<19)United States
`<12)Patent Application
`PICKARD et al.
`
`(54) LIGHTING FIXTURE
`
`US 20080304269A1
`
`Publication
`
`<10)Pub.No.:US 2008/0304269A1
`<43)Pub. Date:
`Dec. 11, 2008
`
`(75)
`
`inventors:
`
`Paul Kenneth PICKARD.
`Morrisville. NC (US): James
`Michael Lay. Cary. NC (US); Gary
`David Trott. Morrisville. NC (US)
`
`Correspondence Address:
`BURR & BROWN
`P0 BOX 7068
`SYRACUSE, NY 13261-7068 (US)
`
`(73) Assignee:
`
`Crcc LED Lighting Solutions,
`lnc.. Durham. N(' (US)
`
`(21) Appl. No.:
`
`12/114,994
`
`(22)
`
`Filed:
`
`May S, 2008
`
`Related U.S.Application Data
`
`(63) Continuation-in-part of application No. 2‘)/279.589.
`filed on May 3. 2007. now Pat. No. D.57l.944. Con­
`tinuation-in-part of application No. 29/284.294. filed
`on Sep. 5.2007.
`
`(60) Provisional application No. 60/916.030. filed on May
`4. 2007.
`
`Publication Classification
`
`Int. (Tl.
`(2006.01)
`FZIV I5/00
`U.S. Cl.
`...................................................... .. 362/365
`
`ABSTRACT
`
`(51)
`
`(52)
`
`(57)
`
`A lighting fixture comprises a mounting assembly and two
`rails. At least one of the rails is slidable relative to the n1ount­
`ing assembly. The rails are each extruded. and have profiles
`which are substantially similar to each other. Each rail has a
`male component which fits within a female component ofthe
`other. Also. a fixture comprising a mounting assembly com­
`prising an opening thmugh which a light engine housing can
`be inserted. and (1) a spring clip and/or (2) a clip engagement
`structure. Also. a fixture comprising a mounting assembly. a
`first set of rails. and a supplemental rail. The supplemental rail
`is slidable relative to the light emitting element mounting
`assembly. Also. a fixture comprising a motuiting assembly. a
`set ofrails. and an engagement element having a first portion
`being in contact with a first rail and a second portion in
`contact with the second rail.
`
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`Patent Application Publication
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`Dec. ll, 2008 Sheet 2 of ll
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`US 2008/0304269Al
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`Patent Application PubI|cati0n
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`Dec. 11 2008 Sheet 8 of 11
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`US 2008/0304269 Al
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`Patent Applicat
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`Dec. 11, 2008 Sheet 10 0f 11
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`US 2008/0304269 A1
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`US 2008/0304269 A 1
`
`Dec. 11, 2008
`
`LIGI-ITIYG FIXTURE
`
`CROSS-REl*'ERl:'NCl:'T0 RELATED
`APPLICATIONS
`
`[0001] This application claims the benefit of U.S. Design
`Patent Application No. 29/279,589, filed May 3, 2007. the
`entirety of which is incorporated l1erei11by reference.
`[0002] This application claims the benefit of U.S. Design
`Patent Application No. 29/284,294, filed Sep. 5, 2007. the
`entirety of which is incorporated herein by reference.
`[0003] This application claims the benefit of U.S. Provi­
`sional l’atentApplication No. 60/916,030, filed May 4, 2007,
`the entirety ofwhich is incorporated herein by reference.
`
`FIELD OF THE INVENTION(S)
`
`inventive subject matter relates to a
`[0004] The present
`lighting fixture. In some embodiments, as discussed below,
`the present
`inventive subject matter relates to a dow111igl1t
`lighting fixture (e.g., a “can” lighting fixture, also referred to
`as a recessed lighting fixture).
`
`BACKGROUND OF THE INVENTION(S)
`
`[0005] A large proportion (some estimates are as high as
`twenty-five percent) of the electricity generated in the United
`States each year goes to lighting. Accordingly, there is an
`ongoing need to provide lighting fixtures (1) which are easier
`to install, (2) Which reduce the possibility of injury during
`installation,
`repair. maintenance,
`replacement
`anchor
`removal, and/or (3) which make it possible for the lighting
`fixture to be held more securely in place.
