Hybrid light fixture housing

Abstract

A hybrid light fixture housing comprising a roll formed or press fabricated metal housing substrate having ceiling interface side members formed from aluminum extrusion processes attached thereto. The ceiling interface side members may comprise a single extruded clip member configured to clip around the ends of the sidewalls of the housing substrate or a first backing bar piece secured to the housing substrate and a second ceiling trim member secured to the housing substrate and the backing bar.

Claims

1. A housing for a light fixture assembly comprising: a housing having a back, a first sidewall extending from the back, and a second sidewall extending from the back, at least one of the first and second sidewalls having an outwardly deflected bend defining a sidewall shoulder; and a clip connected to the housing and having a first side descending to a u-shaped bend and a second side ascending from the u-shaped bend, the second side including an outwardly deflecting bent portion defining a clip shoulder positioned and sized to mate with the sidewall shoulder, wherein the first and second sidewalls extend telescopically wider via a series of bends to define a first chamber, a second chamber larger than the first chamber, and a third chamber larger than the second chamber.

2. The housing of claim 1, wherein the housing is formed from sheet metal.

3. The housing of claim 1, further comprising a hole in an area above the sidewall shoulder for receiving a fastener.

4. The housing of claim 3, further comprising a rivet extending through the hole and connecting the housing and the clip.

5. The housing of claim 1, wherein the clip shoulder receives the sidewall shoulder via friction fit insertion that causes movement of at least one of the clip sides.

6. A housing for a light fixture assembly comprising: a back wall; a first sidewall extending from the back wall and having a first bend, a second bend, and a first end portion with a first outwardly deflected bend defining a first sidewall shoulder; a second sidewall extending from the back wall and having a third bend aligned with the first bend, a fourth bend aligned with the second bend, and a second end portion with a second outwardly deflected bend defining a second sidewall shoulder, wherein the first sidewall and the second sidewall at least partially define a first chamber, a second chamber larger than the first chamber, and a third chamber larger than the second chamber; and a hole in an area above the first sidewall shoulder for receiving a fastener.

7. A housing for a light fixture assembly comprising: a back wall; a first sidewall extending from the back wall and having a first bend, a second bend, and a first end portion with a first outwardly deflected bend defining a first sidewall shoulder; a second sidewall extending from the back wall and having a third bend aligned with the first bend, a fourth bend aligned with the second bend, and a second end portion with a second outwardly deflected bend defining a second sidewall shoulder, wherein the first sidewall and the second sidewall at least partially define a first chamber, a second chamber larger than the first chamber, and a third chamber larger than the second chamber; and a clip connected to the first end portion.

8. The housing of claim 7, wherein the clip includes a first side, a second side, and a u-shaped bend portion.

9. The housing of claim 8, wherein the second side includes an outwardly deflecting bent portion defining a clip shoulder positioned and sized to mate with the first sidewall shoulder.

10. The housing of claim 8, wherein the second side includes a tapered end formed by a portion of the second side angling away from the first side.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above benefits and other advantages of the various embodiments of the present invention will be more apparent from the following detailed description of exemplary embodiments of the present invention and from the accompanying drawing figures, in which:

(2) FIG. 1A is a front view of an embodiment of a hybrid light fixture housing according to the invention.

(3) FIG. 1B is a right side perspective view of a connection point portion of a hybrid light fixture housing according to the invention.

(4) FIG. 2 is a front view of an embodiment of a u-shaped extrusion member according to the invention.

(5) FIG. 3A is front view of a portion of an end of a metal frame sidewall according to an embodiment the invention.

(6) FIG. 3B is a right side perspective view of a portion of an end of a metal frame sidewall according to an embodiment of the invention.

(7) FIG. 4 is an enlarged front view of the connection point of the boxed area of the hybrid light fixture housing depicted in FIG. 1A.

(8) FIG. 5 is a front view of a hybrid light fixture housing according to an embodiment of the invention.

(9) FIG. 6 is a right side perspective view of an connection point of portion of a hybrid light fixture housing according to another embodiment of the invention.

