Downlight apparatus

Abstract

A downlight apparatus includes a light source, a light holder, a driver box, a fixing bracket and two torsion springs. The light holder is used for placing the light source. The light holder has a first side defining a light opening. The driver box is placed on a second side of the light holder. The driver box contains a driver for converting an external power to a driving current supplied to the light source to emit a light from the light opening. The fixing bracket is coupled to the light holder for fixing to an installation cavity. The fixing bracket has a bottom plate and two connector plate. The bottom plate is fixed to the second side of the light holder. The two connector plates are disposed vertically to the bottom plate. Each connector plate has two side units. Each torsion spring has an elastic center and two arms.

Claims

1. A downlight apparatus, comprising: a light source; a light holder for placing the light source, the light holder has a first side defining a light opening; a driver box placed on a second side of the light holder, wherein the driver box contains a driver for converting an external power to a driving current supplied to the light source to emit a light from the light opening; a fixing bracket coupled to the light holder for fixing to an installation cavity, wherein the fixing bracket has a bottom plate and two connector plate, wherein the bottom plate is fixed to the second side of the light holder, wherein the two connector plates are disposed vertically to the bottom plate, wherein each connector plate has two side units; and two torsion springs, wherein each torsion spring has an elastic center and two arms, wherein the two arms are elastically spreading with different angles with respect to the elastic center, wherein the two torsion springs are attached to a lateral side of the two connector plates, wherein either the two torsion springs are elastically squeezed to engage the installation cavity or the side units of the connector plates are elastically squeezed to engage the installation cavity, wherein the bottom plate has multiple bracket connectors, wherein the second side of the light holder has corresponding multiple holder connectors, wherein the bracket connectors are respectively slided to engage the holder connectors by rotating the light holder with respect to the fixing bracket.

2. The downlight apparatus of claim 1, wherein the installation cavity is a cavity in a junction box.

3. The downlight apparatus of claim 1, wherein the bottom plate of the fixing bracket has a central hole for the driver box to pass through.

4. The downlight apparatus of claim 3, wherein the driver box has an elastic hook, wherein when the central hole of the bottom plate passes reaches a bottom edge of the driver box, the elastic hook locks the bottom plate to the second side of the light holder.

5. The downlight apparatus of claim 1, wherein the bottom plate has multiple connection holes for fixing the bottom plate to the installation cavity with bracket connectors.

6. The downlight apparatus of claim 5, wherein the connection hole is a key hole with an larger entrance and a smaller sliding track, wherein the bracket connector enters the larger entrance and then stays in the sliding track to fix the bottom bracket to the installation cavity.

7. The downlight apparatus of claim 1, wherein the connector plates are detachable from the bottom plate.

8. The downlight apparatus of claim 7, wherein the connector plates are fixed to the bottom plate with screws.

9. The downlight apparatus of claim 1, wherein the two side units are two folded plates folding with respect to a main body of the connector plate.

10. The downlight apparatus of claim 9, wherein a folding angle of the folded plate with respect to the main body of the connector plate is larger than 90 degrees.

11. The downlight apparatus of claim 1, wherein the connector plates are made as the same metal piece as the bottom plate and are folded vertically with respect to the bottom plate.

12. The downlight apparatus of claim 1, wherein the fixing bracket has a scraper for scraping a portion of electric insulation layer on the second side of the light holder for electrically connecting the light holder to ground.

13. The downlight apparatus of claim 1, wherein the light source comprises multiple LED modules distributed in a first range, wherein the bottom plate has a larger size than the first range to carry heat of the first range outside the first range.

14. The downlight apparatus of claim 1, wherein a reverse lock structure prevents the bracket connector accidently escape from the holder connector.

15. The downlight apparatus of claim 1, wherein the bracket connector is vertical to the holder connector.

16. The downlight apparatus of claim 1, wherein a top plate of the driver box has a wire socket and a manual switch, wherein the wire socket is connected to a power wire and the manual switch is used for adjusting a setting of the light source.

17. The downlight apparatus of claim 16, wherein the top plate of the driver box further has a rotation switch for continuously setting a maximum light intensity of the light source.

18. The downlight apparatus of claim 1, wherein the light source has a light source plate mounted with LED modules, wherein the light source plate is connected to the light holder to connect to the ground.

19. The downlight apparatus of claim 18, wherein multiple metal shafts are used for electrically connecting the light source plate and the light holder.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 illustrates an exploded view of a downlight apparatus.

