Note: Descriptions are shown in the official language in which they were submitted.
=
LIGHTING FIXTURE MOUNTING SYSTEMS
BACKGROUND OF THE INVENTION
Flat panel lighting fixtures are a convenient lighting option as they can be
mounted to a
mounting surface and a relatively low profile compared to other lighting
fixtures. Light emitting
diode (LED) flat panel lighting fixtures, in particular, generally cannot be
mounted through
traditional lighting fixture methods. For example, generally the lens of LED
flat panel lighting
fixtures is secured to the fixture. Thus, an LED flat panel lighting fixture
cannot be secured to a
mounting surface through by a fastener passing through the back of the
lighting fixture.
Therefore, there is a need for new and improved methods and mounting systems
for
easily and securely mounting an LED flat panel lighting fixture to a mounting
surface.
SUMMARY
Embodiments of the present invention provide new and improved methods and
mounting
systems for mounting an LED flat panel lighting fixture to a mounting surface.
Furthermore, the
methods and mounted systems described herein may be used to mount a variety of
lighting
fixtures in addition to LED flat panel lighting fixtures.
According to one aspect of the present invention, a mounting system for
mounting a
lighting fixture is provided. In an example embodiment, the mounting system
comprises a
mounting frame comprising a frame portion configured to be secured to a
mounting surface; a
central opening defined by the frame portion; and one or more tabs disposed on
the frame portion
and each configured to be inserted into a corresponding slot of the lighting
fixture. When the
frame portion is secured to the mounting surface a junction box is accessible
through the central
opening.
In example embodiments, the mounting system further comprises a lighting
fixture. The
lighting fixture comprises a fixture frame disposed about a perimeter of a
back portion of the
lighting fixture. The fixture frame comprises one or more slots; and one or
more support rail.
Each of the one or more slots provides through a portion of one of the one or
more support rails.
In example embodiments, the lighting fixture is generally rectangular. In
example embodiments,
each of the one or more slots is configured to receive one of the one or more
tabs therein such
that the tab may slide into a tab recess defined at least in part by one of
the one or more support
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rails. In example embodiments, the tab recess is further defined at least in
part by the fixture
frame, the back portion of the lighting fixture, or both. In example
embodiments, either (a) a
defining surface of the tab recess is shaped, (b) a wedge defined on the tab
is shaped, or (c) both
such that as the tab is slide into the tab recess, a space between the
mounting surface and the
back portion of the lighting fixture is reduced. In an example embodiment, one
or more tabs are
configured to engage the one or more support rails so as to secure the
lighting fixture to the
mounting surface. In an example embodiment, the mounting frame further
comprises one or
more frame cables and the lighting fixture further comprises one or more
fixture cables and
wherein a frame cable is configured to be secured to a corresponding fixture
cable.
In an example embodiment, the mounting frame comprises a pair of first frame
portions
and a pair of second frame portions. The pair of first frame portions
comprises two elongated
first frame portions that are generally parallel with one another. The pair of
second frame
portions comprises two elongated second frame portions that are generally
parallel with one
another. The pair of first frame portions and the pair of second frame
portions are secured to each
other such that each first frame portion is secured to one of the second frame
portions at one end
and the other of the second frame portions at an opposite end to form a
quadrilateral.
Additionally, the central opening is defined as an interior of the
quadrilateral. In example
embodiments, each of the second frame portions comprises a tab portion on each
end of the
elongated second frame portion; and the tab portions extend outwardly from an
exterior
perimeter of the quadrilateral.
In example embodiments, when the mounting frame is secured to a mounting
surface, the
mounting frame need not be centered about the junction box. In an example
embodiment, the
mounting frame is configured to be secured to a mounting surface by one or
more mechanical
fasteners.
According to another aspect of the present invention, a lighting fixture
mounting kit for
mounting a flat panel lighting fixture to a mounting surface is provided. In
an example
embodiment, the lighting fixture mounting kit comprises a mounting frame and a
lighting fixture.
The mounting frame comprises a frame portion configured to be secured to a
mounting surface;
and a central opening defined by the frame portion. When the frame portion is
secured to the
mounting surface, a junction box is accessible through the central opening.
The mounting frame
is shaped for engagement and attachment with a lighting fixture. The lighting
fixture comprises a
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fixture frame disposed about a perimeter of a back portion of the lighting
fixture. The fixture
frame is shaped for engagement and attachment with the mounting frame.
In example embodiments, the lighting fixture mounting kit further comprises a
mounting
harness. In an example embodiment, the mounting harness comprises one or more
fixture cables;
and one or more frame cables. At least one of said one or more fixture cables
is configured to be
secured to a corresponding one of the one or more frame cables.
According to still another aspect of the present invention, a mounting system
for
mounting a lighting fixture is provided. In an example embodiment, the
mounting system
comprises a mounting plate. The mounting plate may comprise a plate portion
configured to be
secured to a mounting surface; one or more mounting tabs disposed on the plate
portion and
configured to secure the lighting fixture to the mounting plate and extending
outwardly from a
plane defined by the plate portion; and one or more indexing tabs configured
to be aligned with
corresponding one or more indexing slots of the lighting fixture and extending
outwardly from
the plane defined by the plate portion.
In example embodiments, the mounting system further comprises a lighting
fixture. The
lighting fixture may comprise a back portion having therein one or more
mounting slots and one
or more indexing slots, wherein each mounting slot is configured to receive a
mounting tab
therein and each indexing slot is configured to receive an indexing tab
therein such that insertion
of the indexing tab into the indexing slot guides the alignment of at least
one of the one or more
mounting tabs to the corresponding one of the one or more mounting slots. In
example
embodiments, one side of the lighting fixture is secured to the mounting plate
by a hinge. In
example embodiments, the hinge allows the lighting fixture to (a) rotate with
respect to the
mounting plate at least partially about an axis defined by the hinge and (b)
translate, with respect
to the mounting plate, along at least a portion of the axis. In example
embodiments, at least one
of the one or more mounting tabs comprises a locking portion. In example
embodiments the back
portion of the lighting fixture further comprises at least one locking slot
corresponding to a
mounting slot. The locking slot is configured to receive the locking portion
of the corresponding
mounting tab such that the mounting tab is fixedly secured within the
corresponding mounting
slot. In example embodiments, the one or more indexing tabs are not configured
to suspend the
lighting fixture therefrom.
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In example embodiments, the one or more indexing tabs extend outward from the
mounting plate farther than the one or more mounting tabs. In example
embodiments, at least
one of the one or more mounting tabs is reinforced by (a) an angle
reinforcement configured to
maintain the angle between the mounting tab and the plate portion, (b) an
elongated
reinforcement configured to reduce bending of the mounting tab along an
elongated portion of
the mounting tab, or both.
According to yet another aspect of the present invention, a lighting fixture
mounting kit
for mounting a flat panel lighting fixture to a mounting surface is provided.
In an example
embodiment, the lighting fixture mounting kit comprises a mounting plate and a
lighting fixture.
The mounting plate comprises a plate portion configured to be secured to a
mounting surface;
and one or more indexing tabs configured to be aligned with corresponding one
or more indexing
slots of the lighting fixture and extending outwardly from the plane defined
by the plate portion.
The mounting plate is shaped for engagement and attachment with the lighting
fixture. The
lighting fixture comprises a back portion having therein the one or more
indexing slots. The back
portion is shaped for engagement and attachment with the mounting plate. Each
indexing slot is
configured to receive an indexing tab therein such that insertion of the
indexing tab into the
indexing slot guides the engagement of the lighting fixture with the mounting
plate.
In an example embodiment, the lighting fixture mounting kit further comprises
a hinge
configured to connect one side of the mounting plate to one side of the
lighting fixture. In an
example embodiment, the hinge comprises one or more hinge mounting tabs, one
or more hinge
indexing tabs, or both.
Various embodiments are directed to a mounting system for mounting a lighting
fixture.
In certain embodiments, the mounting system comprises a mounting portion
configured to be
secured relative to a mounting surface, wherein the mounting portion comprises
one or more
mounting catches; and a lighting fixture secured relative to the mounting
portion, wherein the
lighting fixture comprises one or more fixture catches configured to
selectably engage the one or
more mounting catches. In various embodiments, the lighting fixture is
slidable relative to the
mounting portion between: an engaged configuration in which the one or more
fixture catches
are engaged with the one or more mounting catches; and a disengaged
configuration in which the
one or more fixture catches are disengaged from the one or more mounting
catches. In certain
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embodiments, the lighting fixture is pivotable relative to the mounting
portion when in the
disengaged configuration.
Moreover, in certain embodiments, the lighting fixture is pivotable about a
first axis
relative to the mounting portion when in the disengaged configuration; and the
lighting fixture is
may be slidable relative to the mounting portion in a direction perpendicular
to the first axis. In
certain embodiments, the lighting fixture is slidable relative to the mounting
portion in a
direction substantially parallel to the mounting surface. Moreover, the
lighting fixture may be
secured relative to the mounting portion by at least one mounting arm, wherein
the mounting
portion is pivotably secured at a first end of the at least one mounting arm
and the lighting fixture
is pivotably secured at a second end of the at least one mounting arm.