(10) FIG. 7 is a front view of a hybrid light fixture housing according to another embodiment of the invention.

(11) FIG. 8 is a front view of the metal frame sidewall of a hybrid light fixture housing according to an embodiment of the invention.

(12) FIG. 9 is a front view of an end portion of a metal frame sidewall of a hybrid light fixture housing according to an embodiment of the invention.

(13) FIG. 10 is an elevated perspective view of a metal frame sidewall of a hybrid light fixture housing according to an embodiment of the invention.

(14) FIG. 11 is a cross section of the metal frame member of FIG. 10.

(15) FIG. 12A is a front view of an embodiment of a hybrid light fixture housing having extruded interior shoulders for regressed lenses according to the invention.

(16) FIG. 12B is a right side perspective view of a connection point portion of an embodiment of a hybrid light fixture housing having extruded interior shoulders for regressed lenses according to the invention.

(17) FIG. 13A is a front view of an embodiment of a hybrid light fixture housing using the tow-piece extrusion method of the present invention.

(18) FIG. 13B is a front view of a connection point portion of an embodiment of a hybrid light fixture housing using the tow-piece extrusion method of the present invention.

(19) FIG. 14 is an elevated perspective view of a presently preferred embodiment of a hybrid light fixture housing using the two piece extrusion method according to the invention.

(20) FIG. 15 is a front view of a connection point portion a presently preferred embodiment of a hybrid light fixture housing using the two piece extrusion method according to the invention.

(21) FIG. 16 is a front view of a portion of an embodiment of a hybrid light fixture housing using the two piece extrusion method for a grid ceiling.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

(22) In exemplary embodiments of the present invention shown in FIGS. 1-16, there is depicted generally a hybrid light fixture 1 comprising a housing substrate 10 formed of sheet metal that is configured to have flat back 11 and bent sidewalls 12, 13 defining an interior chamber area 14. The sidewalls 12, 13 are generally telescoping outwardly by a series of bends 15 to define separate chambers that typically include (as depicted in FIG. 1) a small, square back ballast compartment 16, a slightly larger regressed reflector area 17, an even slightly larger non-regressed reflector area 18, a progressively larger regressed lens area 19, and/or a large non-regressed lens area 20 terminating at the ends 21, 22 of the sidewalls 12, 13 in a front 23 area of the fixture 1.

(23) According to this embodiment of the invention, as best shown in FIG. 3, the ends 21, 22 of the sidewall 12, 13 of the housing include an outwardly deflected bend defining respective outer shoulders 32, 31. Above the outer shoulders 32, 31 of the ends 21, 22 of the sidewalls 12, 13 are rivet holes 41, 42. The shoulders 31, 32 and rivet holes 41, 42 allow for connection of extrusion members 50 to the housing 10, using rivet 43.

(24) Extrusion members 50 are preferably extruded aluminum strips in lengths corresponding with the length of the housing sidewall to which it will be attached. The strips are bent to define generally u-shaped clips for clipping onto the ends of the sidewalls. As best shown in FIG. 2, each clip member 50 has a cross-section defining a channel 60. As depicted, the clip member 50 has a first straight side 51 descending to a u-bend 52 with the other side 53 ascending therefrom generally linearly but being bent to deflect outwardly and back to define a shoulder 54 positioned and sized to mate with a corresponding shoulder 31 of the housing sidewall end 21. The top of the second side 53 has a tapered end 55 to facilitate accepting the sidewall 21 of the housing into the interior channel 60 of the clip member 50. Both sides of the clip 50 are provided with corresponding rivet holes 41, 42 sized and positioned to allow a single rivet 43 to pass through the rivet holes 41, 42 of the clip 50 and housing sidewall to secure the sidewall in the channel 60 of the clip.