(2) FIG. 2 illustrates a side view of the downlight apparatus of FIG. 1.

(3) FIG. 3 illustrates a top view of the downlight apparatus of FIG. 1.

(4) FIG. 4 illustrates a cross-sectional view of the example in FIG. 1.

(5) FIG. 5 illustrates a perspective view of the leaf spring and the light housing.

(6) FIG. 6 illustrates a top view of the example in FIG. 5.

(7) FIG. 7 illustrates a bottom view of the example in FIG. 5.

(8) FIG. 8 illustrates a side view of the example in FIG. 5.

(9) FIG. 9 illustrates a zoom-up view of a portion of the example in FIG. 5.

(10) FIG. 10 illustrates a zoom-up view of a connection among multiple components.

(11) FIG. 11 illustrates another bottom view of another example.

(12) FIG. 12 illustrates a side view of another example.

(13) FIG. 13 illustrates a wave structure pad example.

(14) FIG. 14 illustrates another example of a light housing.

(15) FIG. 15 illustrates a top view of the example in FIG. 14.

(16) FIG. 16 illustrates an example of a wave structure pad.

(17) FIG. 17 illustrates another view of the example in FIG. 16.

(18) FIG. 18 illustrates another view of the example in FIG. 16.

(19) FIG. 19 illustrates a combination of the shaft connector, the leaf spring and the pad.

(20) FIG. 20 illustrates another view of the example in FIG. 19.

(21) FIG. 21 illustrates a driver box example.

(22) FIG. 22 illustrates another view of the example in FIG. 21.

(23) FIG. 23 illustrates another view of the example in FIG. 21.

(24) FIG. 24 illustrates a connector example.

(25) FIG. 25 illustrates a component in FIG. 24.

(26) FIG. 26 illustrates another component in FIG. 24.

(27) FIG. 27 illustrates the connector disposed on a light source plate.

(28) FIG. 28 illustrates an electricity distance diagram.

(29) FIG. 29 illustrates another downlight example.

(30) FIG. 30 illustrates the example in FIG. 29 with a wire connector.

(31) FIG. 31 illustrates a fixing bar placed on a light housing.

(32) FIG. 32 illustrates a heat dissipation plate placed between a driver box and a light housing.

(33) FIG. 33 illustrates a screw for transmitting heat.

(34) FIG. 34 illustrates a driver box example.

(35) FIG. 35 illustrates a heat dissipation plate in an elongated form.

(36) FIG. 36 illustrates a connector for connecting components.

(37) FIG. 37 illustrates an exploded view of another downlight embodiment.

(38) FIG. 38 illustrates a component in the example of FIG. 37.

(39) FIG. 39 illustrates a bottom view of the example in FIG. 37.

(40) FIG. 40 illustrates another example in a cross-sectional view.

(41) FIG. 41 illustrates a zoom-up view of a connection between components.

(42) FIG. 42 illustrates a reflective cup example.

(43) FIG. 43 illustrates a top view of the example in FIG. 42.

(44) FIG. 44 illustrates a side view of the example in FIG. 42.

(45) FIG. 45 illustrates a top view of a light housing.

(46) FIG. 46 illustrates another top view of the light housing example in FIG. 45.

(47) FIG. 47 illustrates a cross-sectional view of the example in FIG. 46.

(48) FIG. 48 illustrates a diffusion cover.

(49) FIG. 49 illustrates a side view of a downlight example.

(50) FIG. 50 illustrates a top view of the example in FIG. 49.

(51) FIG. 51 illustrates another view of the example in FIG. 50.

(52) FIG. 52 illustrates an exploded view of the example in FIG. 51.

(53) FIG. 53 illustrates an elastic plate example.

(54) FIG. 54 illustrates a connector example.

(55) FIG. 55 illustrates another connector example.

(56) FIG. 56 illustrates a torsion spring zoom-up view.

(57) FIG. 57 illustrates another downlight example.

(58) FIG. 58 illustrates a top view of the example in FIG. 57.

(59) FIG. 59 illustrates another view of the example in FIG. 58.

(60) FIG. 60 illustrates an exploded view of the example in FIG. 59.

(61) FIG. 61 illustrates a connector example.

(62) FIG. 62 illustrates a torsion spring zoom-up view.

(63) FIG. 63 illustrates another downlight example.

(64) FIG. 64 illustrates a top view of the example in FIG. 63.