Moreover, the mounting
portion may be slidably secured at the first end of the at least one mounting
arm. Moreover, the
lighting fixture may be secured relative to the mounting portion by at least
one mounting
harness.
In various embodiments, the lighting fixture is detachably secured relative to
the
mounting portion. Moreover, in certain embodiments, the mounting portion is
configured to be
secured to at least one of a junction box secured within the support surface
or a can light secured
within the support surface. In various embodiments, the one or more mounting
catches are
configured to bias the lighting fixture toward the support surface when in the
engaged
configuration. In certain embodiments, the one or more mounting catches
comprise one or more
locking features configured to bias the lighting fixture into the engaged
configuration. Moreover,
in certain embodiments, the mounting portion defines at least one guide rail,
and wherein the
lighting fixture is slidable along the guide rail relative to the mounting
portion. In various
embodiments, the mounting portion may be one of a mounting plate or a mounting
frame. In
certain embodiments, the lighting fixture is generally rectangular.
Moreover, various embodiments are directed to a method for mounting a lighting
fixture
relative to a support surface. In certain embodiments, the method comprises
steps for: (i)
securing a mounting portion relative to a support surface, wherein the
mounting portion
comprises one or more mounting catches; (ii) pivoting a lighting fixture
secured relative to the
mounting portion from a first position to a second position at least
substantially parallel to the
support surface; and (iii) sliding the lighting fixture relative to the
mounting portion from the
second position to a third position in which the one or more fixture eyes are
engaged with the
CA 2979140 2017-09-14
one or more mounting catches. Moreover, various embodiments comprise steps for
electrically
connecting the lighting fixture with a power source.
In various embodiments, pivoting the lighting fixture relative to the mounting
portion
comprises pivoting the lighting fixture about a first axis and sliding the
lighting fixture relative to
the mounting portion comprises sliding the lighting fixture in a direction at
least substantially
perpendicular to the first axis. In certain embodiments, the method
additionally comprises steps
for securing the lighting fixture relative to the mounting portion. Moreover,
in certain
embodiments, the lighting fixture is pivotably secured to at least one
mounting arm. In such
embodiments securing the lighting fixture relative to the mounting portion may
comprise steps
for securing the at least one mounting arm to the mounting portion. Moreover,
in various
embodiments, securing the mounting portion relative to the support surface
comprises one of:
securing the mounting portion to a junction box secured within the support
surface or securing
the mounting portion to a can light secured within the support surface.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
Having thus described the invention in general terms, reference will now be
made to the
accompanying drawings, which are not necessarily drawn to scale, and wherein:
Figure 1 is a partially exploded view of a mounting system, in accordance with
an
embodiment of the present invention;
Figure 2 is a perspective view of elements of a mounting system in accordance
with an
embodiment of the present invention;
Figure 3 is a perspective view of a lighting fixture secured to a mounting
frame, in
accordance with an embodiment of the present invention;
Figure 4 is a view of a mounting frame secured to a mounting surface, in
accordance with
an embodiment of the present invention;
Figures 5A, 5B, and 5C show a front view, a side view, and a cross-sectional
view,
respectively, of a second frame portion of a mounting frame, in accordance
with embodiments of
the present invention;
Figure 6A and 6B shows perspective views of a lighting fixture being mounted
to a
mounting frame using a mounting harness, in accordance with an embodiment of
the present
invention;
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Figure 7 is a flowchart illustrating various operations and procedures for
mounting a
lighting fixture, in accordance with an embodiment of the present invention;
Figure 8is a partially exploded view of a mounting system, in accordance with
an
embodiment of the present invention;
Figure 9 is a partial perspective view of an indexing tab and indexing slot
being aligned,
in accordance with an embodiment of the present invention;
Figure 10 is a back view of a lighting fixture, in accordance with an
embodiment of the
present invention;
Figures 11A, 11B, and 11C provide a perspective view, side view, and a cross-
sectional
view of a mounting tab, in accordance with an example embodiment of the
present invention;
Figure 12A provides a perspective view of another embodiment of a mounting
plate;
Figure 12B provides a cross-section of a portion of the embodiment of the
mounting plate
shown in Figure 12A;
Figure 12C provides a back view of a lighting fixture configured to be mounted
using the
mounting plate shown in Figure 12A;
Figure 12D provides a cross section of a portion of the mounting system shown
in
Figures 12A and 12D;
Figures 13A and 13B are perspective views of still another embodiment of a
mounting
system;
Figure 13 is a perspective view of yet another embodiment of a lighting
fixture being
mounted to a mounting surface by a mounting plate;
Figure 14 is a flowchart illustrating various operations and procedures for
mounting a
lighting fixture, in accordance with an embodiment of the present invention;
and
Figure 15 is a perspective view of yet another embodiment of a lighting
fixture being
mounted to a mounting surface by a mounting plate.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
The present invention now will be described more fully hereinafter with
reference to the
accompanying drawings, in which some, but not all embodiments of the invention
are shown.
Indeed, the invention may be embodied in many different forms and should not
be construed as
limited to the embodiments set forth herein; rather, these embodiments are
provided so that this
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CA 2979140 2017-09-14
disclosure will satisfy applicable legal requirements. Like numbers refer to
like elements
throughout.
General Overview
Example embodiments of the present invention provide mounting systems and
corresponding methods for mounting a lighting fixture to a mounting surface.
In example
embodiments, a mounting surface may be a ceiling or other substantially
horizontal surface, or a
wall or other substantially vertical surface. In example embodiments, of a
mounting system
comprise a mounting bracket that is configured to be mounted to a mounting
surface. In example
embodiments, the mounting bracket may be a mounting frame or a mounting plate.
The
mounting system may further comprise a lighting fixture configured to be
secured to the
mounting bracket. In example embodiments, the lighting fixture may be secured
to the mounting
bracket through various mechanisms such as snap in, slide in, and/or twist and
lock mechanisms.
For example, the mounting bracket may comprise one or more tabs configured to
be inserted into
one or more corresponding slots disposed on a back portion of the lighting
fixture. In one
embodiment, one or more tabs are disposed on the back portion of the lighting
fixture and one or
more corresponding slots are disposed in the mounting bracket.
Exemplary Mounting Frame Mounting System
Figures 1, 2, and 3 illustrate various views of a mounting system 100
comprising a
mounting frame 101 and a lighting fixture 200 and Figure 4 illustrates a
mounting frame 101
secured to a mounting surface 705. The mounting frame 101 may be configured to
be secured to
a mounting surface 705 such that a junction box 710 is accessible through a
central opening 105
of the mounting frame 101. The mounting frame 101 may be configured to
securely suspend the
lighting fixture 200 therefrom. In yet other embodiments, mounting frame 101
may be
configured to be secured relative to a can light (e.g., via a detachable can
light adapter bracket as
discussed in U.S. Patent Appl. No. 14/720,334_
Exemplary Lighting Fixture 200
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In example embodiments, the lighting fixture 200 is a flat panel lighting
fixture. In
example embodiments, the lighting fixture 200 may comprise one or more LED
chips, LED
modules, LED packages, LED lighting engine, and/or other lighting engine. For
example, in
some embodiments, the lighting fixture 200 is an LED flat panel lighting
fixture. In example
embodiments, the lighting fixture 200 may be rectangular or oval-shaped,
though other shapes
are also considered.
In example embodiments, the lighting fixture 200 may comprise a wire opening
205
disposed on the back portion 210 of the lighting fixture 200. The wire opening
205 may be
configured to allow connecting wires 207 pass therethrough. In example
embodiments, the
connecting wires 207 are configured to electrically connect the lighting
fixture 200 to a power
supply (e.g., line voltage). For example, the connecting wires 207 may be
configured to secured
into electrical communication (e.g., with a quick connect connector, wire
nuts, and/or the like)
with wires 715 of a junction box 710 and/or a can light, and thereby provide
line voltage to the
lighting fixture 200.
In example embodiments, the lighting fixture 200 may comprise driver circuitry
230. For
example, the connecting wires 207 may electrically connect the driver
circuitry 230 to a power
supply. For example, the driver circuitry 230 may comprise a circuit portion
configured to
convert AC voltage into DC voltage. In some embodiments, the driver circuitry
230 may
comprise a circuit portion configured to control the current flowing through
the one or more
LED chips. In certain embodiments, the driver circuitry 230 may comprise a
circuit portion
configured to dim the lighting fixture 200. In various embodiments, additional
circuit
components may be present in the driver circuitry 230. Similarly, in various
embodiments, all or
some of the circuit portions mentioned here may not be present in the driver
circuitry 230. In
some embodiments, circuit portions listed herein as separate circuit portions
may be combined
into one circuit portion. As should be appreciated, a variety of driver
circuitry 230
configurations are generally known and understood in the art and any of such
may be employed
in various embodiments as suitable for the intended application, without
departing from the
scope of the present invention. In example embodiments, the driver circuitry
230 may be
disposed outside of the fixture frame 201.