(25) In operation, the clip 50 is forced fit onto the housing sidewall end 21. The elasticity and bias of the clip's u-shaped design allows it to be elastically deformed during fitting and resiliently clamp down on the sidewall when released. The shoulder of the clip pins the shoulder of the sidewall underneath to hinder slippage. To prevent slippage and ensure proper positioning of the substrate and extrusion member, one or more rivets are threaded between the corresponding rivet holes disposed along the length of the sides. After securing the extrusion members to each side of the housing substrate, the hybrid housing assembly is completed and ready for the next step in the fixture manufacturing and assembly process.

(26) FIGS. 1-11 show additional details and presently preferred details of the parameters of the housing substrate and extrusion members of the present invention for variously sized recessed lighting fixtures such as 2.5 inch, 3.5 inch, 4.0 inch, and 6.0 inch wide fixtures. FIG. 12 depicts a modified extrusion member wherein the extrusion member includes an interior shoulder or flange feature 80 that is particularly adapted for fixtures with recessed lenses.

(27) FIGS. 13-16 depict a presently preferred embodiment of the invention demonstrating what is referred to as the two piece extrusion method. As depicted in the figures, the housing sidewall ends 21, 22 include shoulder bends 31, 32 similar to, but smaller than those of the one-piece extrusion embodiments of FIGS. 1-11. In addition, instead of having a single extruded member bent into a u-shaped clip member, the embodiment of FIGS. 13-17 includes an first outer backing bar 70 and a second, separate ceiling trim extrusion member 80.

(28) As discerned from the various views, the backing bar 70 profile is similar to the outside of the u-clip of the previous embodiments. The top of the backing bar 70 includes a rivet hole 71 as seen in other embodiments. The backing bar 70 also includes a shoulder 71 formed from an outwardly deflecting bend relatively central to the bar 70. The shoulder 71 of the backing bar 70 also operates similarly to the previous embodiments in fitting over a matching shoulder ridge formed in the sidewall of the housing substrate (also resulting in the aligning of the corresponding rivet holes). A notable difference rests in that the backing bar 70 terminates to form a small flange or foot 73 at its distal end.

(29) The ceiling trim extrusion member 80 is similar to the extrusion member of the previous embodiments with several notable exceptions. The ceiling trim extrusion member 80 has a first side 81 that descends generally linearly towards a u-shaped bend 82. However, the first side 81 includes a bend defining a small, outwardly projecting ledge 83. The member 80 follows the u-bend 82 with a small inwardly projecting flange 84 followed by an outwardly-extending L-shaped bend 85. The u-shaped bend 82 and flange 84 define a pocket 90 sized and shaped to accept the foot 73 of the backing bar 70. Preferably, as shown, the foot 73 is tapered and/or angled to allow it to cam past, and be retained under, the flange 84 and within the pocket 90. Once positioned, corresponding rivet holes in the backing bar, housing sidewall, and ceiling trim member allow the composite to be sandwiched and fastened together to prevent slippage and disengagement.

(30) As shown in the figures, and as will be appreciated by one of ordinary skill in the art, the L-shaped bend 85 of ceiling trim member 80 and the u-shaped bend 82 serve as horizontal flanges or stops for the tracks of tee track assemblies 100. The u-shaped bend stop is used for grid ceiling interfaces (best shown on FIG. 15) and the L-shaped bend stop is used for soft grid ceiling interfaces (best shown on FIG. 16).

(31) As will now be readily appreciated by one of ordinary skill in the art armed with the present specification, the inventive methods of the present invention lend themselves to forming metal housing substrates of desired widths and lengths that may be called into service to be recessed into any variety of ceiling types and arrangements. In brief, a plurality of aluminum extrusion members, e.g., ceiling trim members and backing bars, are extruded into predetermined lengths having profiles of the types described herein, or any other suitable configurations, that lend to sandwiching and mating with the housing substrate sidewalls in a manner that secures the housing composite together to form a hybrid fixture housing suitable for the area and conditions of deployment of the light fixture.

(32) The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the scope of the present invention. The description of an exemplary embodiment of the present invention is intended to be illustrative, and not to limit the scope of the present invention. Various modifications, alternatives and variations will be apparent to those of ordinary skill in the art, and are intended to fall within the scope of the invention.