being installed to the fluorescent housing.

FIGS.9-11illustrate one embodiment of engagement of the retention clip assembly210athat is depicted inFIG.8being inserted into the track bracket201that is depicted inFIG.7.FIG.9illustrates the retention clip assembly210ain a pre-installed position proximate to the opening between the ridges R1, R2of the track, in which the opening leads to the race199of the track201.

FIG.10illustrates the initial insertion of the retention clip assembly210ainto the opening of the track bracket201to the race199of the track that is defined between the ridges R1, R2. The outer retention tab204engages the outer surface of the inner sidewall S2that is present between the race199of the track and the portion of the track bracket201that includes the fastener engagement portion198. Still referring toFIG.10, the two inner tabs203′ are depicted as being deformed (compressing the spring) in a first direction D1. At the stage of installation depicted inFIG.10, the back surface of the inner retaining tabs203′ are in direct contact with the first ridge R1, and the deformable opposing surface (also referred to as retaining prong) of the inner retaining tabs203′ are in direct contact with the second ridge R2. Because the width of the opening to the race199of the track is narrower than the relaxed with of the retaining tabs203(as depicted inFIGS.8and9), pressing the inner retaining tabs203against the ridges compresses the retaining tabs.

FIG.11illustrates the retaining tabs203″ after they have been fully inserted into the race199of the track201. When fully inserted, the end of the retaining tabs203″ extend beyond the ridges R1, R2of the sidewalls S1, S2that provide the track201, wherein once fully inserted, any force that compressed the inner retaining tabs203is removed, which allows the inner retaining tabs23to relax. As the inner retaining tabs203relax, the retaining prong portion of the retaining tabs203deflects in a second direction D2(opposite the first direction D1) to provide that the retaining prong snaps back into engagement with at least one of the retaining ridges R1, R2. In the embodiment that is depicted inFIG.11, the retaining prong of the inner retaining tabs203snaps back into the retaining ridge that is identified by reference number R2, which is present between the fastener engagement portion198and the race199. As the inner retaining tabs203are fully seated, the outer retention tab203caps the outer surfaces of the retaining ridge R2that the retaining prong has engaged.

FIGS.10and11further illustrate how fasteners207are used to engage the track bracket201to the luminaire housing50. As illustrated inFIGS.10and11, the fasteners extend through a hole in the luminaire base housing50, and are received in threaded engagement to the track201.

FIGS.12-15illustrate yet another embodiment of the present disclosure.FIG.12illustrates one embodiment that includes retaining tab208that are similar to the embodiments described with reference toFIGS.8-11. However, the retention clip assembly210bthat is depicted inFIGS.12-15includes retaining tabs208having retaining prongs facing in opposing directions to engage both ridges R1, R2of the track bracket201, which is differentiated from the retaining tabs203of the embodiment depicted inFIGS.8-11that only include retaining prongs facing in one direction. The retaining tabs208depicted inFIG.12may be composed of stamped metal, e.g., steal or aluminum, similar to the retaining tabs203that have been described above with reference toFIGS.8-11. However, the retaining tabs208do not include a vertically orientated retention clip back202. Instead, the retaining tabs208are connected to a torsion spring205by fasteners209, e.g., a rivet, threaded bolt and/or nut and bolt arrangement. In the example depicted inFIG.12, the fastener209is a rivet. The torsion spring205may be composed of high carbon spring steel in flat form, as depicted, or the torsion spring may be composed of high carbon spring steel in wire form. Similar to the torsion spring205that is depicted inFIG.18, the torsion spring205that is illustrated inFIG.12may include two arms positioned to provide a V-shape, and a hook may be positioned at the end of each arm.

FIG.13illustrates the retention clip assembly210bin a pre-installed position proximate to the opening between the ridges R1, R2of the track, in which the opening leads to the race199of the track201.