In example embodiments, the lighting fixture 200 may comprise a fixture frame
201 and
a back portion 210. In example embodiments, the back portion 210 is the side
of the lighting
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fixture 200 opposite the portion of lighting fixture configured to provide
and/or project light. In
example embodiments, the fixture frame 201 may be disposed about a perimeter
of the back
portion 210. In example embodiments, the fixture frame 201 and/or back portion
210 may be
made of plastic, aluminum, or other lightweight, rigid material appropriate
for the application. In
example embodiments, the fixture frame 201 may be configured and/or shaped for
engagement
and attachment with a mounting frame 101 (e.g., the frame portion 110, tabs
115, and/or the
like).
The fixture frame 201 may comprise one or more support rails 220. The one or
more
support rails may be configured to support the lighting fixture 200 when the
lighting fixture is
suspended form one or more tabs 115 of a mounting frame 101. In example
embodiments
wherein the lighting fixture 200 defines an elongated axis A (e.g., parallel
to the longer side of a
rectangle or the major axis of an ellipse), the support rails 220 may be
parallel to the elongated
axis A. In example embodiments, the lighting fixture 200 comprises two support
rails 220 and a
first support rail 220 defines a first axis that is parallel to a second axis
defined by the second
support rail 220. For example, both the first axis and the second axis may be
parallel to the
elongated axis A and/or another axis of the lighting fixture 200. In some
embodiments, the
lighting fixture 200 may not have an elongated axis (e.g., the lighting
fixture 200 may be square,
round, hexagonal, and/or the like) or the support rails 220 may be parallel to
a non-elongated
axis of the lighting fixture 200 (e.g., a minor axis and/or the like). In an
example embodiment
having two support rails 220, the support rails 200 may be spaced apart by
more than 50% of the
width of the lighting fixture 200. For example, the first support rail 220 may
be disposed along
one edge of a perimeter of the back portion 210 and the second support rail
220 may be disposed
along an opposite edge of the perimeter of the back portion 210.
In example embodiments, a support rail 220 may comprise one or more slots 215
therein.
Each slot 215 may provide access to a tab recess 217 configured to receive a
tab 115 of the
mounting frame 101 therein. The one or more support rails 220 may have one or
more slots 215
therein providing access to one or more tab recesses 217. For example, the
lighting fixture 200
may comprise two support rails 200 and each support rail 200 may comprise two
slots 215. Each
slot 215 may correspond to a tab recess 217. In example embodiments, each tab
recess may
define a tab axis and each tab axis may be parallel to the first and second
axes defined by the first
and second support rails 220. Each tab recess 217 may be at least in part
defined by a support rail
CA 2979140 2017-09-14
220, the back portion 210, and/or another portion of the fixture frame 201. In
an example
embodiment, each tab recess 217 at least partially defined by a support rail
220 is equidistant
from a center point of the support rail 220. In another example embodiment,
the tab recesses 217
are equally spaced along the support rail 220. For example, if a support rail
220 at least partially
defines two tab recesses 217 and a first tab recess 217 is a distance d from a
first end of the
support rail 220, the second tab recess 217 is a distance d from the opposite
end of the support
rail 220.
In various embodiments, a surface of the tab recess 217 may be contoured such
that as a
tab 115 is slid into the tab recess 217 from the corresponding slot 215, a
component of the tab's
115 movement is parallel to the support rail 220 that at least partially
defines the tab recess 217
and another component of the tab's 115 movement is perpendicular to the
support rail 220 such
that the tab 115 moves closer to the back portion 210 as it is slides into the
tab recess 217. For
example, as the tab 115 is slid into the tab recess 217, the lighting fixture
200 may be pulled
closer to the mounting surface to which the mounting frame 101 is secured by
the contour of at
least one surface of the tab recess 217.
Exemplary Mounting Frame 101
In example embodiments, the mounting frame 101 comprises a frame portion 110
configured to be secured to a mounting surface. For example, the frame portion
may be secured
to a mounting surface 705 by one or more mechanical fasteners 130 (e.g.,
screws, nails, bolts). In
example embodiments, the frame portion 110 may be generally rectangular in
shape. In some
embodiments, the frame portion 110 may be shaped similarly to the lighting
fixture 200. In
example embodiments, the mounting frame 101 and/or the frame portion 110 may
be configured
and/or shaped for engagement and attachment with the lighting fixture 200
(e.g., the fixture
frame 201).
The frame portion 110 may define a central opening 105. When the frame portion
is
mounted to a mounting surface 705, a junction box 710 (e.g., the junction box
wires 715) may be
accessible through the central opening 105. Generally a mounting bracket is
centered on a
junction box such that the lighting fixture mounted by the mounting bracket is
centered on the
junction box. Indeed, generally the mounting bracket may be secured to the
junction box.
However, the mounting frame 101 is not secured to the junction box and need
not be centered on
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the junction box 710. Indeed, the junction box 710 may be located in a corner
of the central
opening 105, as shown in Figure 4. Rather than centering the mounting frame
101 over the
junction box 710, the mounting frame 101 may be mounted such that the junction
box 710 (e.g.,
the junction box wires 715) is accessible through some portion of the central
opening 105. Thus,
the mounting frame 101 of the present invention provides an installer of the
lighting fixture 100 a
greater amount of flexibility regarding where to mount the lighting fixture
100 with respect to
the junction box 710 and mounting surface 705. For example, an installer may
choose to mount
the lighting fixture 100 further from a wall where previously the junction box
710 location would
have forced the installer to mount the lighting fixture 100 closer to the wall
than desired or too
close to the wall for the lighting fixture 100 to fit.
Moreover, as discussed herein, frame portion 110 may be secured relative to a
can light,
for example, via a detachable can light adapter bracket as discussed herein.
For example, the
frame portion 110 may be configured to be secured relative to a detachable can
light adapter
portion (e.g., via one or more fasteners) such that the frame portion 110 may
be secured relative
to a can light. In various embodiments, the frame portion 110 may be
configured to be secured
relative to a junction box 710 and/or support surface when the can light
adapter portion is
removed. For example, frame portion 110 may comprise one or more brackets
configured to be
secured relative to a junction box, such as those described in U.S. Patent
Appl. No. 15/272,645,
filed on September 22, 2016.
In such embodiments, the frame portion may comprise one or more brackets
configured
to be secured relative to a junction box and/or relative to one or more can
light adapter brackets
configured to secure the frame portion relative to a can light.
In example embodiments, the frame portion 110 comprises a pair of first frame
portions
125 and a pair of second frame portions 120. Each of the first frame portions
125 may be an
elongated frame portion. For example, the first frame portion 125 may be
generally rectangular
in shape. For example, the first frame portion 125 may be made of aluminum or
other
lightweight metal or material appropriate for the application. The first frame
portion 125 may be
relatively thin. In example embodiments, the first frame portion 125 may be
approximately an
eighth of an inch to a quarter of an inch thick. In other embodiments, the
first frame portion 125
may be thinner than an eighth of an inch (e.g., a sixteenth of an inch) or
thicker than a quarter of
an inch (e.g., three-eighths of an inch). In example embodiments, the length
of the first frame
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=
portion 125 is approximately six inches to twenty inches. For example, the
first frame portion
125 may be one foot long. In other embodiments, the first frame portion 125
may be shorter or
longer as appropriate for the application. In example embodiments, the first
frame portion 125 is
approximately half an inch to three inches wide. First frame portions 125 of
other widths may be
used as appropriate for the application.
Each of the second frame portions 120 may be an elongated frame portion. For
example,
the second frame portion 120 may be generally rectangular in shape. For
example, the second
frame portion 120 may be made of aluminum or other lightweight metal or
material appropriate
for the application. The second frame portion 120 may be relatively thin, but
thicker than the first
frame portion 125. For example, at least a portion of the second frame portion
120 may be a
quarter of an inch to half an inch thick, though in other embodiments, the
second frame portion
120 may be thicker or thinner as appropriate for the application. In example
embodiments, the
length of the second frame portion 120 is approximately six inches to twenty
inches. For
example, the second frame portion 120 may be nine inches long. In some
embodiments, the
second frame portion 120 is shorter than the first frame portion 120. In
example embodiments,
the second frame portion 120 is approximately half an inch to three inches
wide. Second frame
portions 120 of other widths may be used as appropriate for the application.
In some embodiments, the second frame portion 120 is a solid piece of material
and in
other embodiments, the second frame portion 120 may comprise, for example, a
one eighth inch
thick sheet of metal that has been bent to create three sides of a rectangular
prism. For example,
Figures 5A, 5B, and 5C show an example embodiment of a second frame portion
120. For
example, the second frame portion 120 may comprise a main portion 122, an
inner bent portion
123 and an outer bent portion 124. For example, the inner bent portion 123 and
the outer bent
portion 124 may extend outward from the main portion 122. For example, the
inner bent portion
123 and the outer bent portion 124 may be approximately normal to the main
portion 122. The
inner bent portion 123 may not extend as far along the length of the second
frame portion 120 to
allow the first frame portion 120 to overlap with the main portion 122 of the
second frame
portion 120. In example embodiments, the length of the outer bent portion 124
may be
configured such that the outer bent portion 124 does not get caught on the
supporting rail 220 as
the lighting fixture 200 is being mounted on to the mounting bracket 101. For
example, the
maximum length of the outer bent portion 124 may be determined by the distance
W between the
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interior edges of the supporting rails 220 (e.g., along an axis perpendicular
to the elongated axis
A of the lighting fixture 200), as shown in Figure 1. The inner and out bent
portions 123, 124
may be configured to add structural integrity to the second frame portion 120
and the frame
portion 110. In example embodiments, the second frame portion 120 may further
comprise one
or more fastener holes 132 configured to receiving a fastener 130 therethrough
such that the
fastener 130 may secure the second frame portion and/or the mounting frame 101
to the
mounting surface 705.
