Patent ID: 12228258

DETAILED DESCRIPTION

FIG.1ashows a cross-sectional longitudinally facing view of a linear luminaire10configured to be mounted directly to a ceiling or wall, recessed in a ceiling or wall or can be supported on a pendant, andFIG.2shows an exploded view of linear luminaire10. Terms used herein, including vertically, horizontally, higher, lower, above and below, unless otherwise stated, are used in reference to the orientation present when the luminaire10is mounted to the ceiling as an overhead light, or in the ceiling as a recessed light. Luminaire10includes a linear channel12and a linear light inset14. Linear channel12includes a channel base wall16and two channel side walls18,20extending away from base wall16. When luminaire10is mounted to the ceiling as an overhead light, channel base wall16constitutes the top of the luminaire10. Channel12may be formed by a single piece of a metal. In one example, channel12is formed of aluminum. In particular, channel12may be formed of extruded aluminum. In other examples, channel12may be formed as sheet metal parts that are welded together—i.e., with walls16,18,20as separate sheet metal parts that are welded together. In other examples, channel may also be formed of plastic.

Linear light inset14is configured for being inserted into channel12in a space22between the two channel side walls18,20. Light inset14includes a cover24and two printed circuit boards (PCBs)26,28fixed to cover24. PCBs26,28each support a plurality of light sources in the form of light emitting diodes30to emit light through cover24.

Cover24includes a cover base wall32and two cover side walls34,36extending away from the cover base wall32. PCBs26,28are each fixed to the two cover side walls34,36. Cover base wall32forms a translucent portion, and LEDs30arranged for emitting light through cover base wall32. Light inset14defines an interior space14abetween walls32,34,36and PCBs26,28through which light travels before passing through cover base wall32.

Cover24also includes two cover connectors38,40, and each of cover connectors38,40is fixed to a respective one of the two cover side walls34,36. Cover connectors38,40are configured for being snapped into the channel12to hold the cover24in the space22between the two channel side walls18,20. The connection by connectors38,40to channel12prevents light insert14from falling downward from channel12through an opening42defined at lower ends18a,20aof channel side walls18,20.

Cover connectors38,40are positioned above an upward facing side26aof upper PCB26—i.e., the side facing channel base wall16, which is opposite a downward facing side26bof upper PCB26—i.e., the side facing cover base wall32. LEDs30are fixed to downward facing side26bof PCB26. Each of cover connectors38,40is formed integrally as a single piece with an end of the respective cover side wall34,36. Further, cover side walls34,36are formed integrally as a single piece with cover base wall32. In other words, cover base wall32, cover side walls34,36and cover connectors38,40are formed integrally as a single piece to constitute cover24. In one advantageous example, cover24may be formed of plastic and may have an opal color such that it is translucent, but not transparent. In other examples, cover24may be translucent and transparent or cover24may be translucent and colored.

Each of the two channel side walls18,20includes a channel connector44,46. Each of cover connectors38,40is configured for being snapped onto one of the channel connectors44,46to create a form fit connection between the channel12and the cover.

FIG.1bshows an enlarged section of a portion ofFIG.1aincluding cover connectors40and channel connector46. The following discussion of connectors40,46also applies to connectors38,44. Referring toFIGS.1aand1btogether, each of cover connectors38,40includes an outwardly extending section39aextending horizontally away from a longitudinal center plane CCRof cover24. Longitudinal center plane CCRof cover24extends along a length of cover24. Outwardly extending sections39aare each configured for contacting a securing surface45aof the respective channel connector44,46to prevent the cover24from falling out of the linear channel12and away from the channel base wall16. More specifically, outer downwardly facing surfaces41aof outwardly extending sections39acontact securing surfaces45a,respectively, to prevent the cover24from falling out of the linear channel12and away from the channel base wall16. Outer downwardly facing surfaces41aare inclined with respect to longitudinal center plane CCRsuch that surfaces41aface away from longitudinal center plane CCRand also face downwardly toward the respective side wall34,36. In other words, outer downwardly facing surfaces41aextend both vertically and horizontally. Securing surfaces45aface upward toward the channel base wall16and also angle toward center plane CCR, such that surfaces45aalso extend vertically while extending horizontally.

