LED lighting apparatus with adapter bracket for a junction box

{
  "publication_number": "US11047538B2",
  "country": "US",
  "kind": "B2",
  "title": "LED lighting apparatus with adapter bracket for a junction box",
  "abstract": "An LED lighting apparatus comprises a housing having at least one sidewall, an LED board, a lens having a back side facing the LED board and a front side opposite to the back side, and a driver module cover. The lens is disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens. An adapter bracket is employed to couple the LED lighting apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snapped into the junction box, the driver module cover is at least partially disposed in the junction box.",
  "claims": [
    "1. A system comprising: an LED lighting apparatus, comprising: a housing comprising a rear side and at least one sidewall having a front facing edge and a back facing edge surrounding the rear side and positioned adjacent to a ceiling when the LED lighting apparatus is installed in an opening of the ceiling, wherein: a depth of the at least one sidewall of the housing, between the front facing edge and the back facing edge, is less than one inch; and a thickness of at least a portion of the at least one sidewall is less than five millimeters; an LED board coupled to the housing, the LED board comprising a plurality of LEDs; a driver to receive an input voltage of at least one of 120 or 277 Volts AC and to convert the input voltage to provide a lower output voltage to the LED board; and a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens; and at least one adapter bracket to couple the LED lighting apparatus to a junction box, the junction box being installed above a ceiling in a building, the at least one adapter bracket comprising: a ring-shaped base, disposed on the rear side of the housing of the LED lighting apparatus, surrounding a first hole, the ring-shaped base including a plurality of second holes, smaller than the first hole, disposed in the ring-shaped base to accommodate a plurality of screws to attach the at least one adapter bracket to the junction box; and a collar around a perimeter of the first hole and integrally formed with the ring-shaped base, wherein the LED lighting apparatus includes a plurality of coupling elements to couple the apparatus to the at least one adapter bracket.",
    "2. The system of claim 1, wherein: the lens is coupled to a front side of the housing; the LED lighting apparatus further comprises a driver module cover coupled to the rear side of the housing; the plurality of coupling elements is disposed around a perimeter of the driver module cover; and the driver module cover fits through the first hole of the ring-shaped base of the at least one adapter bracket.",
    "3. The system of claim 2, wherein: the LED lighting apparatus is snapped into the at least one adapter bracket to couple the apparatus to the junction box; and the plurality of coupling elements includes a plurality of spring-loaded elements.",
    "4. The system of claim 3, wherein the plurality of spring-loaded elements includes one of a plurality of spring clips or a plurality of friction fit clips.",
    "5. The system of claim 3, wherein the plurality of spring-loaded elements engage with the collar of the at least one adapter bracket to facilitate snapping the LED lighting apparatus into the at least one adapter bracket.",
    "6. The system of claim 5, wherein: the driver is housed inside the driver module cover coupled to the rear side of the housing; and the plurality of LEDs includes at least one hundred LEDs.",
    "7. The system of claim 6, wherein: the input voltage, when present, is from an electrical power wiring network of the building in which the junction box is installed; and the LED lighting apparatus further comprises wires passing through the driver module cover to provide the input voltage from the electrical power wiring network of the building in which the junction box is installed.",
    "8. A system, comprising: an LED lighting apparatus, comprising: a housing comprising a rear side and at least one sidewall, wherein a thickness of at least a portion of the at least one sidewall is less than five millimeters; an LED board coupled to the housing, the LED board comprising a plurality of LEDs; a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens; a driver module cover coupled to the housing; and a driver housed inside the driver module cover; and at least one adapter bracket to couple the apparatus to a junction box installed above a ceiling in a building or a structure, the at least one adapter bracket comprising: a ring-shaped base, disposed on the rear side of the housing of the LED lighting