FIG.14illustrates the initial insertion of the retention clip assembly210binto the opening of the track bracket201to the race199of the track that is defined between the ridges R1, R2. The retaining clip assembly210bdoes not include an outer retention tab, such as the outer retention tab of the embodiment that is described with reference toFIGS.8-11. The retention clip assembly210bonly includes inner retention tabs208, e.g., four inner retention tabs208. In the embodiment depicted inFIG.14, the retention clip assembly210bincludes four inner retention tabs208. The retention tabs208of the retention clip assembly210bthat is depicted inFIG.14include retention prongs that are positioned to engage each of the retaining ridges R1, R2. For example, two of the retention prongs are arranged so that the retaining prong of the retention tabs208snap into engagement of a first ridge R1of the track bracket201, and two of the retaining prongs are arranged so that the retaining prong of the retention tabs208snap into engagement of a second ridge R2.

Still referring toFIG.14, the four retention tabs208, e.g., inner retention tabs, are depicted as being deformed (compressing the spring) in a first initial direction. Because the width of the opening to the race199of the track is narrower than the relaxed width of the retaining tabs208(as depicted inFIGS.12and13), pressing the inner retaining tabs208against the ridges compresses the retaining tabs.

FIG.15illustrates the retaining tabs208after they have been fully inserted into the race199of the track201. When fully inserted, the end of the retaining tabs208extend beyond the ridges R1, R2of the sidewalls S1, S2that provide the track201, wherein once fully inserted, any force that compressed the retaining tabs208is removed, which allows the inner retaining tabs208to relax. As the inner retaining tabs208relax, the retaining prong portion of the retaining tabs208deflects in a direction opposite the direction of deformation depicted inFIG.14to provide that the retaining prong snaps back into engagement with at least one of the retaining ridges R1, R2.

FIGS.13-15further illustrate how fasteners207are used to engage the track bracket201to the luminaire housing50. As illustrated inFIGS.13-15, the fasteners207extend through a hole in the luminaire base housing50, and are received in threaded engagement to the track201.

FIGS.16-19illustrate yet another embodiment of the present disclosure.FIG.16illustrates another embodiment of a retention clip assembly210c. The retention clip assembly210cillustrated inFIG.16includes a holder plate215having sliding retaining tabs211with a geometry corresponding to the geometry of the side cross-section of the race199of the track bracket201. The holder plate215may be composed of a rigid material, such as a metal or plastic. For example, the holder plate215may be composed of steel or aluminum, which is stamped into the geometry depicted inFIGS.16-19. Similar to the embodiment that is depicted inFIGS.8-11, in some instances the holder plate215may include a vertically oriented portion, e.g., retention clip back202, that includes a retention loop206for affixing the torsion spring205to the holder plate215. The torsion spring205may be composed of high carbon spring steel in flat form, as depicted, or the torsion spring may be composed of high carbon spring steel in wire form. Similar to the torsion spring205that is depicted inFIG.18, the torsion spring105that is illustrated inFIG.12may include two arms positioned to provide a V-shape, and a hook may be positioned at the end of each arm.

The holder plate215also includes a base portion for engaging the track bracket201. In this instance, the retention clip assembly210cincludes sliding retaining tabs211that have an inverted T-shaped geometry. The inverted T-shaped geometry of the sliding tabs211includes a horizontally elongated portion211athat has a width W3that engaged the ridges R1, R2of the track bracket201. In the embodiment that is depicted inFIGS.16-19, as opposed to the sliding retaining tabs211being deformed to be inserted into the race199of the track bracket201as employed in the embodiments depicted with reference toFIGS.1-15, the retention clip assembly210is initially inserted into the race199of the track bracket through an installation opening216. In this embodiment, the installation opening216may be machined into the extrusion that provides the track bracket201. The installation opening216has a width W4that exceeds the width W5that separates the retaining ridges R1, R2.

FIG.17illustrates the retaining clip assembly210cin a pre-installed position proximate to the installation opening216of the track, in which the installation opening has a width W4that allows for insertion of the sliding tabs211to the race199of the track201.

FIG.18illustrates the retaining clip assembly210cbeing inserted into the installation opening216prior to the retaining clip assembly210cbeing slid into the portion of the track adjacent to the installation opening216having a reduced width W4including retaining ridges R1, R2for retaining the sliding tabs211of the retaining clip assembly210cin the race199.