Each of cover connectors38,40also includes an inwardly extending section39bextending horizontally away from the respective cover side wall34,36and toward the longitudinal center plane CCRof cover24. Inwardly extending sections39bare each configured for contacting a respective abutment surface45bof the respective channel connector44,46to prevent the cover24from being forced further into the linear channel12toward the channel base wall16. More specifically, upwardly facing surfaces41bof inwardly extending sections39bare each configured for contacting a respective abutment surface45bto prevent the cover24from being forced further into the linear channel12toward the channel base wall16. Abutment surfaces45bextend horizontally and face downwardly away from the channel base wall16. Inwardly extending sections39balso include horizontally extending downwardly facing surfaces41econtacting or are at least directly facing surface26aof PCB26. Each of the inwardly extending sections39bis formed integrally with an upper end34b,36bof the respective cover side wall34,36.

Each of cover connectors38,40further includes an intermediate section39cconnecting inwardly extending section39bto outwardly extending section39a.Each of intermediate sections39cis configured for laterally contacting an alignment surface45cof the respective channel connector38,40to center the cover24within the channel12. Alignment surfaces45cface toward each other. More specifically, each alignment surface45cfaces toward longitudinal center plane CCRand away from the respective channel side wall18,20and extends vertically upward from the respective abutment surface45bto the respective securing surface45a.

Each of cover connectors38,40additionally includes an insertion section39dtapering inward from outwardly extending section39aby extending horizontally toward longitudinal center plane CCRand horizontally away from the respective cover side wall34,36while extending vertically toward channel base wall16and away from PCB26. More specifically, each insertion section39dincludes an inclined surface41dthat extends horizontally and vertically away from surface41atoward longitudinal center plane CCR.

Each of cover side walls34,36is also provided with two circuit board support sections including an upper support section48and a lower support section50. Sections48,50extend along an entire length of cover24. Upper support section48vertically supports upper PCB26and lower support section50vertically supports lower PCB28. Cover side walls34,36include outer surfaces35afacing away from light inset interior space14aand toward the respective channel side walls18,20and inner surfaces35bfacing toward interior space14aand away from the respective side walls18,20. Support sections48,50protrude horizontally inward from the respective inner surface35btoward longitudinal center plane CCR. Each of support sections48,50includes a respective horizontally extending support surface48a,50afor contacting the lower surface26b,28bof the respective PCB26,28. Lateral ends28cof PCB28are received in gaps52aformed vertically between the respective support surface50aand a respective lower horizontally extending surface48bof support section48, and lateral ends26cof PCB26are received in gaps52bformed vertically between the respective support surface48aand the horizontally extending downwardly facing surfaces41eof the respective cover connector38,40.

As shown inFIGS.4aand6, providing two different support sections48,50at two different vertical positions provides flexibility during the installation of luminaire10. In particular, for example, if a plurality of standard length PCBs26or28are used and luminaire is not an integer multiple of this standard length, PCBs26,28can overlap with each other in the longitudinal direction. As an illustrative example, if each of PCBs26,28are ten inches long, and luminaire has a length of forty-five inches, four different PCBs26can be provided on upper support sections48and a fifth PCB28can be provided on lower support sections50overlapped in the longitudinal direction by five inches with one of upper PCBs.FIG.6shows a cross-sectional lateral facing view of luminaire10, illustrating a longitudinal overlap LO of an upper PCB26and a lower PCB28.

As shown inFIGS.1a,2,4a,4band5, luminaire10further includes a fall down protection fastener54configured for being connected to channel base wall16on a first end54athereof and to one of PCBs26,28at a second end54bthereof. Fall down protection fastener54includes a cord56extending from a first end connector58to a second end connector60. First end connector58is configured for being removably connected to channel base wall16and second end connector60is configured for being removably connected to one of PCBs26,28. End connector58includes a threaded section59afor being screwed to threaded section16aof channel base wall16and end connector60includes a threaded section59bfor being screwed to threaded section27of PCBs26,28. In the illustrated example, threaded sections59a,59bare formed as male connectors including external threads and threaded sections16a,59bare formed as female connectors including internal threads, but this arrangement can be reversed. The connection of fastener54to channel base wall16and PCB26or28prevents light inset14from being disconnected from channel12and falling to the ground in the event that connectors38,40fail. In other embodiments, instead of a screw connection, the connectors58,60can be welded or riveted to the channel base wall16and PCB26,28, respectively.