apparatus, surrounding a first hole and including a plurality of second holes, smaller than the first hole, disposed in the ring-shaped base to accommodate a plurality of screws to attach the at least one adapter bracket to the junction box; and a collar around a perimeter of the first hole and integrally formed with the ring-shaped base, wherein: in operation, the driver receives an input voltage of at least one of 120 or 277 Volts AC from an electrical power wiring network of the building in which the junction box is installed and provides a stable output voltage or current to the plurality of LEDs; and the driver module cover includes a plurality of coupling elements disposed around a perimeter of the driver module cover to couple the apparatus to the at least one adapter bracket.",
    "9. The system of claim 8, wherein: the LED lighting apparatus is snapped into the at least one adapter bracket to couple the apparatus to the junction box; and the plurality of coupling elements includes a plurality of spring-loaded elements.",
    "10. The system of claim 9, wherein the plurality of spring-loaded elements includes one of a plurality of spring clips or a plurality of friction fit clips.",
    "11. The system of claim 9, wherein the plurality of spring-loaded elements engage with the collar of the at least one adapting bracket to facilitate snapping the apparatus into the at least one adapter bracket.",
    "12. The system of claim 8, wherein the driver module cover includes at least one vertical groove perpendicular to the rear side of the housing.",
    "13. A system, comprising: an LED lighting apparatus, comprising: a housing comprising at least one sidewall; an LED board coupled to the housing, the LED board comprising at least one hundred LEDs; a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens; and a driver module cover coupled to the housing; and at least one adapter bracket to couple the LED lighting apparatus to a junction box installed and positioned above the ceiling such that when the apparatus is snapped into the junction box, the driver module cover is at least partially disposed in the junction box and the at least one adapter bracket is disposed between the housing of the LED lighting apparatus and the junction box.",
    "14. The system of claim 13, wherein the at least one adapter bracket comprises: a ring-shaped base surrounding a first hole, the first hole having a dimension so as to accommodate the driver module cover; a plurality of second holes, smaller than the first hole, to accommodate a plurality of screws to attach the at least one adapter bracket to the junction box; and a collar around a perimeter of the first hole.",
    "15. The system of claim 14, wherein the housing of the LED lighting apparatus includes a plurality of coupling elements to facilitate snapping the apparatus into the at least one adapter bracket.",
    "16. The system of claim 15, wherein the plurality of coupling elements includes a plurality of spring-loaded elements.",
    "17. The system of claim 16, wherein the plurality of spring-loaded elements engage with the collar of the at least one adapting bracket to facilitate snapping the apparatus into the at least one adapter bracket.",
    "18. The system of claim 16, wherein the plurality of spring-loaded elements is disposed around a perimeter of the driver module cover.",
    "19. The system of claim 18, in combination with the junction box.",
    "20. The combination of claim 19, wherein the junction box is one of a 3½ inch or 4 inch square, octagon, or round junction box.",
    "21. A kit, comprising: an LED lighting apparatus, comprising: a housing comprising a rear side and at least one sidewall; an LED board coupled to the housing, the LED board comprising a plurality of LEDs; and a lens coupled to the housing, the lens having a back side facing the LED board and a front side opposite to the back side, the lens being disposed with respect to the LED board such that the plurality of the LEDs illuminate the back side of the lens; and at least one adapter bracket to couple the apparatus to a junction box installed above a ceiling in a building or a structure, wherein: the at least one adapter bracket comprises: a ring-shaped base surrounding a first hole and including a plurality of second holes, smaller than the first hole, disposed in the ring-shaped base to accommodate a plurality of screws to attach the at least one adapter bracket to the junction box; and a collar around a perimeter of the first hole and integrally formed with the ring-shaped base; the housing of the LED lighting apparatus includes a plurality of coupling elements to couple the apparatus to the at least one adapter bracket; and the ring-shaped base is disposed on the rear side of the housing of the LED lighting apparatus when the LED lighting apparatus is coupled to the at least one adapter bracket.",