FIG.19illustrates the retaining clip assembly210cbeing slid along the track bracket201from the installation opening216to a portion of the race199at which the retaining ridges R1, R2product a less width W4than the installation opening216. The reduced width W4separating the retaining ridges R1, R2is sufficient to obstruct the horizontally elongated portion211aof the sliding tab (e.g., having a width W3) that engages the ridges R1, R2of the track bracket201from being removed from the race199.

Under these conditions, the retaining clip assembly210cis first inserted into the race199of the track bracket201through the installation opening216having a width W5for receiving the retention clip assembly210c, and then the retention clip assembly210cis slid into the portion of the track bracket201having a reduced width W4including the retaining ridges R1, R2, at which the retaining ridges R1, R2engage the horizontally elongated portion211aof the sliding tabs211.

FIGS.17-19further illustrate how fasteners207are used to engage the track bracket201to the luminaire housing50. As illustrated inFIGS.13-15, the fasteners207extend through a hole in the luminaire base housing50, and are received in threaded engagement to the track201.

FIGS.20-23illustrate yet another embodiment of a retention clip assembly210dfor use with the track bracket201(e.g., the track bracket201depicted inFIG.7). The retention clip assembly210dillustrated inFIG.20includes a torsion spring205, a holder boss212and a holder boss fastener213. The torsion spring205has been described above with reference to the embodiment that is depicted inFIGS.12-15.

The holder boss212has a geometry, e.g., width W6, for insertion into the race of the track bracket201through an insertion opening106; yet the geometry also allows for engaging the ridges R1, R2of the track bracket201for securing the retention clip assembly210dat a fixed position to the track bracket201. The holder boss212may be composed of a rigid material, e.g., metal or plastic. In some embodiments, the holder boss212is composed of aluminum or steel. The head of the holder boss212may have a perimeter that can be substantially circular; however, multi-sided geometries are also contemplated. The head of the boss holder212is the portion of the holder boss212for insertion into the race199of the track bracket201, and the head of the boss holder212can contact the ridges R1, R2.

The holder boss212includes an engagement point for engagement to the holder boss fastener213. In some embodiments, the engagement point of the holder boss212is threaded for reversible engagement by a holder boss fastener213having a compatible thread. In addition to the thread of the holder boss fastener213, the holder boss fastener213may also include a head that includes a drive. The drive may have the configuration of Phillips-head, flat-head, hex, torx, double hex, Robertson (scrulox), etc. The holder boss fastener213may be composed of steel, stainless steel and/or brass, but other materials may be equally suitable. Still referring toFIG.20, the holder boss fastener213is inserted through an opening in the torsion spring205, and the tip of the holder boss fastener213is then inserted into the holder boss212, which fastens the torsion spring205to the holder boss212.

FIG.21illustrates the retention clip assembly210din a pre-installed position proximate to the insertion opening216of the track201.FIG.22illustrates the initial insertion of the retention clip assembly210dinto the insertion opening216of the track bracket201to the race199of the track that is defined between the ridges R1, R2. At the point of installation depicted inFIG.22, the holder boss fastener213has not been driven to provide for clearance between the holder boss and the retaining ridges R1, R2so that the retaining clip assembly210dcan be slid along the race199until in a position at which the retaining clip assembly210dcan be fixed for further installation of the retrofit of the light emitting diode (LED) luminaire to the fluorescent base housing300. It is noted that the above concept may be avoided for providing for increased installation simplicity. The screw can be retightened in the factory to the necessary settings.

FIG.23illustrates the retention clip assembly210dbeing traversed from the position in the track bracket201including the insertion opening216to a portion of the track bracket201at which the race199includes the retaining ridges R1, R2. The torsion spring205is present on a first side of the retaining ridges R1, R2that is exterior to the track199. The head of the holder boss fastener213is also present on the first side of the retaining ridges R1, R21that is exterior to the track199. The threaded portion of the boss fastener213(as well as at least a portion of the shank portion (when present)) of the boss fastener213) are present extending through the opening separating the retaining ridges R1, R2. The tip of the boss fastener213, as well as the holder boss212are present within the race199. In some embodiments, when the drive of the retaining fastener213is torqued, i.e., driven, the boss fastener213threads into the holder boss212, which brings the head of the holder boss212into contact with the back surface of the retaining ridges, and secures the retention clip assembly into place at a fixed position to the track bracket201.

