Downlight apparatus

Abstract

A downlight apparatus includes a driver box, a light source, a light housing, multiple leaf springs, multiple shaft connectors and multiple pads. The light housing has a light holder and a rim. The light holder has a holder plate and a holder wall defining a holder cavity. The multiple leaf springs are placed between the driver box and the light holder. Each pad has a pad hole and a pad scraper surrounding the pad hole. The pad scraper has a protruding part engaging an electric insulation layer on a top side of the holder plate. The shaft connector sequentially passes through a spring hole of the leaf spring, the pad hole and the top plate of the light holder. The protruding part of the pad scraper scraps a portion of the electric insulation layer of the holder plate for connecting the holder plate to ground.

Claims

1. A downlight apparatus, comprising: a driver box; a light source; a light housing with a light holder and a rim, wherein the light holder has a holder plate and a holder wall defining a holder cavity, wherein the light source is placed on an inner side of the holder plate in the holder cavity; multiple leaf springs, wherein the multiple leaf springs are placed between the driver box and the light holder; multiple shaft connectors; and multiple pads, wherein each pad has a pad hole and a pad scraper surrounding the pad hole, wherein the pad scraper has a protruding part engaging an electric insulation layer on a top side of the holder plate, wherein the shaft connector sequentially passes through a spring hole of the leaf spring, the pad hole and the top plate of the light holder, wherein the protruding part of the pad scraper scrapes a portion of the electric insulation layer of the holder plate for connecting the holder plate to ground.

2. The downlight apparatus of claim 1, wherein the leaf spring has a spring head and spring tail, wherein the spring tail is rotated to extend outside the light holder.

3. The downlight apparatus of claim 1, wherein the shaft connector is a first screw.

4. The downlight apparatus of claim 3, wherein the first screw is rotated to carry the pad scraper to move for removing the portion of the electric insulation layer.

5. The downlight apparatus of claim 1, wherein when the leaf spring is rotated, the pad scraper is moved to erase the portion of the electric insulation layer.

6. The downlight apparatus of claim 1, wherein a bottom edge of the driver box has multiple rotation grooves for the spring tails to extend and moving the multiple rotation grooves.

7. The downlight apparatus of claim 6, wherein a limiting unit is placed between the driver box and the light holder for limiting rotation of the leaf springs.

8. The downlight apparatus of claim 1, wherein the pad scraper is a circular wave structure.

9. The downlight apparatus of claim 1, wherein the protruding part is roughened to increase friction.

10. The downlight apparatus of claim 1, wherein the pads and the shaft connectors are made of metal material.

11. The downlight apparatus of claim 1, wherein the spring tail is extended for engaging a platform cavity for keeping the downlight apparatus in the platform cavity.

12. The downlight apparatus of claim 1, wherein a driver plate is placed inside the driver box, wherein the driver plate is kept a distance from a bottom of the driver box and the light holder.

13. 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.

14. The downlight apparatus of claim 13, wherein multiple metal shafts are used for electrically connecting the light source plate and the light holder.

15. The downlight apparatus of claim 1, wherein the leaf spring engages a junction box to connect to the ground.

16. The downlight apparatus of claim 1, wherein the shaft connector is electrically connected to a ground electrode disposed inside the driver box.

17. 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.

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

19. The downlight apparatus of claim 1, wherein a heat dissipation plate is placed between the light holder and the driver box for carrying away both heat of the driver box and the light source.

20. The downlight apparatus of claim 19, wherein the heat dissipation plate has a portion not covered by the light holder and the driver box.

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 apparatus embodiment.

DETAILED DESCRIPTION

(88) Please refer to FIG. 87, which illustrates a downlight apparatus example.

(89) In FIG. 87, a downlight apparatus includes a driver box 6006, a light source 6017, a light housing 6016, multiple leaf springs 6009, multiple shaft connectors 6008 and multiple pads 6013.

(90) The light housing 6016 has a light holder 6014 and a rim 6015. The rim 6015 has a larger diameter than the light holder 6014. In some embodiments, the downlight apparatus is installed in a cavity or a junction box of a ceiling. The rim 6015 conceals the downlight body in the cavity, except exposing a light opening for light to emit outside the downlight apparatus.

(91) The light holder 6014 has a holder plate 6021 and a holder wall 6022 defining a holder cavity 6023.

(92) The light source 6017 is placed on an inner side of the holder plate 6021 in the holder cavity 6023.

(93) The multiple leaf springs 6009 are placed between the driver box 6006 and the light holder 6016.

(94) Each pad 6013 has a pad hole and a pad scraper surrounding the pad hole.

(95) FIG. 16 shows an example of such pad in more detail. In FIG. 16, the pad 11 has a pad hole 113 and a pad scraper 112. The pad scraper 112 are extended from an inner ring 111. The pad scraper 112 has a protruding part, e.g. with a wave structure with protruding portions extending above the central body.

(96) In FIG. 87, the pad scraper engaging an electric insulation layer 6024 on a top side of the holder plate 6021.

(97) The shaft connector 6008 sequentially passes through a spring hole 6012 of the leaf spring 6010, the pad hole and the top plate 6021 of the light holder 6016.

(98) The protruding part of the pad scraper scraps a portion of the electric insulation layer 6024 of the holder plate 6021 for connecting the holder plate 6021 to ground.