    "22. The kit of claim 21, further comprising the plurality of screws.",
    "23. The kit of claim 21, wherein: the apparatus is snapped into the at least one adapter bracket to couple the apparatus to the junction box; and the plurality of coupling elements includes a plurality of spring-loaded elements.",
    "24. The kit of claim 23, wherein: the at least one sidewall of the housing has a front facing edge and a back facing edge; a depth of the at least one sidewall of the housing, between the front facing edge and the back facing edge, is less than one inch; a thickness of at least a portion of the at least one sidewall is less than three millimeters; and the plurality of LEDs includes at least one hundred LEDs.",
    "25. The kit of claim 23, wherein the plurality of spring-loaded elements includes one of a plurality of spring clips or a plurality of friction fit clips.",
    "26. The kit of claim 21, wherein the plurality of coupling elements includes a plurality of magnets.",
    "27. The kit of claim 21, wherein: the lens is coupled to a front side of the housing; the LED lighting apparatus further comprises a driver module cover coupled to the rear side of the housing; and the plurality of coupling elements is disposed around a perimeter of the driver module cover.",
    "28. The kit of claim 27, wherein the driver module cover includes at least one vertical groove perpendicular to the rear side of the housing.",
    "29. The kit of claim 27, wherein: the LED lighting apparatus further comprises a driver housed inside the driver module cover coupled to the rear side of the housing.",
    "30. The kit of claim 29, wherein: during operation, the driver receives an input current from an electrical power wiring network of the building or structure in which the junction box is installed and provides a stable output voltage or current to the plurality of LEDs; and the LED lighting apparatus further comprises wires passing through the driver module cover to provide the input current from the electrical power wiring network of the building or structure in which the junction box is installed."
  ],
  "description_excerpt": "Some conventional surface mount LED downlights may be coupled to a junction box disposed behind a ceiling and may be employed in new construction or retrofit architectural projects. One such example is the “Disk Light” provided by Commercial Electric and manufactured by Cree (manufacturer model number CE-JB6-650L-27K-E26). The Disk Light can be installed in an existing recessed can or a four-inch junction box and includes a semi recessed lens. The Commercial Electric Disk Light may be used indoors and in an outdoor enclosed setting, and is generally intended for kitchens, hallways, bathrooms, closets, porches and garage work rooms, Another example is the Halo Surface Mount LED Downlight (SMD) series, which are low-profile surface mount luminaires designed for installation in many 3½″ and 4″ square, octagon, or round junction boxes.\n\nVarious inventive concepts disclosed herein relate generally to a thin surface mount type of luminaire, wherein “thin” refers to the protruding portion of the luminaire below the line of the ceiling, for example. In various implementations, the luminaire can be installed from below the ceiling by a twist lock mechanism or by clips into a junction box that is installed in the ceiling. Some implementations include a test switch that is accessible from the portion of the luminaire that protrudes below the ceiling line. The lens of some implementations combines a total internal reflection lens with a conical structure buried at its center. In other implementations, the luminaire includes a plurality of light sources distributed evenly across a light producing portion of the luminaire.",
  "cpc": [
    "F21S 8/043",
    "F21K 9/68",
    "F21S 8/026",
    "F21S 8/03",
    "F21S 9/022",
    "F21V 21/047",
    "F21V 21/088",
    "F21V 23/04",
    "F21V 29/87",
    "F21Y 2105/16",
    "F21Y 2105/18",
    "F21Y 2115/10",
    "G02B 6/0021",
    "G02B 6/0031"
  ],
  "ipc": [
    "F21K 9/68",
    "F21S 8/00",
    "F21S 8/02",
    "F21S 8/04",
    "F21S 9/02",
    "F21V 21/088"
  ],
  "assignees": [
    "DMF Inc"
  ],
  "inventors": [
    "Michael D. Danesh",
    "Vincent Williams",
    "Mark Jongewaard"
  ],
  "filing_date": "2020-10-30",
  "publication_date": "2021-06-29",
  "grant_date": "2021-06-29",
  "priority_date": "2017-06-22",
  "application_number": "US-202017085636-A",
  "family_id": "64692131",
  "cited_by_count": 46,
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