FIGS.21-23further illustrate how fasteners207are used to engage the track bracket201to the luminaire housing50. As illustrated inFIGS.21-23, the fasteners207extend through a hole in the luminaire base housing50, and are received in threaded engagement to the track201.

FIGS.24-27depict yet another embodiment of the present disclosure, in which a torsion spring is configured to provide an entirety of the retention clip210e. The retention clip210eincludes a base225for engaging the retaining ridges R1, R2of the track bracket201. Similar to the above described torsion spring205, the retention clip210emay be composed of high carbon spring steel in wire form. The torsion spring205may also include arms205bthat extend from the loop of the wire form spring steel material that provides the base225in a V-shaped geometry. In some embodiments, the tips of the arms205beach include a hook that is designated by reference number205c. The width of the V-shaped geometry for the arms205bof the torsion spring205, and the deflecting nature of the torsion spring material allows for the torsion spring205to be compressed to width that allows for the arms205bof the torsion spring205to be inserted into the installation slot302of the of the pre-installed fluorescent housing300. The base225includes a coil of the torsion spring wire with a width in a direction D3perpendicular to the direction D4that the arms205bextend along. This provides the width W7of the retention clip210ethat is positioned within the race199of the track bracket201, and is retained within the race199of the track bracket201by the ridges R1, R2.

FIG.25illustrates the retention clip210ein a pre-installed position proximate to the insertion opening216of the track201.FIG.26illustrates the initial insertion of the retention clip assembly210einto the insertion opening216of the track bracket201.FIG.27illustrates the retention clip210ebeing traversed from the position in the track bracket201including the insertion opening216to a portion of the track bracket201at which the race199includes the retaining ridges R1, R2.

Referring toFIG.27, the arms205bof the torsion spring that provide the retention clip210eextend through an opening between the ridges so that a majority of the arms205bare present on a first side of the retaining ridges R1, R2that is exterior to the track199. The base225of the retention clip210eis present within the race199. The width of the base225of the retention clip201eis sufficiently wide to contact with the back surface of the retaining ridges R1, R2, which secures the base portion225of the retention clip210ewithin race199of the track bracket201.

FIGS.25-27further illustrate how fasteners207are used to engage the track bracket201to the luminaire housing50. As illustrated inFIGS.25-27, the fasteners207extend through a hole in the luminaire base housing50, and are received in threaded engagement to the track201.

FIGS.28-31illustrate an even further embodiment of a retention clip assembly210ffor use with the track bracket201(e.g., the track bracket201depicted inFIG.7). The retention clip assembly210fillustrated inFIG.28includes a torsion spring205, a holder plate230, a holder boss212and a holder boss fastener213. The torsion spring205has been described above with reference to the embodiment that is depicted inFIGS.12-15.

The holder plate230depicted inFIG.28is similar to the retention clip back202that is depicted inFIG.8. For example, the holder plate230may include a retention loop206for the torsion spring205. The retention loop206is an element of the vertically orientated portion of the retention clip back202. The base of the holder plate230is horizontally oriented, and includes an opening for engagement by the holder boss fastener213. The holder boss fastener213extends through the opening of the base of the holder plate into engagement with holder boss212, in which the holder boss212and the head of the holder boss fastener213are on opposing sides of the base of the holder plate230. The holder boss212engages the retaining ridges R1, R2of the track bracket while being positioned within the race199. The holder plate230may be composed of a metal, such as steel or aluminum. For example, the holder plate230of the retention clip assembly210fmay be formed from sheet metal and stamped. The retention back clip202when viewed from a side view can have an L-shaped cross-section.

The holder boss212and holder boss fastener213that are depicted inFIG.28are similar to the holder boss212and the holder boss fastener213that is illustrated inFIGS.20-23. In accordance with some embodiments, the description of the holder boss212and the holder fastener213for these elements depicted inFIGS.20-23is suitable for describing these similar elements having similar reference numbers inFIGS.28-31.