`[0006]
`In addition, Withthe growing popularity of lighting
`elements which include solid state light emitters (e.g., light
`emitting diodes), there is an increasing demand for lighting
`fixtures (and components thereof) which facilitate the use of
`such lighting elements wl1ile maximizing the benefits
`obtained from using such lighting elements and minimizing
`or eliminating any drawbacks from using such ligl1ti11gele­
`ments.
`[0007] One example of a conventional recessed light fixttue
`comprises a metal cylinder (“can”) mounted into the ceiling
`using horizontal metal struts attached to the ceiling joints.
`Within the cylinder, mounted on an adjustable sliding plate, is
`light bulb socket into which a light bulb is inserted. Typically
`a 60 \V incandescent
`li@t bulb or a 15 WVcompact fluorescent
`bulb is used. For example, a conventional recessed light fix­
`ture is depicted in FIG. 1.
`[0008]
`In this conventional fixture, around the annulus of
`the bulb a11dextending downward to the lower inside edge of
`the cylinder is a baffie or refiecting cone. A cosmetic ring is
`placed around the bottom edge of the cylinder and extending
`outward to cover the area i111111ediatelysurrounding the cir­
`cular cutout in the ceiling and create an attractive edging
`around the light output aperture.
`[0009] Theposition (height) ofthe bulb can be set such that
`the bulb is not directly visible to the people standing in the
`room a11dthe light from the fixture is directed so that
`it
`principally illuminates an area below the fixture.
`[0010] These fixtures are popular because they do not cre­
`ate significant glare (being recessed) and highlight objects
`situated below them.
`[0011]
`In many cases (e.g., most residential applications),
`the “cans” are required to be substantially airtight around the
`sides a11dtop to prevent the loss of ambient heat or cooling
`
`from the room into the ceiling cavity through the fixture. As
`the lamp is mounted in t_hecan. much of the l1eatgenerated by
`the light source is trapped within the can, because the air
`heated in the can rises a11dis trapped within the ca11.Special
`insulation is usually required around the can within the ceil­
`ing cavity to prevent fire.
`[0012] As indicated above, some aspects of the present
`inventive subject matter are directed to providing lighting
`fixtures which are suitable for use with light emitting ele­
`ments whicl1includes solid state light emitters. The environ­
`ment inside a conventional can are described above is not
`ideal for solid-state lighting. LEDs, for example, have signifi­
`cant energy and lifetime benefits over incandescent and fluo­
`rescent light sources—I ,EDs, however. do not operate well in
`high temperatures. LED light sources have operating life­
`times of decades as opposed to just months or 1-2 years for
`many incandescent bulbs. An I.ED’s lifetime is significantly
`shortened, however. i1'it operates at elevated temperatures. It
`is generally accepted that the junction temperature of an LED
`should not exceed 70 degrees C. ifa long lifetime is desired.
`[0013] Efficient individual LED light sources typically pro­
`vide between 3 and 50 lumens of light per source (LED die or
`lamp) depending on the size of the LED die. A typical
`recessed downlight using a 60 WVincandescent bulb provides
`about 500 lumens of light, so it can be seen that to provide a
`similar amount of light from LEl)s, multiple LED light
`sources would be required.
`[0014] To provide a similar amount of light using “small
`die” (typically 300 square micrometers). approximately 200
`die would be required, or, alternatively using large “power”
`die (typically approximately l square millimeter) 10-20 die
`would be required.
`[0015] For the above and other reasons, efforts have been
`ongoing to develop ways by which solid state light emitters
`can be used in place of incandescent lights, fluorescent lights
`and other light-generating devices in a wide variety of appli­
`cations. In addition. where light emitting diodes (or other
`solid state light emitters) are already being used, efforts are
`ongoing to provide light emitting diodes (or other solid state
`li@t emitters) which are improved, e.g., with respect
`to
`energy efficiency, color rendering index (CRI Ra), contrast,
`efiicacy (1 m/W), cost and/or duration of service.
`
`BRIEF SUMMARY OF THE INVENTIVE.