Luminaire10further includes an electrical driver62received in space22inside of channel12. Electrical driver62connects to channel base wall16and electrically connects to PCBs26,28to provide electricity to LEDs30. Each PCB26,28is provided with an electrical connector64for connecting to driver62, directly via wiring or via wiring to another PCB26,28.

As denoted inFIGS.1aand5, in order to organize the wires66for providing electricity from electrical driver62to LEDs30, luminaire10includes a plurality of wire securing assemblies68each configured for being fixed to channel base wall16for securing wires66above light inset14. Each wire securing assembly68includes two flexible arms68afor receiving wires66and clips68bfor removably gripping a longitudinally extending support rail70fixed to channel base wall16. Support rail70includes one or more threaded sections16aintegrally formed therein. Arms68aface each other and each defines a receptacle72for receiving a subset of wires66. Assembly68includes a base68cfor contacting support rail70, and for contacting further rails74positioned on both lateral sides of rail70. Two sets of clips68bextend upward from opposite longitudinal sides of base68c,and arms68aextend downward from opposite lateral sides of base68c.Each of clips68bincludes two prongs68dfor laterally contacting opposite sides of rail70. Arms68aeach include a vertical section69aextending downward from base68c,a horizontal section69bextending from the respective vertical section69atoward the other arm68a,and inclined section69cextending upward from horizontal section69band horizontally toward the other arm68a.Inclined sections69cintersect each other to define an upside-down V-shape, as shown inFIG.1a.Wires66are inserted into receptacles72by forcing wires66upward into the V-shape to force inclined sections69caway from each other to define a gap between sections69cfor the wires66to pass through. After wires clear the intersection of sections69c,the resiliency of arms68acause sections69cto move back toward each other. The gap is eliminated and inclined sections69creturn into contact with each other.

A method for installing linear luminaire10includes fixing linear channel12to a support structure and inserting linear light inset14into channel12in a space22between the two channel side walls18,20and connecting the linear light inset14to the channel12in the space by cover connectors38,40of the linear light insert14. Prior to the installation of light inset14into channel12, PCBs26and/or PCBs28are slid in the longitudinal direction into respective gaps52a,52band onto respective support sections48,50of side walls34,36such that PCBs26and/or PCBs28are connected to cover24. As noted above, depending on whether or not the desired length of light insert14is an integer multiple of the length of PCBs26,28, solely PCBs26are used, solely PCBs28are used, or both at least one PCB26and at least one PCB28are used with one PCB26longitudinally overlapping with one PCB28. It is noted that in one advantageous embodiment, PCBs26are exactly the same as PCBs28.

After PCBs26and/or PCBs28are connected to cover24to form light inset14, light inset14is inserted into the opening42defined at lower ends18a,20aof channel side walls18,20with connectors38,40leading the way. Insertion sections39dof connectors38,40are forced into respective channel connectors44,46such that insertions sections39dand outwardly extending sections39aare forced laterally inward toward center plane CCRof cover24as outer tips39eat an intersection of sections39a,39dare slid along the respective surfaces45cand past respective surface45a.After outer tips39epass the respective surfaces41a,sections39amove laterally outward to engage the respective surfaces41ato hold inset14in channel12. Surfaces41bof inwardly extending sections39bcontact abutment surface45bto align light inset14vertically in channel12.

Prior to the installation of light inset14into channel, fall down protection fasteners54are connected to two or more of PCBs, PCBs26,28by connecting end60to the respective PCB26,28. Each of cords56of fasteners54is elastically deformable to increase the distance between the respective ends58,60. This allows fasteners54to be stretched from the orientation shown inFIG.5to the orientation shown inFIGS.4a,4b. With end60connected to the respective PCB26,28and light inset14spaced from the opening42, end58is raised upward into space22of channel12and connected to base wall16of channel12by screwing end58into threaded section16aof channel base wall16. In the example shown inFIGS.4a,4b, fall down protection fasteners54are used to secure inset14to channel12, one at each longitudinal end of luminaire10. Then, light inset14is pushed upward into channel12and connected to channel12via connectors38,40.

The preceding specification refers to specific exemplary embodiments and examples. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative manner rather than a restrictive sense.