The second frame portion 120 may further comprise one or more tabs 115. For
example,
at each end of the elongated frame portion, the second frame portion 120 may
comprise a tab
115. For example, the outer and inner bent portions 123, 124 may not extend
along the entire
length of the main portion 122 such that at least one end portion of the
second frame portion 120
only comprises the main portion 122. This end portion of the second frame
portion 120 is a tab
115. The tabs 115 may be configured to be slide through a slot 215 into a tab
recess 217 of the
lighting fixture 200. For example, the tabs 115 may be configured to suspend
the lighting fixture
200 therefrom by engaging a support rail 220 or other surface of the tab
recess 217.
In the illustrated example embodiment, the tab 115 comprises a wedge 117. The
wedge
117 may be configured to pull the lighting fixture 200 toward the mounting
frame 101 and/or the
mounting surface 705 as the tab 115 is slid into the tab recess 217. For
example, the wedge 117
may engage a portion of the fixture frame 201 or back portion 210, causing the
lighting fixture
200 to be pulled toward the mounting frame 101 and/or the mounting surface
705. In an example
embodiment, the wedge 117 is approximately one-eighth of an inch thick at the
widest part of the
wedge. For example, the wedge 117 may be configured to reduce the gap between
the lighting
fixture 200 and the mounting surface 705 by up to approximately one-eighth of
an inch. The
wedge 117 may have a maximum thickness of more or less than one-eighth of an
inch in various
embodiments, as appropriate for the application.
Each first frame portion 125 may be configured to be fixedly secured to two
second
frame portions 120. For example, each end of the elongated first frame portion
may be
configured to be fixedly secured to a second frame portion 120. Similarly,
each second frame
portion 120 may be configured to be fixedly secured to two first frame
portions 125. For
example, a pair of first frame portions 125 and a pair of second frame
portions 120 may be
fixedly secured together to form a quadrilateral. For example, the pair of
first frame portions 125
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CA 2979140 2017-09-14
and the pair of second frame portions 120 may be fixedly secured together to
form a rectangle.
For example, a pair of first frame portions 125 and a pair of second frame
portions 120 may be
fixedly secured to one another to define a quadrilateral and/or rectangular
central opening 105. In
example embodiments, the tabs 115 may extend outward from an exterior
perimeter of the
quadrilateral and/or rectangle formed by fixedly securing the first pair of
first frame portions 125
to the pair of second frame portions 120 and lie in approximately the same
plane as the
quadrilateral and/or rectangle. For example, the tabs 115 may extend outward
from the
quadrilateral and/or rectangle approximately a quarter of an inch to two
inches. In example,
embodiments, a first frame portion 125 may be secured to a second frame
portion 120 by a weld
128, a mechanical fastener, and/or the like.
When the mounting frame 101 is secured to the mounting surface 705, a side of
the first
frame portions 125 may be flush against the mounting surface 705. In some
embodiments, an
edge surface of the inner bent portion 123 and an edge surface of the outer
bent portion 124 are
flush against the mounting surface 705. In example embodiments, a gap may
exist between a tab
115 and the mounting surface 705, such that a support rail 220 of the lighting
fixture 200 may be
slid between the tab and the mounting surface 705 with the lighting fixture is
secured to the
mounting frame 101. In some embodiments, the tab 115 defines a plane that is
generally parallel
to a plane defined by the mounting surface 705 when the mounting frame 101 is
secured to the
mounting surface 705.
Exemplary Mounting Harness
Figures 6A and 6B illustrate an example embodiment of a mounting system 100'
comprising a mounting harness 150. In example embodiments, a mounting harness
150
comprises a frame cable 155 secured to a mounting frame 101' and a fixture
cable 165 secured to
a lighting fixture 200'. The frame cable 155 and the fixture cable 165 may be
secured to one
another by loop 156 and clip 166. For example, the loop 156 may be inserted
into clip 166 to
secure the frame cable 155 to the fixture cable 165. In the illustrated
embodiment, the clip 166 is
attached to the fixture cable 165. In other embodiments, the clip 166 is
attached to the frame
cable 155. In example embodiments, a mounting harness 150 may comprise two
sets of fixture
and frame cables 155, 165. For example, a mounting harness 150 may be
configured to secure
CA 2979140 2017-09-14
two different corners of mounting system 101' to the corresponding two corners
of a lighting
fixture 200'.
In example embodiments, the mounting frame 101' may be a mounting frame 101
having
one or more frame cables 155 secured thereto. For example, a frame cable 155
may be secured to
an outer bent portion 124. For example, a screw 154 may secure a loop 152 of
the frame cable
155 to an outer bent portion 124 or other portion of the mounting frame 101'.
In various
embodiments the one or more frame cables 155 may be secured to the mounting
frame 101' by
various methods, as appropriate for the application.
In example embodiments, the lighting fixture 200' may be a lighting fixture
200 having
one or more fixture cables 165 secured thereto. For example, a fixture cable
165 may be secured
to the support rail 220 or other portion of the fixture frame 201. For example
a screw 164 my
secure a loop 162 of the fixture cable 165 to a support rail 220 or other
portion of the fixture
frame 201. In various embodiment the one or more fixture cables 165 may be
secured to the
lighting fixture 200' by various methods, as appropriate for the application.
In various embodiments, the mounting harness 150 may be configured to allow a
single
installer to mount the lighting fixture 200'. For example, the mounting
harness 150 may support
the weight of the lighting fixture 200' while an electrical connection is made
between the
connecting wires 207 and the junction box wires 715. In an example embodiment,
the length of
the combined cable (e.g., the fixture cable 165 secured to the corresponding
frame cable 155)
may be approximately nine inches. In other embodiments, the length of the
combined cable may
be shorter or longer than nine inches as appropriate for the application. In
various embodiments,
the mounting harness 150 may be left intact (e.g., the fixture cable 165 may
continue to be
secured to the corresponding frame cable 155) when the lighting fixture 200'
is secured to the
mounting frame 101'.
Mounting a Lighting Fixture with a Mounting Frame
Figure 7 provides a flowchart illustrating processes and procedures for
installing a
lighting fixture 200, 200' using the mounting system 100, 100'. Starting at
step 302, the
installer(s) may secure the mounting frame 101, 101' to the mounting surface
705. For example,
an installer may secure the mounting frame 101, 101' to the mounting surface
705 with one or
more fasteners 130 secured to the surface 705 such that the junction box 710
(e.g., the junction
16
CA 2979140 2017-09-14
box wires 715) are accessible through the central opening 105. As discussed
herein, in certain
embodiments, the installer may secure the mounting frame 101, 101' relative to
a can light. In
such embodiments, the installer may secure the can light adapter portion
relative to the mounting
frame 101, 101', and may secure the can light adapter portion with the secured
mounting frame,
relative to an existing can light fixture within a support surface. For
example, the can light
adapter portion may be configured to snap into can light, as discussed in
previously mentioned
Appl. No. 14/720,334.
Optionally, at step 304, the installer(s) may mechanically connect the
lighting fixture
200' to the mounting frame 101' using a mounting harness 150. For example, the
installer(s)
may secure one or more frame cables 155 to corresponding one or more fixture
cables 165. The
lighting fixture 200' may be allowed to hang from the attached frame and
fixture cables 155,
165, allowing the installer(s) to access the connecting wires 207 and the
junction box wires 715
while the lighting fixture 200' is held in an appropriate position for an
electrical connection to be
made between the connecting wires 207 and the junction box wires 715. Thus,
use of the
mounting harness 150 may allow a single installer to efficiently and safely
mount the lighting
fixture 200' to the mounting surface 705.
At step 306, the installer(s) may electrically connect the lighting fixture
200, 200' to a
power supply. For example, the installer(s) may electrically connect the
connecting wires 207 to
the junction box wires 715 (and/or a can light electrical connector, socket,
and/or the like) so as
to provide line voltage to the driver circuitry 230 and/or other electrical
components of the
lighting fixture 200, 200'. For example, the installer may electrically
connect the connecting
wires 207 to the junction box wires 715 with quick connect connectors, wire
nuts, and/or the
like. In example embodiments, the connecting wires 207 may be configured such
that the portion
of the connecting wires 207 that makes the electrical connection to the
junction box wires 715
may be positioned within the junction box 710 after the electrical connection
has been made.
At step 308, the slots 215 of the lighting fixture 200, 200' may be aligned
with the tabs
115 of the mounting frame 101, 101'. For example, the installer(s) may align
the slots 215 of the
lighting fixture 200 with the tabs 115 of the mounting frame 101, 101'.