`SUBJECT MATTER
`
`[0016] There are a variety of well-known lighting fixtures
`which are typically mounted by attaching support rails to
`construction elements (e.g., ceiling joists). Some aspects of
`the present inventive subject matter relate to devices and
`methods for mounting lighting fixtures using rails. In addi­
`lion. there are a variety of considerations involved in mount­
`ing such fixtures, discussed in more detail below, which are
`affected by the use of lighting fixtures which include one or
`111oresolid state light emitters. Some aspects of the present
`inventive subject matter relate to devices and methods which
`address such considerations.
`[0017] Also, there are a variety of well-known structures
`for use i11mounting lighting fixtures in. 011or in relation to
`construction elements (e.g.. ceiling joists with sheetrock ceil­
`ings). Some aspects of the present inventive subject matter
`relate to devices and methods which simplify and/or improve
`various features of such mountings. I11addition, the use of
`lighting fixtures which include one or more solid state light
`emitters ca11afiect such mountings, and the present inventive
`
`

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`US 2008/0304269 A 1
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`Dec. 11, 2008
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`subject matter provides devices and methods Whichare usefiil
`in mounting such lighting fixtures.
`[0018] According to a first aspect of the present inventive
`subject matter, there is provided a lighting fixture comprising
`a light emitting element mounting assembly and at least a first
`set of rails. The first set of rails comprises a first rail and a
`second rail. the first rail and second rail each being connected
`to the light emitting element mounting assembly. at least one
`of the first rail and the second rail being slidable relative to the
`light emitting element mounting assembly. The first rail has a
`major dimension extending in a first direction and the second
`rail has a major dimension extending i11a second direction,
`the first direction being substantially parallel to the second
`direction. The expression “major dimension”. as used herein,
`means a dimension of a structure which is equal to or longer
`than the other dimensions of the structure. The first rail is
`slidable relative to the second rail along the first direction.
`The first rail and the second rail are each extruded (i.e.. they
`are formed by extrusion). The first rail has a first profile, the
`first profile comprising a first profile male component a11da
`first rail female component. The second rail has a second
`profile, the second profile comprising a second profile male
`component and a second rail female component. The first
`profile male component is positioned Withinthe second pro­
`file female component, and the second profile male compo­
`nent is positioned Withinthe first profile female component.
`The second profile is substantially similar to the first profile
`except for the first profile being rotated I80 degrees relative to
`the second profile.
`[0019]
`ln some embodiments according to this aspect ofthe
`present inventive subject matter, the first rail and the second
`rail each have a beam structure in both up-doWnand side-to­
`side bending.
`[0020]
`ln some embodiments according to this aspect ofthe
`present
`inventive subject matter,
`the first a11dsecond rails
`together have a combined external profile Which is substan­
`tially rectangular.
`[0021]
`ln some embodiments according to this aspect ofthe
`present
`inventive subject matter,
`the first a11dsecond rails
`together have a combined external profile Whichis free from
`angles in excess of90 degrees.
`[0022]
`In some embodiments according to this aspect ofthe
`present inventive subject matter, the first rail female compo­
`nent extends greater than 180 degrees around the second rail
`male component, and the second rail female component
`extends geater
`than I80 degrees around the first rail male
`component.
`[0023]
`ln some embodiments according to this aspect ofthe
`present inventive subject matter, there is provided an engage­
`ment element which serves to inhibit (but not prevent) the
`rails from sliding relative to one another, such that the rails
`can be stretched to a desired extent and then attached to
`construction elements (e.g.. ceilingjoists), without having the
`engage set screws or the like. Accordingly, in some embodi­
`ments. the lighting fixture fiirther comprises at least one
`engagement element, the engagement ele111entbeing attached
`to the light emitting element mounting assembly. the engage­
`ment element comprising at least a first engagement ele111e11t
`portion and a second engagement element portion. the frst
`engagement element portion being in contact With a first
`portion of the first rail, the second engagement element por­
`tion being i11contact with a first portion of the second rail. In
`some of such embodiments, the engagement element com­
`prises a support element, a first pad and a second pad, the first
`
`pad being mounted on a first portion of the support element,
`the second pad being mounted on a second portion of the
`support element, the first pad comprising the first engagement
`element portion and being in contact with the first portion of
`the first rail, the second pad comprising the second engage­
`ment element portion and being in contact Withthe first por­
`tion of the second rail.