(99) For example, an electric insulation paint is attached on surface of a metal light holder 6016 to form an electric insulation layer mentioned here. To prevent electric shock for users to touch the light housing, it is important to get the light housing to a ground, particularly when the light housing is made of metal material.

(100) In such case, the light housing is connected to ground via the shaft connector 6008, e.g. a metal screw or a metal shaft. Sometimes, the light housing is attached with electric insulation layer. The pad scraper is used for removing a portion of electric insulation layer to connect the light housing to ground.

(101) In some embodiments, the leaf spring has a spring head 6011 and spring tail 6010.

(102) The spring tail 6010 is rotated to extend outside the light holder 6016.

(103) For example, FIG. 14 shows three leaf springs 5 are disposed on a light housing to rotate extending outside the light housing so as to expand a diameter to keep the downlight apparatus in a cavity or a junction box. The leaf springs may be rotated to expand or decrease the expanding diameter to attach or to detach the downlight from the installation cavity.

(104) In some embodiments, the shaft connector is a first screw.

(105) In some embodiments, the first screw is rotated to carry the pad scraper to move for removing the portion of the electric insulation layer. For example, the screw is fixed to the pad scraper so that when the screw is rotated, the pad scraper is rotated too. When the pad scraper rotates, it engages and removes a portion of the electric insulation layer on the light holder to get the leaf spring electrically connected to the light housing and then to connect to a ground.

(106) In some embodiments, when the leaf spring is rotated, the pad scraper is moved to erase the portion of the electric insulation layer. Another design is to keep the pad scraper to move with the leaf spring. As mentioned above, the leaf spring is rotated when installing the downlight apparatus to a cavity or a junction box. In such way, the pad scraper is carried to move for removing the portion of electric insulation layer on the light holder.

(107) In FIG. 87, a bottom edge of the driver box has multiple rotation grooves 6007 for the spring tails to extend and move the multiple rotation grooves.

(108) In some embodiments, a limiting unit is placed between the driver box and the light holder for limiting rotation of the leaf springs.

(109) FIG. 6 shows such an example. The leaf spring is limited by the limiting unit within a rotation angle.

(110) In some embodiments, the pad scraper is a circular wave structure.

(111) FIG. 16 shows such an example of such pad scraper 112.

(112) In some embodiments, the protruding part is roughened to increase friction so as to more easily remove the surface paint on the light holder.

(113) In some embodiments, the pads and the shaft connectors are made of metal material.

(114) In some embodiments, the spring tail is extended for engaging a platform cavity for keeping the downlight apparatus in the platform cavity.

(115) In FIG. 87, a driver plate 6005 is placed inside the driver box 6006.

(116) The driver plate 6005 is kept a distance 6019 from a bottom of the driver box 6006 and the light holder 6016.

(117) In some embodiments, the light source 6017 has a light source plate 6016 mounted with LED modules 6027.

(118) The light source plate 6026 is connected to the light holder 6016 to connect to the ground.

(119) In some embodiments, multiple metal shafts 6028 are used for electrically electrically connecting the light source plate 6026 and the light holder 6016.

(120) In some embodiments, the leaf spring engages a junction box to connect to the ground. Junction boxes are used widely in some countries and are known to persons of ordinary skilled in the art and thus are not illustrated. The junction box may be connected to ground. When the leaf spring engages the junction box, the light housing is also connected to the ground with the connection to the leaf spring.

(121) In some embodiments, the shaft connector is electrically connected to a ground electrode disposed inside the driver box. For example, a ground electrode may be placed in the driver box 6006 to further connecting to a ground wire connecting to a ground.

(122) In some embodiments, a top plate of the driver box has a wire socket 6002 and a manual switch 6003. The manual switch 6003 may be operated to change a setting, e.g. a mixed light color temperature, a mixed light color, or other parameter. The wire socket 6002 may be used for connecting a power wire and/or a ground wire.

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

(124) In some embodiments, the top plate of the driver box further has a rotation switch 6004 for continuously setting a maximum light intensity of the light source. For example, the light source may emit an X light intensity level to its maximum, the rotation switch 6004 may be operated to change the maximum light intensity to any continuous ratio of the X light intensity level within a predetermined range.

(125) In some embodiments, a heat dissipation plate is placed between the light holder and the driver box for carrying away both heat of the driver box and the light source.

(126) For example, FIG. 32 shows a heat dissipation plate 8831 is placed between the light holder and the driver box. FIG. 35 shows such heat dissipation plate 8831 as an elongated bar shape structure.

(127) In some embodiments, the heat dissipation plate has a portion not covered by the light holder and the driver box. FIG. 32 and FIG. 35 shows such arrangement.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(151) FIG. 24 illustrates a connector example.

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

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

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

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

(156) FIG. 29 illustrates another downlight example.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(175) FIG. 48 illustrates a diffusion cover.

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

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

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

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

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

(181) FIG. 54 illustrates a connector example.

(182) FIG. 55 illustrates another connector example.

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

(184) FIG. 57 illustrates another downlight example.

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

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

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

(188) FIG. 61 illustrates a connector example.

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

(190) FIG. 63 illustrates another downlight example.

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

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

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

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

(195) FIG. 68 illustrates a connector example.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

(214) 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.

(215) 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.

(216) 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.