(65) FIG. 65 illustrates another view of the example in FIG. 64.

(66) FIG. 66 illustrates an exploded view of the example in FIG. 65.

(67) FIG. 67 illustrates an elastic plate example.

(68) FIG. 68 illustrates a connector example.

(69) FIG. 69 illustrates a side view of a diffusion cover and related components.

(70) FIG. 70 illustrates a zoom-up view of the diffusion cover and related components.

(71) FIG. 71 illustrates a rim part example.

(72) FIG. 72 illustrates another view of the example in FIG. 71.

(73) FIG. 73 illustrates a wiring unit example.

(74) FIG. 74 illustrates an exploded view of the example in FIG. 73.

(75) FIG. 75 illustrates a driver box with the wiring unit.

(76) FIG. 76 illustrates a side view of the wiring unit.

(77) FIG. 77 illustrates another view of the wiring unit.

(78) FIG. 78 illustrates another view of the wiring unit.

(79) FIG. 79 illustrates a fixing bracket example.

(80) FIG. 80 illustrates another fixing bracket example.

(81) FIG. 81 illustrates an elastic stop unit example.

(82) FIG. 82 illustrates a top view of a downlight example with the fixing bracket.

(83) FIG. 83 illustrates another view of the example in FIG. 82.

(84) FIG. 84 illustrates a top view of another downlight example.

(85) FIG. 85 illustrates another view of the example in FIG. 84.

(86) FIG. 86 illustrates a component in the example of FIG. 85.

(87) FIG. 87 shows another downlight example.

(88) FIG. 88 shows a range diagram.

DETAILED DESCRIPTION

(89) In FIG. 87, a downlight apparatus includes a light source 6003, a light holder 6004, a driver box 6002, a fixing bracket 6001 and two torsion springs 6010.

(90) The light holder 6004 is used for placing the light source 6003. The light holder 6004 has a first side 6012 defining a light opening 6011.

(91) The driver box 6002 is placed on a second side 6013 of the light holder 6004.

(92) The driver box 6002 contains a driver 6011 for converting an external power to a driving current supplied to the light source 6003 to emit a light from the light opening 6011.

(93) The fixing bracket 6001 is coupled to the light holder 6004 for fixing to an installation cavity, e.g. a cavity in a ceiling or a junction box. A junction box refers to a metal or a plastic box pre-installed in a cavity or other platform for inserting a downlight apparatus.

(94) The fixing bracket 6001 has a bottom plate 6005 and two connector plate 6006.

(95) The bottom plate 6005 is fixed to the second side 6013 of the light holder 6004.

(96) The two connector plates 6006 are disposed vertically to the bottom plate 6005.

(97) Specifically, the two connector plates 6006 may be disposed with 90 or similar angle with respect to the bottom plate 6005.

(98) Each connector plate 6006 has two side units.

(99) FIG. 67 shows an example of the connector plate 44301. The connector plate 44301 has two side units 440302 on two sides of the connector plate 44301.

(100) In FIG. 87, each torsion spring 6610 has an elastic center and two arms.

(101) FIG. 57 shows such an example. In FIG. 57, a torsion spring has an elastic center 555 with two arms 553.

(102) The two arms 553 are elastically spreading with different angles with respect to the elastic center 555. When an external force is applied on the two arms 553, the angle between the two arms 553 is changed, thus changing a spreading span of the two arms 553.

(103) The spreading span is changed to insert the torsion springs into a junction box.

(104) In FIG. 87, the two torsion springs 6610 are attached to a lateral side of the two connector plates 6006.

(105) Either the two torsion springs are elastically squeezed to engage the installation cavity 6016 or the side units of the connector plates 6006 are elastically squeezed to engage the installation cavity.

(106) There are several sizes of junction boxes defining different diameters of the installation cavity 6016. In some larger installation cavity, the torsion springs are used for attaching the downlight apparatus to the installation cavity. In some smaller installation cavity, the side units of the connector plates 6006 engages the installation cavity to attach the downlight apparatus to the installation cavity.

(107) In some embodiments, the installation cavity is a cavity in a junction box.

(108) In FIG. 66, the bottom plate of the fixing bracket has a central hole 44991 for the driver box to pass through.

(109) In FIG. 66, the driver box or the holder plate has an elastic hook 44992.

(110) When the central hole 44991 of the bottom plate passes reaches a bottom edge of the driver box, the elastic hook 44992 locks the bottom plate to the second side of the light holder.