`[0024] According to a second aspect of the present inven­
`tive subject matter, there is provided a lighting fixture com­
`prising a li@t emitting element mounting assembly compris­
`ing a11opening through which a light engine housing ca11be
`inserted. the light emitting element mounting assembly coin­
`prising at least one of (l) at least one spring clip and (2) at
`least one clip engagement structure, the clip engagement
`structure comprising at least one clip engagement region
`(e.g., a plurality ofslots). For example, i11some embodiments
`according to the present inventive subject matter. there is
`provided structure which makes it possible to insert the “can”
`through a “rou@-in” which has been fonned in a ceiling and
`securely hold the can in place.
`[0025]
`In some embodiments according to this aspect of the
`present inventive subject matter, the lighting fixture further
`comprises a light emitting element received in the opening. In
`some of such embodiments,
`the light emitting element
`mounting assembly comprises at least a first spring clip, a11d
`the light emitting element comprises at
`least a first clip
`engagement structure, the first clip engagement structure
`comprising a plurality of clip engagement regions, the first
`spring clip engaging one of the clip engagement regions. In
`others of such embodiments, the light emitting element com­
`prises at least a first spring clip, and the light emitting element
`mounting assembly comprises at least a first clip engagement
`structure, the first clip engagement structure comprising a
`plurality of clip engagement regions, the first spring clip
`engaging one ofthe clip engagement regions. In some ofsuch
`embodiments, at least a first pair of clip engagement regions
`are spaced from each other by a distance Which is less than
`o11e-tenthof a major dimension of the light engine housing.
`[0026] According to a third aspect of the present inventive
`subject matter, there is provided a lighting fixture comprising
`a light emitting element mounting assembly, at least a first set
`of rails, and at least a first supplemental rail. The first set of
`rails comprises a frst rail and a second rail, the frst rail and
`second rail each being connected to the light emitting element
`mounting assembly. at least one of tl1efirst rail and the second
`rail being slidable relative to the light emitting element
`motmting assembly. The first rail has a major dimension
`extending in a first direction, and the second rail has a major
`dimension extending in a second direction. the first direction
`being substantially parallel to the second direction The first
`rail is slidable relative to the second rail along the first direc­
`tion. The first supplemental rail is slidable relative to the light
`emitting element mounting assembly along a third direction
`Which is parallel to the first direction.
`[0027]
`In some embodiments according to this aspect of the
`present inventive subject matter, the lighting device can be
`easily mounted to construction element(s). e.g., i11relatively
`tightly spacedjoists (e.g., betWeen9" and 13"), by removing
`the rails a11dattaching the lighting device to the construction
`element(s) with the supplemental rail(s).
`[0028]
`I11 some embodiments according to the present
`inventive subject matter, there is provided structure which
`makes it possible to keep the rails substantially stationary in
`
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`US 2008/0304269 A 1
`
`Dec. 11, 2008
`
`relation to each other, when desired, without the necd to use
`a screw to lock down the rails.
`[0029] For instancc, according to a fourth aspect of the
`present inventive subject matter, there is provided a lighting
`fixture comprising:
`[0030]
`a light emitting element mounting assembly;
`[0031]
`at least a first set of rails, the first set of rails com­
`prising a first rail and a second rail, the first rail and second rail
`each being connected to the ligl1temitting eleme11tmounting
`assembly, at least one of the first rail and the second rail being
`slidable relative to the ligl1t emitting element mounting
`assembly, the first rail having a major dimension cxtending in
`a first direction, the second rail having a major dimension
`extending in a second direction, the first direction being sub­
`stantially parallel to the second dircction, thc first rail being
`slidable relative to the second rail along the first direction, and
`[0032]
`at least one engagement element, the engagement
`ele111e11tbeing attached to the ligl1t emitting element mount­
`ing assembly, the engagement clement comprising at least a
`first engagement element portion and a second engagement
`ele111e11tportion, the first engagement element portion being
`in contact With a first portion of the first rail. the second
`engagement element portion being in contact with a first
`portion of the second rail.