FIG.29illustrates the retention clip assembly210fthat is illustrated inFIG.28in a pre-installed position proximate to the insertion opening216of the track201.FIG.30illustrates the initial insertion of the retention clip assembly210finto the insertion opening216of the track bracket201to the race199of the track that is defined between the ridges R1, R2. At the point of installation depicted inFIG.29, the holder boss fastener213has not been driven to provide for clearance between the holder boss and the retaining ridges R1, R2so that the retaining clip assembly210fcan be slid along the race199until in a position at which the retaining clip assembly210fcan be fixed for further installation of the retrofit of the light emitting diode (LED) luminaire to the fluorescent base housing300.

FIG.31illustrates the retention clip assembly210fbeing traversed from the position in the track bracket201including the insertion opening216to a portion of the track bracket201at which the race199includes the retaining ridges R1, R2. The torsion spring205is present on a first side of the retaining ridges R1, R2that is exterior to the track199. The head of the holder boss fastener213is also present on the first side of the retaining ridges R1, R2that is exterior to the track199. The threaded portion of the boss fastener213(as well as at least a portion of the shank portion (when present)) of the boss fastener213) are present extending through the opening separating the retaining ridges R1, R2. The tip of the boss fastener213, as well as the holder boss212are present within the race199. In some embodiments, when the drive of the retaining fastener213is torqued, i.e., driven, the boss fastener213threads into the holder boss212, which brings the head of the holder boss212into contact with the back surface of the retaining ridges, and secures the retention clip assembly210finto place at a fixed position to the track bracket201.

FIGS.29-31further illustrate how fasteners207are used to engage the track bracket201to the luminaire housing50. As illustrated inFIGS.29-30, the fasteners207extend through a hole in the luminaire base housing50, and are received in threaded engagement to the track201.

FIG.32illustrates the embodiment of the retention clip assembly210fthat is depicted inFIGS.29-30that provides a retaining mechanism200for the luminaire retrofit being integrated with an assembly mechanism150for the luminaire retrofit. It is noted that any of the retaining clip assemblies210a,210b,210c,210dand retaining clips210edescribed herein may be substituted for the retaining clip assembly210fthat is depicted inFIG.32.

While the retaining mechanism200and the assembly mechanism150may be employed with retrofit installation of LED light panels into an existing ceiling-mounted fluorescent light fixtures, the inventive retrofit panel and anchor/hanging system has application in potentially any type of light fixture. In some embodiments, the retrofit panel50may have a lens, screen, diffuser, LED panel, or other insert used in the openings of similar ceiling-mounted light fixtures.

In some embodiments, the electronics of representative LED light panel50discussed are described in US Patent Application Publication Nos. 2013/0033861 and 2015/0023010. However, the present disclosure is not intended to be limited by these examples, as the methods and structures are directed to the installation of LED light panels50in retrofit applications, e.g., installation into existing ceiling-mounted fluorescent light fixtures, and is not to be limited by the different electrical implementations. In some examples, the LED light panel50generally has a border frame that encloses a sheet of LED sources disposed behind a light diffusing lens. A “light-emitting diode (LED)” is a semiconductor device that emits light when current flows through it. Some examples of LED light emitters that are suitable for the methods and structures described herein include inorganic semiconductor light-emitting diodes (LEDs), organic light-emitting diodes (OLED), polymer light-emitting diodes (PLED) or combinations thereof. Although the following description describes an embodiment in which the solid-state light emitters are provided by light emitting diodes, any of the aforementioned solid-state light emitters may be substituted for the LEDs. In some embodiments, the LEDs of the luminaire are selected to be capable of being adjusted for the color of the light they emit. The term “color” denotes a phenomenon of light or visual perception that can enable one to differentiate objects. Color may describe an aspect of the appearance of objects and light sources in terms of hue, brightness, and saturation. Some examples of colors that may be suitable for use with the methods and structures described herein can include red (R), orange (O), yellow (Y), green (G), blue (B), indigo (I), violet (V) and combinations thereof, as well as the numerous shades of the aforementioned families of colors. It is noted that the aforementioned colors are provided for illustrative purposes only and are not intended to limit the present disclosure as any distinguishable color may be suitable for the methods, systems and computer program products described herein.