At step 310, the lighting fixture 200, 200' may be slid such that each tab 115
slides into a
corresponding tab recess 217 through the corresponding slot 215. For example,
the installer(s)
may slide the lighting fixture 200, 200' such that each tab 115 slides into a
corresponding tab
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CA 2979140 2017-09-14
recess 217 through the corresponding slot 215. In example embodiments, as the
lighting fixture
200, 200' is slid such that the tabs 115 slide into the corresponding tab
recesses 217, the lighting
fixture 200, 200' may be pulled toward the mounting surface 705. For example,
based on the
contour of the tab recesses 217 and/or the wedge 117, a component of the
lighting fixtures 200,
200' movement may be parallel to the length of the lighting fixture 200, 200'
and/or the
elongated axis A and another component of the lighting fixture's 200 movement
is perpendicular
to the elongated axis A and toward the mounting surface 705. For example, as
the tab 115 is slid
into the tab recess 217, the lighting fixture 200, 200' may be pulled closer
to the mounting
surface 705 to which the mounting frame 101 is secured by the contour of at
least one surface of
the tab recess 217 and/or the wedge 117. For example, due to the contour of a
defining surface of
each of the tab recesses 217 or the wedge 117, as the tabs 115 are slid into
the corresponding tab
recesses 217, a space between the mounting surface 705 and the back portion
210 of the lighting
fixture 200, 200' is reduced.
Exemplary Mounting Plate Mounting System
Figures 8, 9, 10 11A, 11B, and 11C illustrate various views of a mounting
system 400
comprising a mounting plate 401 and a lighting fixture 500. The mounting plate
401 may
comprise one or more indexing tabs 420 configured to be aligned with one or
more indexing
slots 520 disposed on back portion 510 of a lighting fixture 500. The indexing
tabs 420 and
indexing slots 520 may be configured to allow an installer to easily align the
mounting tabs 415
to the mounting slots 515 to secure the lighting fixture 500 to the mounting
plate 401. The
mounting plate 401 may be configured to securely suspend the lighting fixture
500 therefrom.
Exemplary Lighting Device 500
In example embodiments, the lighting fixture 500 is a flat panel lighting
fixture. In
example embodiments, the lighting fixture 500 may comprise one or more LED
chips, LED
modules, LED packages, LED lighting engine, and/or other lighting engine. For
example, in
some embodiments, the lighting fixture 500 is an LED flat panel lighting
fixture. In example
embodiments, the lighting fixture 500 may be rectangular or square, though
other shapes are also
considered.
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CA 2979140 2017-09-14
In example embodiments, the lighting fixture 500 comprises a back portion 510.
The
back portion 510 may be made of plastic, aluminum, or other appropriate
material. In example
embodiments, the back portion 510 may be configured and/or shaped for
engagement and
attachment with a mounting plate 401. In example embodiments, the back portion
510 may
comprise one or more mounting slots 515, one or more locking slots 517, and/or
one or more
indexing slots 520. For example, one or more mounting slots 515, one or more
locking slots 517,
and/or one or more indexing slots 520 may be disposed in the back portion 510.
For example,
one or more mounting slots 515, one or more locking slots 517, and/or one or
more indexing
slots 520 may extend through the back portion 510 of the lighting fixture 500.
In example embodiments, a mounting slot 515 may be configured to receive
therethrough
a mounting tab 415. For example, in one embodiment, a mounting slot may
measure
approximately 4.8 mm by 28 mm, although other sized slots may be used as
appropriate for the
application. For example, a mounting tab 415 may be inserted into the mounting
slot 515 and slid
until a locking portion 417 of the mounting tab 415 engages the locking slot
517. In example
embodiments, the locking slot 517 may be configured to receive therethrough a
locking portion
417 of a mounting tab 415. In example embodiments, the locking slot 517 may be
similar in
width to the mounting slot 515, but shorter in length. In example embodiments,
the mounting slot
515 and the locking slot 517 are configured such that when the locking portion
417 of the
mounting tab 415 is engaged within the locking slot 517, the mounting tab 415
is securely
engaged with the back portion 510 of the lighting fixture 500 such that the
lighting fixture 500
may be securely suspended from the mounting plate 401.
In example embodiments, the back portion 510 may further comprise one or more
indexing slots 520. In example embodiments, an indexing slot 520 is configured
to receive an
indexing tab 420 therein. In example embodiments, the indexing tab 420 does
not engage the
indexing slot 520 to suspend or partially suspend the lighting fixture 500
therefrom. Rather, the
indexing slot is configured to receiving an indexing tab 420 therein to aid
the installer(s) in
aligning the mounting tabs 415 and the mounting slots 515. In example
embodiments, the
indexing slots 520 may be longer than the corresponding indexing tab 420 such
that the indexing
tab 420 may be slid along the indexing slot 520 when the mounting tab 415 is
slid into the
mounting slot 515 and into engagement with the locking slot 517. For example,
the length of the
indexing slot 520 may be determined such that when the indexing tab 420 is
positioned at a first
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CA 2979140 2017-09-14
end of the indexing slot 520, a mounting tab 415 is aligned with a mounting
slot 515 and when
the indexing tab 420 is positioned at an opposite end of the indexing slot
520, the locking portion
417 may fully engage the locking slot 517.
In example embodiments, each indexing slot 520 and each mounting slot 515 may
define
a slot axis. The set of slot axes defined by the indexing slot(s) 520 and the
mounting slot(s) 515
may be mutually parallel. For example, a first mounting slot 515 may define a
first slot axis that
is parallel to a second slot axis defined by a second mounting slot 515 and/or
an indexing slot
520. In an example embodiment, the mounting slots 515 and/or indexing slots
520 are disposed
adjacent the perimeter of the back portion 510. For example, in one
embodiment, two mounting
slots 515 and two indexing slots 520 are disposed adjacent a first edge of the
perimeter of the
back portion 510 and two mounting slots 515 and two indexing slots 520 are
disposed adjacent
an opposite edge of the perimeter of the back portion 510.
In example embodiments, the back portion 510 of the lighting fixture 500 may
further
comprise one or more wire openings 505 configured to allow electrical
connecting wires to pass
through the back portion 510. The wire opening 505 may be configured to allow
connecting
wires to pass therethrough. In example embodiments, the connecting wires are
configured to
electrically connect the lighting fixture 500 (e.g., driver circuitry and/or
other electrical
components of the lighting fixture 500) to a power supply (e.g., line
voltage). For example, the
connecting wires may be configured to be secured into electrical communication
(e.g., with a
quick connect connector, wire nuts, and/or the like) with junction box wires
715 of a junction
box 710 and thereby provide line voltage to the lighting fixture 500.
Exemplary Mounting Plate 401
In example embodiments, a mounting plate 401 may be configured to be secured
to a
mounting surface 705 about a junction box 710 and have a lighting fixture 500
securely
suspended therefrom. In example embodiments, a mounting plate 410 may be made
of aluminum
or another metal, plastic, or other appropriate material for the application.
In example embodiments, a mounting plate 401 comprises a plate portion 410. In
example embodiments, the plate portion 410 may be generally rectangular and/or
square. In
example embodiments, the plate portion 410 is configured to be secured to a
mounting surface
705. For example, the plate portion 410 may comprise fastener openings 425
configured to
CA 2979140 2017-09-14
receive a fastener 430 therethrough to securely mount the mounting plate 401
to the mounting
surface 705. In example embodiments, the plate portion 410 may further
comprise a central
opening 405 configured to allow connecting wires and/or junction box wires 715
pass
therethrough. In example embodiments, the mounting plate 401 is mounted to the
mounting
surface 705 such that a junction box 710 (e.g., junction box wires 715) are
accessible through the
central opening 405. In yet other embodiments, plate portion 410 may be
configured to be
secured relative to a junction box and/or a can light (e.g., via a detachable
can light adapter
bracket as discussed in previously mentioned Appl. No. 14/720,334). In such
embodiments, the
interior of the can light (and thus electrical connection of the can light)
may be accessible via the
central opening 405 such that the lighting fixture 500 may be electrically
connected to the can
light.
In example embodiments, a mounting plate 401 may comprise mounting tabs 415
configured for suspending a lighting fixture 500 therefrom. In example
embodiments, the
mounting plate 401 may be configured and/or shaped for engagement and
attachment with a
lighting fixture 500 and/or a back portion 510. In an example embodiment, a
mounting plate 401
may comprise four mounting tabs 415, with each mounting tab 415 generally
disposed in a
corner of the plate portion 410. For example, two mounting tabs 415 may be
positioned along a
first edge of a perimeter of the plate portion 410 and two mounting tabs 415
may be positioned
along an opposite edge of the perimeter of the plate portion 410. The mounting
tabs 415 may
generally extend outwardly from the plate portion 410. For example, the
mounting tabs 415 may
extend out from the plate portion 410 such that the mounting tab 415 extends
generally normal
and/or perpendicular to a plane defined by the plate portion 410. In example
embodiments, the
mounting tabs 415 may be reinforced such that the angle between the plate
portion 410 and the
mounting tab 415 may be maintained. For example, a mounting tab 415 may
comprise an angle
reinforcement 418 configured to maintain the angle between the plate portion
410 and the
mounting tab 415.