`[0033]
`In some embodiments according to this aspect ofthe
`present
`inventive subject matter, the engagement element
`comprises a support element, a first pad and a second pad, the
`first pad being mounted on a first portion of the support
`clement. the second pad being mounted on a second portion
`of the support element, the first pad comprising the first
`engagement element portion and being in contact with the
`first portion of the first rail, the sccond pad comprising the
`second engagement element portion and being in contact With
`the first portion of the second rail. In some of such embodi­
`ments. the support element is spring biased such that thc first
`pad exerts force on the first portion of the first rail a11dthe
`second pad exerts force on the first portion of the second rail
`(and in son1eof such embodiments, the support element flir­
`ther comprises a tensioning element which can be tightened
`to increase the force exerted bythe first pad on the first portion
`ofthe first rail and to increase the force exerted by the second
`pad o11t_hefirst portion of the second rail). I11others of such
`embodiments, the support element ftuther comprises a ten­
`sioning element which can be tightened to cause the first pad
`to exert force on t_hefirst portion of the first rail and the second
`pad to exert force on the first portion of the second rail.
`[0034]
`In some embodiments of the present inventive sub­
`ject matter. there is provided a lighting fixture which com­
`prises one or more solid state light emitters, e.g., one or more
`light emitting diodes (LEDs).
`[0035]
`In some embodiments of the present inventive sub­
`jcct matter. there is provided a lighting fixture comprising a
`die-cast upper housing a11da die-cast lower housing which
`can be utilized in multiple applications, an extruded heat sink
`mounted external to the fixture “can” for heat rcmoval. and
`extruded alum_im|mprofile rails.
`
`BRIEF DESCRIPTION OF THE DRAWING
`FIGURES
`
`[0036] FIG. l depicts a first embodiment of a lighting fix­
`ture according to the present inventive subject matter.
`[0037] FIG. 2 is a cutaway view of the lighting fixture
`depicted i11I-‘IG. 1.
`
`[0038] FIG. 3 depicts a second embodiment ofa lighting
`fixture according to the present inventive subject matter.
`[0039] FIG. 4 depicts a third embodiment of a light fixture
`according to the present inventive subject matter.
`[0040]
`FIG. 5 is a close-up view oI'a portion oI' the th_ird
`embodiment.
`[0041]
`I-‘IG.6 depicts a profile of a11embodiment of a rail
`according to the present inventive subject matter.
`[0042] FIG. 7 depicts profiles of an embodiment of mated
`rails 17 and 18 according to the present inventive subject
`matter.
`[0043] FIG. 8 depicts an isometric view of the mated rails
`17 and 18 shown in FIG. 7.
`[0044] FIG. 9 dcpicts an embodiment which includes a first
`rail 17 and a second rail 18.
`[0045] FIG. 10 is a close-up view of a portion of the
`embodiment depicted in EIG. 9.
`[0046] FIG. 11 depicts an embodiment oI'a lighting fixture
`according to the present inventive subject matter.
`[0047] FIG. 12 depicts profiles ofan embodiment of mated
`rails 17 and 18 according to the present inventive subject
`matter.
`I-‘IG.13 depicts a11embodiment ofa lighting fixture
`[0048]
`according to the present inventive subject matter.
`[0049] FIG. 14 is a close-up view of a portion of an embodi­
`ment according to the present inventive subject matter.
`[0050] FIG. 15 depicts a portion oI' an embodiment oI' a
`lighting fiXILl1’€which includes stops.
`[0051]
`I-‘IG.16 depicts profiles of another embodiment ot
`mated rails according to the present invcntive subject mattcr.
`[0052] FIG. 17 depicts an isometric view of the mated rails
`shown in FIG. 16.
`
`DETAILED DESCRIPTION OI-‘EMBODIMENTS
`OF THE INVENTIV E SUBJECT MATTER
`
`[0053] The prescnt inventive subject matter now will bc
`described more fully hereinafter with reference to the accom­
`panying drawings, i11which embodiments of the inventive
`subjcct matter are shown. However, this invcntive subject
`matter should not be construed as limited to the embodiments
`set forth herein. Rather, these embodiments are provided so
`that this disclosure will be thorough and complcte, and will
`fully convey the scope of the inventive subject matter to those
`skilled in the art. Like ntunbers refer to like elements through­
`out. As used hcrein the term “and/of’ includes any and all
`combinations oI' one or 111oreoI' the associated listed items.
`[0054] The tcrminology used herein is for the purpose of
`describing particular embodiments only and is not intended to
`be limiting of the inventive subject matter. As used herein, the
`singular forms “a”, “an” a