(111) In FIG. 66, the bottom plate has multiple connection holes 441 for fixing the bottom plate to the installation cavity with bracket connectors, e.g. screws.

(112) In some embodiments, the connection hole is a key hole with an larger entrance 44101 and a smaller siding track 44102, as shown in FIG. 66.

(113) The bracket connector enters the larger entrance and then stays in the sliding track to fix the bottom bracket to the installation cavity.

(114) In FIG. 66, the connector plates 443 are detachable from the bottom plate 442.

(115) In some embodiments, the connector plates are fixed to the bottom plate with screws, as shown in the exploded view in FIG. 66.

(116) In FIG. 66, the two side units 44302 are two folded plates folding with respect to a main body 44301 of the connector plate 443.

(117) In some embodiments, a folding angle of the folded plate with respect to the main body of the connector plate is larger than 90 degrees.

(118) In some embodiments, the connector plates are made as the same metal piece as the bottom plate and are folded vertically with respect to the bottom plate.

(119) In some embodiments, the fixing bracket has a scraper, e.g. a sharpen surface or a wave structure 112 in FIG. 18 for scraping a portion of electric insulation layer on the second side of the light holder for electrically connecting the light holder to ground.

(120) In FIG. 88, the light source includes multiple LED modules distributed in a first range 6033.

(121) The bottom plate on the holder plate 6031 of the light holder has a larger size 6032 than the first range to carry heat of the first range outside the first range.

(122) In FIG. 83, the bottom plate has multiple bracket connectors 962.

(123) The second side of the light holder has corresponding multiple holder connectors 963.

(124) The bracket connectors 962 are respectively slided to engage the holder connectors 963 by rotating the light holder with respect to to the fixing bracket.

(125) In FIG. 81, a reverse lock structure 9643 prevents the bracket connector 963 accidently escape from the holder connector 963.

(126) In some embodiments, the bracket connector is vertical to the holder connector, as shown in FIG. 83.

(127) In FIG. 87, a top plate of the driver box has a wire socket 6007 and a manual switch 6008.

(128) The wire socket 6007 is connected to a power wire and the manual switch 6008 is used for adjusting a setting of the light source.

(129) In some embodiments, the top plate of the driver box further has a rotation switch 6009 for continuously setting a maximum light intensity of the light source.

(130) In some embodiments, the light source has a light source plate mounted with LED modules.

(131) The light source plate is connected to the light holder to connect to the ground.

(132) In FIG. 87, multiple metal shafts 6010 are used for electrically connecting the light source plate and the light holder.

(133) FIG. 1 illustrates an exploded view of a downlight apparatus.

(134) FIG. 2 illustrates a side view of the downlight apparatus of FIG. 1.

(135) FIG. 3 illustrates a top view of the downlight apparatus of FIG. 1.

(136) FIG. 4 illustrates a cross-sectional view of the example in FIG. 1.

(137) FIG. 5 illustrates a perspective view of the leaf spring and the light housing.

(138) FIG. 6 illustrates a top view of the example in FIG. 5.

(139) FIG. 7 illustrates a bottom view of the example in FIG. 5.

(140) FIG. 8 illustrates a side view of the example in FIG. 5.

(141) FIG. 9 illustrates a zoom-up view of a portion of the example in FIG. 5.

(142) FIG. 10 illustrates a zoom-up view of a connection among multiple components.

(143) FIG. 11 illustrates another bottom view of another example.

(144) FIG. 12 illustrates a side view of another example.

(145) FIG. 13 illustrates a wave structure pad example.

(146) FIG. 14 illustrates another example of a light housing.

(147) FIG. 15 illustrates a top view of the example in FIG. 14.

(148) FIG. 16 illustrates an example of a wave structure pad.

(149) FIG. 17 illustrates another view of the example in FIG. 16.

(150) FIG. 18 illustrates another view of the example in FIG. 16.

(151) FIG. 19 illustrates a combination of the shaft connector, the leaf spring and the pad.

(152) FIG. 20 illustrates another view of the example in FIG. 19.

(153) FIG. 21 illustrates a driver box example.

(154) FIG. 22 illustrates another view of the example in FIG. 21.

(155) FIG. 23 illustrates another view of the example in FIG. 21.

(156) FIG. 24 illustrates a connector example.

(157) FIG. 25 illustrates a component in FIG. 24.

(158) FIG. 26 illustrates another component in FIG. 24.