In example embodiments, a mounting tab 415 may further comprise an elongated
portion
419 that defines a plane that is generally perpendicular with a plane defined
by the plate portion
410. In an example embodiment, the length L of the elongated portion 419 is
approximately 23
mm. In other embodiments, the elongated portion 419 may be shorter or longer
as appropriate for
the application. In example embodiments, the elongated portion 419 may be
reinforced by an
21
CA 2979140 2017-09-14
elongated reinforcement 416 configured to prevent the elongated portion 419
from bending or
twisting. For example, the elongated reinforcement 416 may define a plane that
is generally
parallel to the plane defined by the plate portion 410. In an example
embodiment, the width W of
the elongated reinforcement 416 is approximately 4 mm, though other widths may
be used as
appropriate for the application.
In example embodiments, a mounting tab 415 may comprise a locking portion 417.
For
example, the locking portion 417 may be a protrusion from the elongated
portion 419 that
extends back toward the plate portion 410. The locking portion 417 may be
configured to engage
a locking slot 517 of the lighting fixture 500 to securely suspend the
lighting fixture 500 from the
mounting tab 415. For example, the locking portion 417 may be configured to
engage the
locking slot 517 such that the mounting tab 415 cannot inadvertently slide
back out through the
mounting slot 515. In example embodiments, the locking portion 417 defines the
same plane as
the elongated portion 419. For example, the locking portion 417 and the
elongated portion 419 of
the same mounting tab 415 are co-planar.
Figures 12A, 12B, 12C, 12D show an alternative embodiment of a mounting system
400'
that is similar to mounting system 400 but wherein the mounting tabs 415' are
T-posts and the
corresponding mounting slots 515' are keyhole shaped. Thus, the mounting tabs
415' comprise a
post portion 419' and a disc portion 417'. The post portion 419' extends away
from and/or
perpendicularly out from the plane defined by the back portion 410 of the
mounting plate 401'.
One end of the post portion 419' is secured to the back portion 410 and the
disc portion 417' is
secured to the opposite end of the post portion 419'. The disc portion 417'
defines a plane that is
generally parallel to the back portion 410.
In the illustrated embodiment, the post portion 419' is generally cylindrical,
though other
shapes are contemplated. In the illustrated embodiment, the disc portion 417'
is generally
circular, though other shapes are contemplated. As shown in Figures 12A and
12B, the diameter
of the disc portion 417' is larger than the diameter of the post portion 419'.
In general, the
projection of the disc portion 417' onto a plane parallel to the plane defined
by the back portion
410 is larger than projection of the end of the post portion 419' onto a plane
parallel to the plane
defined by the back portion 410.
The mounting slot 515' may be sized such that the disc portion 417' may fit
therethrough.
Once, the disc portion 417' is through the mounting slot 515', with a portion
of the post portion
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CA 2979140 2017-09-14
419' within the mounting slot 515', the mounting tab 415' may be slid along
the locking portion
517' of the mounting slot 515' such that the post portion 419' passes through
the locking portion
517'. The locking portion 517' is sized such that the disc portion 417' cannot
pass there through.
For example, the width of the locking portion 517' (e.g., the dimension of the
locking portion
517' perpendicular to the elongated axis thereof) is smaller than the diameter
of the disc portion
417'. Additionally, the a stopper 519' may be positioned along interior
surface of the back
portion 510 such that once the disc portion 417' has been slid along the
locking portion 517' and
released by the installer so that the weight of the lighting fixture 500' is
suspended from the disc
portions 417' of the mounting plate 401', the mounting tab 415' will not be
prevented from
sliding along the locking portion 517' by engagement of the disc portion 417'
with the stopper
519'.
Figures 13A and 13B show still another embodiment of a mounting system 400'r.
Mounting system 400'r is similar to mounting system 400', but the lighting
fixture 500r and the
mounting plate 401'r are round. Additionally, the mounting slots 515'r are
disposed on the
mounting plate 401'r and the mounting tabs 415'r are disposed on the lighting
fixture 500r. In
particular, the mounting tabs 415'r are T-post mounting tabs similar to
mounting tabs 415'. The
mounting slots 515'r are similar to the keyhole mounting slots 515', but are
shaped in an arcuate
manner. For example, the keyhole mounting slots 515'r are shaped such that the
mounting tab
415'r may be positioned through the keyhole mounting slots 515'r and then the
lighting fixture
500r may be secured to the mounting plate 401'r by rotating the lighting
fixture 500r such that
the mounting tabs 415'r rotate along the keyhole mounting slots 515'r into the
locking portion
517'r of the keyhole mounting slots 515'r. For example, a keyhole mounting
slots 515'r may
define a radial arc of length 5-90 degrees. Thus, the lighting fixture may be
rotated through n
degrees to secure the lighting fixture 500r to the mounting plate 401'r, where
n degrees is
approximately the arc length of the mounting slots 515'r. In example
embodiments, the
mounting plate 401'r may comprise two, three, four, or more mounting slots
515'r and the
lighting fixture 500r may comprise two, three, four, or more corresponding
mounting tabs 415'r.
Returning to Figures 8, 9, 10 11A, 11B, and 11C, in example embodiments, the
mounting
plate 401 further comprises one or more indexing tab 420. For example, an
indexing tab may
extend outward from the plate portion 410. For example, an indexing tab may
define a plane that
is generally perpendicular to a plane defined by the plate portion 410 and
exactly or generally
23
CA 2979140 2017-09-14
parallel to a plane formed by the elongated portion 419 of a mounting tab 415.
In an example
embodiment, the mounting plate 401 may comprise two or more indexing tabs 420
and two or
more mounting tabs 415. Each indexing tab 520 may define a plane and each
elongated portion
419 of the mounting tabs 415 may define a plane. The set of planes defined by
the indexing tabs
420 and the elongated portions 419 of the mounting tabs 415 may be mutually
parallel. For
example, a first plane defined by a first indexing tab 420 may be parallel to
a second plane
defined by a second indexing tab 420 and/or an elongated portion 419 of a
mounting tab 415.
In example embodiments, the indexing tab 420 may be longer than mounting tab
415. For
example, an indexing tab 420 may extend further from the mounting plate 401.
For example,
when a lighting fixture 500 is being secured to a mounting plate 401, as the
lighting fixture 500
is being moved toward the mounting plate 401, the indexing tabs 420 will
engage the indexing
slots 520 before the mounting tabs 415 engage the mounting slots 515. The
indexing tabs 420
may be configured such that aligning the indexing tabs 420 with the indexing
slots 520 causes
the lighting fixture 500 to be in the appropriate orientation for the mounting
tabs 415 to align
with the mounting slots 515. Thus, the indexing tabs 420 may be configured to
aid an installer in
securing the lighting fixture 500 to the mounting plate 401. In example
embodiments, the
indexing tabs 420 are not configured for suspending the lighting fixture 500
from the mounting
plate 401. For example, none of the weight of the lighting fixture 500 may
rest on or be
supported by the indexing tab 420. In an example embodiment, a mounting frame
100 and
lighting fixture 200 may be modified to include one or more indexing tabs and
one or more
indexing slots as described herein to aid the installer(s) in aligning the
tabs 115 with the slots
215.
Alternative Hinged Embodiment
Figure 13 illustrates another example embodiment of a mounting system 400"
comprising
a mounting plate 401" and a lighting fixture 500". The mounting plate 401" and
lighting fixture
500" may be similar to the mounting plate 401 or 401' and lighting fixture 500
or 501' described
above, however the mounting plate 401" and lighting fixture 500" are attached
to one another by
a hinge 425" such that the lighting fixture 500" may be attached to the
mounting plate 401" as
the mounting plate 401" is being secured to the mounting surface 705 and while
the electrical
connection is being made between the connecting wires 507 and the junction box
wires 715.
= 24
CA 2979140 2017-09-14
In an example embodiment, the hinge 425" comprises one or more hinge mounting
tabs
415" and/or one or more hinge indexing tabs 420". For example, the hinge
mounting tab 415"
and hinge indexing tab 420" may be configured to provide a slideable hinge
attachment that
secures the lighting fixture 500" to the mounting plate 401" and allows the
lighting fixture 500"
to translate along a portion of the axis defined by the hinge 425". For
example, the lighting
fixture 500" may be suspended from the mounting plate 401" by the hinge 425".
For example,
the hinge mounting tab 415" and the hinge indexing tab 420" be shaped such
that the tabs 415"
and 420" are held within the corresponding slots 515 and 520 while the
lighting fixture 500" is
rotated with respect to the mounting plate 401" and about the axis defined by
the hinge 425".
The hinge mounting tab 415" and the hinge indexing tab 420" may be further
shaped such that
they may slide along the length of the corresponding slots 515 and 520 such
that the lighting
fixture 500" may be slide or translated in a direction parallel or anti-
parallel to the axis defined
by the hinge 525" with respect to the mounting plate 401". When the lighting
fixture 500" is
translated in a direction parallel or anti-parallel to the axis defined by the
hinge 525" with respect
to the mounting plate 401" when the mounting tabs 415 are aligned at least
partially within the
mounting slots 515, the mounting tabs 415 may engage the mounting slots 515
such that the
mounting tabs 415 may be secured within the mounting tabs. The relative length
of the tabs 415"
and 420" compared to the corresponding slots 515 and 520 will define the
distance the lighting
fixture 500" may be translated along the axis defined by the hinge 525" with
respect to the
mounting plate 401".