The LEDs of the retrofit LED light panels50may also be selected to allow for adjusting the “color correlated temperature (CCT)” of the light they emit. The color temperature of a light source is the temperature of an ideal black-body radiator that radiates light of a color comparable to that of the light source. Color correlated temperature is a characteristic of visible light that has applications in lighting, photography, videography, publishing, manufacturing, astrophysics, horticulture, and other fields. Color correlated temperature is meaningful for light sources that do in fact correspond somewhat closely to the radiation of some black body, i.e., those on a line from reddish/orange via yellow and more or less white to blueish white. Color correlated temperature is conventionally expressed in kelvins, using the symbol K, a unit of measure for absolute temperature. Color correlated temperatures over 5000 K are called “cool colors” (bluish white), while lower color temperatures (2700-3000 K) are called “warm colors” (yellowish white through red). “Warm” in this context is an analogy to radiated heat flux of traditional incandescent lighting rather than temperature. The spectral peak of warm-colored light is closer to infrared, and most natural warm-colored light sources emit significant infrared radiation. The LEDs of the luminaires provided by the present disclosure in some embodiments can range from 2000K to 6500K.

The retrofit LED light panels50also include a driver or similar control mechanism that is disposed within an interior of the panel opposite the lens. An electrical source is connected to the driver to power the LED light panel. The electrical source may be switched or otherwise adjustable.

In some comparative light panels, the border frame is sized and configured to occupy the same space in a ceiling as the housing on a prior art ceiling-mounted light fixture. This would typically be the frame in a drop tile or hard lid ceiling, but may also be an opening in a drywall or stucco ceiling.

In contrast, in some embodiments of the luminaire retrofit assemblies of the present disclosure, the LED light panel50can be configured to fit within the opening of the housing300of an existing ceiling-mounted light fixture, such as the pre-installed fluorescent base housing300that is depicted inFIGS.5and6. In some embodiments, the border frame12is configured and sized so that the LED light panel50sits flush with the housing300as would the lens of the existing ceiling-mounted light fixture. This resizing and reconfiguring of the border frame12makes the LED light panel50have a slightly smaller dimension than typical prior art LED light panels intended to replace standard 2×4 fluorescent light fixtures. Because the retrofit LED light panel50occupies the same space as the lens of the existing ceiling-mounted light fixture, minimal removal of components is required as described more fully below.

As shown inFIG.1, the back-side of the border frame12includes provisions to mount the track bracket201that has been described with reference toFIG.7. The fasteners207for mounting the track bracket201to the border frame12of the LED light panel50can also provide for fastening the assembly mechanism150to the LED light panel50, as depicted inFIGS.1,2,4,15,19,31and32. In some embodiments, track brackets201are fastened to two sides of the border frame12of the LED light panel50. In some embodiments, this provides two tracks having a race199that provide for engagement of the retaining mechanism200(the retaining mechanism200being provided by any of the retaining clip assemblies210a,210b,210c,210d,210fand retaining clips210eof the present disclosure). The race199allows for the retaining mechanism200to be adjusted within the tracks, e.g., to correspond in location to the slot, so that the retaining mechanism200can be engaged to the slot302of the fluorescent base housing300providing that the luminaire retrofit is seated in installation to the fluorescent base housing300.

In some embodiments, the track bracket201that includes the race199for the retaining mechanism200(the retaining mechanism200being provided by any of the retaining clip assemblies210a,210b,210c,210d,210fand retaining clips210eof the present disclosure) has a generally U-shaped cross-section with ridges R1, R2partially enclosing the top of the U-shape all the way around the perimeter. One or more cut-outs, i.e., installation openings216, in the track are present to permit insertion of the retaining mechanism200(the retaining mechanism200being provided by any of the retaining clip assemblies210a,210b,210c,210d,210fand retaining clips210eof the present disclosure) into the race199of the track bracket201.

As illustrated inFIG.1, the track bracket201may be configured to accept one or more of the retaining mechanism200. The retaining mechanism200include torsion springs205that extend from the opening between the ridges R1, R2of the track bracket201. The torsion springs205engage the slots302of the fluorescent base housing300providing that the luminaire retrofit is seated in installation to the fluorescent base housing300.