(159) FIG. 27 illustrates the connector disposed on a light source plate.

(160) FIG. 28 illustrates an electricity distance diagram.

(161) FIG. 29 illustrates another downlight example.

(162) FIG. 30 illustrates the example in FIG. 29 with a wire connector.

(163) FIG. 31 illustrates a fixing bar placed on a light housing.

(164) FIG. 32 illustrates a heat dissipation plate placed between a driver box and a light housing.

(165) FIG. 33 illustrates a screw for transmitting heat.

(166) FIG. 34 illustrates a driver box example.

(167) FIG. 35 illustrates a heat dissipation plate in an elongated form.

(168) FIG. 36 illustrates a connector for connecting components.

(169) FIG. 37 illustrates an exploded view of another downlight embodiment.

(170) FIG. 38 illustrates a component in the example of FIG. 37.

(171) FIG. 39 illustrates a bottom view of the example in FIG. 37.

(172) FIG. 40 illustrates another example in a cross-sectional view.

(173) FIG. 41 illustrates a zoom-up view of a connection between components.

(174) FIG. 42 illustrates a reflective cup example.

(175) FIG. 43 illustrates a top view of the example in FIG. 42.

(176) FIG. 44 illustrates a side view of the example in FIG. 42.

(177) FIG. 45 illustrates a top view of a light housing.

(178) FIG. 46 illustrates another top view of the light housing example in FIG. 45.

(179) FIG. 47 illustrates a cross-sectional view of the example in FIG. 46.

(180) FIG. 48 illustrates a diffusion cover.

(181) FIG. 49 illustrates a side view of a downlight example.

(182) FIG. 50 illustrates a top view of the example in FIG. 49.

(183) FIG. 51 illustrates another view of the example in FIG. 50.

(184) FIG. 52 illustrates an exploded view of the example in FIG. 51.

(185) FIG. 53 illustrates an elastic plate example.

(186) FIG. 54 illustrates a connector example.

(187) FIG. 55 illustrates another connector example.

(188) FIG. 56 illustrates a torsion spring zoom-up view.

(189) FIG. 57 illustrates another downlight example.

(190) FIG. 58 illustrates a top view of the example in FIG. 57.

(191) FIG. 59 illustrates another view of the example in FIG. 58.

(192) FIG. 60 illustrates an exploded view of the example in FIG. 59.

(193) FIG. 61 illustrates a connector example.

(194) FIG. 62 illustrates a torsion spring zoom-up view.

(195) FIG. 63 illustrates another downlight example.

(196) FIG. 64 illustrates a top view of the example in FIG. 63.

(197) FIG. 65 illustrates another view of the example in FIG. 64.

(198) FIG. 66 illustrates an exploded view of the example in FIG. 65.

(199) FIG. 67 illustrates an elastic plate example.

(200) FIG. 68 illustrates a connector example.

(201) FIG. 69 illustrates a side view of a diffusion cover and related components.

(202) FIG. 70 illustrates a zoom-up view of the diffusion cover and related components.

(203) FIG. 71 illustrates a rim part example.

(204) FIG. 72 illustrates another view of the example in FIG. 71.

(205) FIG. 73 illustrates a wiring unit example.

(206) FIG. 74 illustrates an exploded view of the example in FIG. 73.

(207) FIG. 75 illustrates a driver box with the wiring unit.

(208) FIG. 76 illustrates a side view of the wiring unit.

(209) FIG. 77 illustrates another view of the wiring unit.

(210) FIG. 78 illustrates another view of the wiring unit.

(211) FIG. 79 illustrates a fixing bracket example.

(212) FIG. 80 illustrates another fixing bracket example.

(213) FIG. 81 illustrates an elastic stop unit example.

(214) FIG. 82 illustrates a top view of a downlight example with the fixing bracket.

(215) FIG. 83 illustrates another view of the example in FIG. 82.

(216) FIG. 84 illustrates a top view of another downlight example.

(217) FIG. 85 illustrates another view of the example in FIG. 84.

(218) FIG. 86 illustrates a component in the example of FIG. 85.

(219) The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings.

(220) The embodiments were chosen and described in order to best explain the principles of the techniques and their practical applications. Others skilled in the art are thereby enabled to best utilize the techniques and various embodiments with various modifications as are suited to the particular use contemplated.

(221) Although the disclosure and examples have been fully described with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of the disclosure and examples as defined by the claims.