In example embodiments, once the mounting plate 401" is secured to the
mounting
surface and the electrical connecting between the connecting wires 507 and the
junction box
wires 715 is secured, the lighting fixture may be rotated about the hinge 425"
such that one or
more indexing tabs 420 on a side of the mounting plate 401" opposite the hinge
425" may be
aligned with the corresponding indexing slots 520 on the lighting fixture
500". The lighting
fixture 500" may be further rotated about the hinge 425" such that the
mounting tabs 415" on the
side of the mounting plate 401" opposite the hinge 425" are inserted into the
mounting slots 515
of the lighting fixture 500". In various embodiments, the hinge 425" may be
configured to allow
a single installer to mount the lighting fixture 500". For example, the hinge
425" may support the
weight of the lighting fixture 500" while an electrical connection is made
between the connecting
wires 507 and the junction box wires 715.
CA 2979140 2017-09-14
Mounting a Lighting Fixture with a Mounting Plate
Figure 14 provides a flowchart of various processes and procedures for
installing a
lighting fixture 500 using the mounting system 400. Starting at step 602, the
installer(s) may
secure the mounting plate 401 to the mounting surface 705. For example, an
installer may secure
the mounting plate 401 to the mounting surface 705 with one or more fasteners
430 secured to
the surface 705 such that the junction box 710 (e.g., the junction box wires
715) are accessible
through the central opening 405. As discussed herein, in certain embodiments,
the installer may
secure the mounting plate 401 relative to a can light. In such embodiments,
the installer may
secure the can light adapter portion relative to the mounting plate 401, and
may secure the can
light adapter portion with the secured mounting plate relative to an existing
can light fixture
within a support surface. For example, the can light adapter portion may be
configured to snap
into can light, as discussed in previously mentioned Appl. No. 14/720,334.
At step 604, the installer(s) may electrically connect the lighting fixture
500 to a power
supply. For example, the installer(s) may electrically connect the connecting
wires 507 to the
junction box wires 715 so as to provide line voltage to the driver circuitry
and/or other electrical
components of the lighting fixture 500. For example, the installer may
electrically connect the
connecting wires 507 to the junction box wires 715 with quick connect
connectors, wire nuts,
and/or the like. In example embodiments, the connecting wires 507 may be
configured such that
the portion of the connecting wires that makes the electrical connection to
the junction box wires
715 may be positioned within the junction box 710 after the electrical
connection has been made.
At step 606, the indexing slots 520 are aligned with the indexing tabs 420.
For example,
the installer(s) may align the indexing slots 520 with the indexing tabs 420.
For example, the
indexing slots 520 may be engaged by the indexing tabs 420 to place the
lighting fixture 500 in
appropriate alignment with the mounting plate 401 for securing the lighting
fixture 500 to the
mounting plate 401.
At step 608, the mounting slots 515 may be aligned with the mounting tabs 415.
For
example, the installer(s) may check to ensure the mounting slots 515 are
aligned with the
mounting tabs 415, move the lighting fixture 500 toward the mounting plate 401
such that the
mounting tabs 415 are generally inserted into the mounting slots 515, and/or
the like. In general,
alignment and/or engagement of the indexing slot(s) 520 and the corresponding
indexing tab(s)
420 facilitates easy alignment of the mounting slots 515 and the mounting tabs
415.
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At step 610, the lighting fixture 500 is slid along the mounting tabs 415 to
secure the
lighting fixture 500 to the mounting plate 410. For example, the mounting tabs
415 may be
inserted into the corresponding mounting slots 515 and the lighting fixture
500 may be slid along
the mounting tabs 415 until the locking portions 417 engage the corresponding
locking slots 517,
thus securing the lighting fixture 500 to the mounting plate 401 and the
mounting surface 705.
Additional Pivotable Embodiment
Figure 15 illustrates yet another example embodiment of a mounting system 1400
comprising a mounting portion (e.g., mounting plate 1401) and a lighting
fixture 1500. The
mounting plate 1401 and lighting fixture 1500 may be similar to the mounting
plate 401, 401', or
401" and lighting fixture 500, 501', or 501" described above, however the
mounting plate 1401
and lighting fixture 1500 are moveably secured (e.g., slidably secured,
pivotably secured, and/or
the like) relative to one another by a mounting arm 1426 extending between a
mounting point
1425 of the mounting plate 1401 and a light fixture pivot point 1427. In
various embodiments,
the mounting arm 1426 may be pivotably secured relative to the light fixture
pivot point 1427 at
an arm pivot point defined proximate an end of the mounting arm 1426. In the
illustrated
embodiment of Figure 15, the mounting point 1425 is defined within a guide
rail 1420 defined
along an edge of the mounting plate 1401. As will be discussed in greater
detail herein, the guide
rail may facilitate movement of the lighting fixture 1500 from a disengaged
configuration as
shown in Figure 15 to an engaged configuration in which the light fixture 1500
is supported at
least substantially parallel to and adjacent a support surface onto which the
mounting plate 1401
is secured. Moreover, as shown in Figure 15, the light fixture pivot point
1427 may be defined
within a back portion 1510 of lighting fixture 1500. For example, the light
fixture pivot point
1427 may be defined within a fixture frame 1520 extending at least partially
around the
perimeter of the back portion 1510 of the lighting fixture 1500. As will be
discussed in greater
detail herein, at least a portion of the fixture frame 1520 may be at least
substantially parallel and
adjacent the guide rail 1420 when the lighting fixture 1500 is in the engaged
configuration
relative to the mounting plate 1401.
In various embodiments, the mounting arm 1426 may be configured to pivot about
the
mounting point 1425 and/or the light fixture pivot point 1427 such that the
light fixture 1500
may be pivotably moveable relative to the mounting plate 1401. For example,
the mounting arm
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1426 may be configured to pivot about a first axis extending through the
mounting point 1425
and/or a second axis extending through the light fixture pivot point 1427.
Accordingly, the
lighting fixture 1500 may be pivotable about at least one (e.g., two) axis
relative to the mounting
plate 1401. In various embodiments, the first axis and the second axis may be
at least
substantially parallel, and may be oriented at least substantially
perpendicular to a length of the
one or more guide rails 1420.
Moreover, in various embodiments, the mounting arm 1426 may be detachably
secured at
the mounting point 1425 and/or the light fixture pivot point 1427 (e.g., via
one or more fasteners,
such as screws, bolts, rivets, and/or the like) such that the light fixture
1501 may be detachably
secured relative to the mounting plate 1401. Accordingly, the mounting plate
1401 may be
secured relative to a support surface (e.g., a horizontal support surface such
as a ceiling, a
vertical support surface such as a wall, and/or an angled support surface), a
junction box, a can
light assembly, and/or the like before the lighting fixture 1500 is secured
relative to the mounting
plate 1401.
In various embodiments, the mounting system 1400 may define a slide mechanism
such
that the lighting fixture 1501 may be slidably secured relative to the
mounting plate 1401. As
will be discussed herein, the slide mechanism may enable the lighting fixture
1501 to slide
relative to the mounting plate 1401 such that one or more mounting features
engages and/or
disengages between the lighting fixture 1501 and the mounting plate 1401 when
moving the
lighting fixture 1500 to and/or from the engaged configuration. For example,
as shown in Figure
15, the mounting arm 1426 may define a slide slot 1428 configured to enable
the mounting arm
1426 and the lighting fixture 1500 to slide relative to the mounting point
1425 and the mounting
plate 1401. However, it should be understood that the guide rail 1420 and/or
the fixture frame
1520 may, in certain embodiments, define the slide slot 1428 to enable the
lighting fixture 1500
to slide relative to the mounting plate 1401.
In various embodiments, the slide mechanism may be configured such that the
lighting
fixture 1501 may slide in a direction perpendicular to the one or more pivot
axes discussed
herein (e.g., axis extending through the one or more mounting points 1425
and/or axis extending
through the one or more light fixture pivot points 1427). In various
embodiments, the slide
mechanism may be configured such that the lighting fixture 1500 slides
relative to the one or
more mounting points 1425 and/or the one or more light fixture pivot points
1427, and
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accordingly the lighting fixture 1500 slides relative to the one or more pivot
axes. For example,
the lighting fixture 1500 (and mounting arm 1426) may be configured to slide
from a first
position in which the mounting points 1425 are at a first side of a slide slot
1428 (and
accordingly the pivot axis extending through the mounting points 1425 is
located at the first side
of the slide slot 1428) to a second position in which the mounting points 1425
are at a second
side of the slide slot 1428, opposite the first side (and accordingly the
pivot axis extending
through the mounting points 1425 are located at the second side of the slide
slot 1428).
In various embodiments, such as that illustrated in Figure 15, the mounting
system 1400
may comprise a mounting arm 1426 and/or a mounting harness 1150 similar to
mounting harness
150 described herein. Collectively, the mounting arm 1426 and the mounting
harness 1150 may
be configured to suspend the lighting fixture 1500 a distance away from the
mounting plate 1401
to facilitate establishing an electrical connection between lighting fixture
connecting wires 1507
and wires of a junction box or other power source (not shown) extending
through a central
opening 1405 of the mounting plate 1401.