As noted above, the retaining mechanisms200are retaining clip assemblies210a,210b,210c,210d,210for retaining clips210e, that include a portion for engaging the back surfaces of the ridges R1, R2. For example, the retaining clip assemblies210a,210b,210c,210d,210finclude at least one of an outer retention tab204, two inner tabs203, retaining tabs208, sliding retaining tabs211and/or holder boss212for engaging the ridges R1, R2; or the retention clip210eincludes a base225formed of spring wire with a width for being positioned in the race199and engaging the retaining ridges R1, R2. Once inserted into the race199, the retaining clip assemblies210a,210b,210c,210d,210for the retention clip210eshould slide freely within the race199such that the retaining mechanisms200is adjustable in its position around the perimeter of the track.

Referring toFIGS.1,3and4, the assembly mechanism structure150is one of the design features for the luminaire retrofit kit that provides key design features for easy and quick installation. The assembly mechanism structure150includes a rod151, a tether cable152and a housing bracket153. retaining clip assemblies210a,210b,210c,210d,210for the retention clip210e

As noted, the bracket153is engaged to the LED light panel50using fasteners, and may be installed at the factory. In some embodiments, the positioning of the bracket153is preselected to correspond to the openings301of a previously installed housing300, i.e., fluorescent base housing300. For example, when installing the LED light panel50in an existing ceiling-mounted light fixture, the rod151is designed to pivot and pass through the opening301in the housing300. The sizing of the rod151is selected to allow for it to fit into the opening301in the housing300, and is sized to permit the rod151to pass through the opening301when pivoted, but be retained by the geometry of the opening301when the rod151is oriented to transverse the opening301. The opening301may be a pre-existing hole in the housing300, or may the opening301may be specially drilled by the installer to accept the assembly mechanism structure150.

When inserted into the opening in the fluorescent base housing300of an existing ceiling-mounted light fixture, the assembly mechanism structure150secures at least a portion of the LED light panel50at a maximum distance from the fluorescent base housing300to the length of the tether cable152.

In some embodiments, the LED light panel50has at least two assembly mechanisms150spaced equally spaced around the perimeter of the border frame so as to support the entire LED light panel50. Most preferably, assuming a rectangular or square panel, the LED light panel50has four assembly mechanisms150positioned proximate to separate corners of the border frame so as to fully support and balance the LED light panel50relative to the housing300. The positioning of the assembly mechanism150are to support the LED light panel50in a pre-installed position that allows for manipulation of the LED light panel50, as well as the associated retaining mechanisms200so that the LED light panel50can be configured for final installation by being secured to the fluorescent base housing300by engagement of the torsion springs205to the slots302in the fluorescent base housing300.

In some embodiments, once the assembly mechanism150are connected to the fluorescent base housing300, the installer may then connect the retaining mechanisms200to the fluorescent base housing300. The retaining mechanisms200are configured to engage a slot302in the fluorescent base housing300. In some embodiments, the installer pinches the torsion springs205to compress the springs205, e.g., compress the spring arms205b, wherein the compressed spring arms205bhave a width dimension that will fit through the slot302. Once the compressed torsion springs205, e.g., torsion spring arms205b, are through the slot302, the force compressing the torsion springs205is released, and the torsion spring arms205bdecompress and spring back to their originally width, at which point the torsion spring arms205bengage the edges of the slot opening302to secure the light panel50to the fluorescent base housing300. In some embodiments, when the torsion spring arms205bof the retaining mechanisms200are fully seated into the slots302of the fluorescent base housing300, the LED panel50may be fully seated to the fluorescent base housing300.

In one embodiment, the LED light panel50may be secured to the fluorescent base housing300using at least two retaining mechanisms200spaced equally spaced around the perimeter of the LED light panel50, so as to support the entire LED light panel. In one example, assuming a rectangular or square panel, the LED light panel50has four retaining mechanisms200positioned proximate to separate corners of the border of the LED light panel50so as to fully support and balance the LED light panel50relative to the fluorescent base housing300.