Moreover, as shown in Figure 15, the mounting plate 1401 may comprise one or
more
mounting catches 1430 configured to engage one or more corresponding fixture
catches 1530 of
the lighting fixture 1500. In various embodiments, the mounting catches 1430
may comprise one
or more support plates configured to engage and/or support the fixture catches
1530. The support
plates may each be fixed relative to the mounting plate 1401 via one or more
standoff portions
configured to support the support plate at a distance away from a surface of
mounting plate 1401.
In various embodiments, the support plate and standoff portion may form a
substantially "L"
shape secured relative to the mounting plate 1401 at the top portion of the
"L." Accordingly, the
standoff portions may be secured proximate an end of the support plate.
In various embodiments, the mounting catches 1430 may be embodied as a
continuous
portion of the mounting plate 1401 (e.g., a portion of sheet metal defining
the mounting plate
1401), such that a portion of the mounting plate 1401 is bent to form the
standoff portion and the
support plate. However, it should be understood that the standoff portion
and/or the support plate
may be a separate portion secured relative to the mounting plate 1401. In the
illustrated
embodiment of Figure 15, the standoff portion may be oriented at least
substantially
perpendicular to the mounting plate 1401. The support plate may be oriented at
a right or acute
angle relative to the standoff portion, such that the fixture catch 15 is
securely supported by the
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CA 2979140 2017-09-14
support plate. For example, in the illustrated embodiment of Figure 15, the
support plate is
oriented at an acute angle relative to the standoff portion, such that the
fixture catch 1530 is
biased toward the standoff portion when supported by the mounting catch 1430.
In various embodiments, the mounting catch 1430 may be flexible and/or elastic
and
configured to bias a lighting fixture 1500 toward a support surface against
which the mounting
plate 1401 is secured. For example, as a fixture catch 1530 is being inserted
into the mounting
catch 1430, the mounting catch 1430 may be configured to flex away from
mounting plate 1401
to accommodate the movement of the fixture catch 1530 onto the support plate
(e.g., between the
support plate and the mounting plate 1401). The mounting catch 1430 may be
configured to
apply a return force attempting to return the mounting catch 1430 toward its
unflexed
orientation, thereby biasing the fixture catch 1530, and therefore the
lighting fixture 1500,
toward the mounting plate 1401 and/or the support surface.
Moreover, as shown in Figure 15, the support plate may define an entry edge
opposite the
standoff. The entry edge may be configured to facilitate movement of a portion
of the fixture
catch 1530 onto the support plate of the mounting catch 1430. For example, the
entry edge may
be angled relative to the remainder of the support plate to guide the portion
of the fixture catch
1530 onto the support plate of the mounting catch 1430. For example, in the
illustrated
embodiment of Figure 15, the entry edge may be angled away from the mounting
plate 1401
such that the fixture catch 1530 may be guided toward the mounting plate 1401
and onto the
support plate of the mounting catch 1430 when the lighting fixture 1500 is
moved toward the
engaged configuration.
In various embodiments, the mounting catch 1430 may comprise one or more
locking
features configured to maintain the fixture catch 1530 within the mounting
catch 1430 when
inserted therein. The locking features may be embodied as one or more stoppers
(e.g., bumps,
protrusions, and/or the like) disposed on a surface of the support plate, one
or more clips, and/or
the like). For example, the illustrated embodiment of Figure 15 incorporates
one or more bumps
extending from a surface of the support plate. The bumps extending from a
surface of the support
plate impede the fixture catch 1530 from sliding off of the mounting catch
1430. Moreover, in
embodiments in which the mounting catch 1430 biases the fixture catch 1530
toward the
mounting plate 1401, the locking features (e.g., bumps) may further impede
movement of the
CA 2979140 2017-09-14
fixture catch 1530 out of the mounting catch 1430 by increasing the required
force necessary to
overcome the biasing force of the mounting catch 1430.
As illustrated in Figure 15, the fixture catch 1530 may comprise an at least
substantially
"U"-shaped plate secured relative to the back portion 1510 of the lighting
fixture 1500. The
fixture catch 1530 may comprise a catch plate supported between two eye-
standoffs configured
to position the catch plate at a distance away from the back portion 1510 of
the lighting fixture
1500. In various embodiments, the fixture catch 1530 may be secured relative
to the back portion
1510 via one or more fasteners (e.g., screws, bolts, adhesives, and/or the
like).
In various embodiments, at least a portion of the fixture catch 1530 is
configured to fit
around the support plate of the mounting catch 1430 such that the fixture
catch 1530 is supported
by the mounting catch 1430. Moreover, in various embodiments, a leading edge
of the catch
plate (e.g., the edge of the catch plate oriented to engage the mounting catch
1430 first) may be
angled away from the back portion 1510. Accordingly, the leading edge of the
catch plate may
be configured to facilitate movement of the catch plate onto the support plate
to engage the
fixture catch 1530 with the mounting catch 1430. Moreover, in various
embodiments, the trailing
edge of the catch plate (e.g., the edge opposite the leading edge) may be
angled toward the back
portion 1510. Accordingly, the trailing edge of the catch plate may be
configured to impede
unintentional movement of the catch plate off of the support plate. For
example, when the fixture
catch 1530 is engaged with the mounting catch 1430, the trailing edge of the
catch plate may be
configured to engage one or more locking features of the mounting catch 1430
to impede
unintentional movement of the lighting fixture 1500 relative to the mounting
plate 1401.
In various embodiments, the fixture catch 1530 may have any of a variety of
shapes. For
example, the fixture catch 1530 may have an "L" shape corresponding to the
shape of the
mounting catch 1430 such that the fixture catch 1530 and the mounting catch
1430 interlock. In
yet another embodiment, the fixture catch 1530 may have an "L" shape and the
mounting catch
1430 may have an at least substantially "U" shape configured to engage the "L"
shaped fixture
catch 1530. It should be understood that any of a variety of fixture catch
1530 and mounting
catch 1430 configurations may be utilized in which the fixture catch 1530 is
configured to
engage the mounting catch 1430 to secure the lighting fixture 1500 in a
secured configuration.
Various embodiments of the lighting fixture 1500 may be installed in a manner
similar to
that described herein. In various embodiments, installation of the lighting
fixture 1500 may begin
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CA 2979140 2017-09-14
by securing the mounting plate 1401 relative to a support surface, a Jbox, a
canister light (e.g.,
utilizing a can light retrofit bracket such as that described in U.S. Patent
Appl. No. 14/720,334,
filed May 22, 2015). For
example, the
mounting plate 1401 may be secured to the support surface via one or more
fasteners (e.g.,
screws, bolts, nails, wall anchors, adhesive, and/or the like). In specific
example embodiments,
the mounting plate 1401 may be secured directly to the support surface via the
one or more
fasteners such that the mounting plate 1401 is secured and remains parallel
and adjacent to the
support surface.
In embodiments in which the lighting fixture 1500 is not previously secured
relative to
the mounting plate 1401 (e.g., via mounting harness 1150 and/or mounting arm
1426), the
lighting fixture 1500 is secured relative to the mounting plate 1401. An
electrical connection is
then established between connecting wires 1507 and junction box wires.
Thereafter, the lighting
fixture 1500 is pivoted about mounting point 1425 and/or lighting fixture
pivot point 1427 such
that a back portion 1510 is at least substantially parallel with support
surface and the one or more
fixture catches 1530 are aligned with corresponding mounting catches 1430.
With reference to
Figure 15, the lighting fixture 1500 is moved in the direction of the
illustrated curved directional
arrow from the illustrated position toward the support surface. The lighting
fixture 1500 is then
slid relative to mounting plate 1401 along a slide mechanism (e.g., slide slot
1428 within
mounting arm 1426) such that the fixture catches 1530 are moved at least
substantially linearly
toward corresponding mounting catches 1430 until fixture catches 1530 are
engaged with
corresponding mounting catches 1430. As discussed herein, as the lighting
fixture 1500 is slid
relative to mounting plate 1401, at least a portion of fixture frame 1520 may
slide adjacent guide
rail 1420 such that the lighting fixture 1500 is guided along a substantially
linear travel path.
Moreover, as discussed herein, mounting catches 1430 may be configured to bias
engaged
fixture catches 1530 toward the support surface, such that the lighting
fixture 1500 is positioned
adjacent the support surface.
Although light fixture 1500 is discussed herein as being mounted relative to a
mounting
plate 1401, it should be understood that in various embodiments, the light
fixture 1500 may be
secured relative to a mounting frame similar to those discussed herein. In
such embodiments, the
mounting frame may comprise one or more features discussed herein in reference
to mounting
plate 1401 to enable mounting of the lighting fixture 1500.
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Conclusion
Many modifications and other embodiments of the invention set forth herein
will come to
mind to one skilled in the art to which the invention pertains having the
benefit of the teachings
presented in the foregoing descriptions and the associated drawings.
Therefore, it is to be
understood that the invention is not to be limited to the specific embodiments
disclosed and that
modifications and other embodiments are intended to be included within the
scope of the
appended claims. Although specific terms are employed herein, they are used in
a generic and
descriptive sense only and not for purposes of limitation.
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