After the assembly mechanism150are connected to the fluorescent base housing300and either after the retaining mechanisms200are connected to the fluorescent base housing300, an installer may connect electrical power (not shown) to the electrical components of the LED light panel50, e.g., the driver of the LED light panel50.

The assembly mechanism150help the LED light panel50to hang a pre-determined installation distance from the fluorescent base housing300. This pre-determined installation distance is such that an installer can reach into the space to connect the electrical service. Once the electrical service is connected and tested to confirm that the LED light panel50operates, the installer simply pushes the LED light panel50upward against the fluorescent base housing300, at which point the retaining mechanisms200can fully engage the slots302via the torsion springs205.

For example, as the arms205bfor the torsion springs205of the retaining mechanisms move further through the slot302, the spring action of the relaxing torsion spring205forces the arms205boutward from their previously compressed, e.g., pinched, position. This outward movement of the arms205bof the torsion spring205from the pinched position toward an extended position levers the arms205bagainst an inner edge of the slot302and acts to draw the LED light panel50closer to the fluorescent base housing300and hold it there.

Preferably, the LED light panel50engages the fluorescent base housing300closely enough so that the205ba reach their fully extended position or a substantially fully extended position. Once the arms205breach this extended position, the LED light panel10will be fully engaged with the housing300and be flush with the edge of the housing300. It could also be flush with the ceiling if the housing is recessed.

To access and/or remove the LED light panel50, one simply needs to pull down on the edge of the border frame of the LED light panel50with sufficient force to pull the torsion springs205of the retaining mechanisms200back through the slots302of the fluorescent base housing300. The inner edges of the slots302will pinch the arms205bof the torsion springs205for the retaining mechanisms200together against the spring force as the LED light panel50is pulled away from the housing18. Referring toFIGS.2,8,12,16,17,18,20,21,22,24,25,26,27,28,29,30, and31, the retaining mechanisms200are retaining clip assemblies210a,210b,210c,210d,210for retaining clips210eincluding torsion springs200having hooks205cpresent at their ends. The hooks205ccan catch the inner edges of the slot openings302and hold the LED light panel50in the retracted position. If the hooks205cfail to catch the edge of the slot302during the retraction process or if the retention mechanisms200fail for any reason, the assembly mechanisms150provide a failsafe against the LED light panel50falling out of the fluorescent base housing300.

One particular advantage of the inventive LED light panel50is that it is easily retrofitted into existing ceiling-mounted light fixtures, e.g., pre-installed fluorescent base housings300. To install the retrofit LED light panel50into an existing ceiling-mounted light fixture, such as a standard 2×4 fluorescent light fixture, one need only remove the lens and/or the fluorescent lamps from the existing fixture. The LED light panel50occupies the same space as the lens in an existing fluorescent light fixture. The LED light panel50has a low profile such that none of the other components need to be removed from the existing fixture. For safety purposes and so that they do not break, the fluorescent bulbs should also be removed, but it is not necessary when installing the LED light panel50.

In some embodiments, the LED light panel50is an entire retrofit package including all electronics needed connecting the LED light panel50to the local power source. However, in some embodiments, the ballasts and connection plugs for the old bulbs from the fluorescent light fixture can be left in the fluorescent base housing300for use with the newly installed LED light panel50. This minimizes the demolition or deconstruction to needs to be done when installing an LED light panel50. The LED light panel50can be sized to fit other sizes of existing fixtures 1×4, 2×2, 2×4, etc.

Spatially relative terms, such as “forward”, “back”, “left”, “right”, “clockwise”, “counter clockwise”, “beneath,” “below,” “lower,” “above,” “upper,” and the like, can be used herein for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the FIGS. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the FIGS. Having described preferred embodiments of LUMINAIRE RETROFIT KIT, it is noted that modifications and variations can be made by persons skilled in the art in light of the above teachings. It is therefore to be understood that changes may be made in the particular embodiments disclosed which are within the scope of the invention as outlined by the appended claims. Having thus described aspects of the invention, with the details and particularity required by the patent laws, what is claimed and desired protected by Letters Patent is set forth in the appended claims.