Note: Descriptions are shown in the official language in which they were submitted.
FLUSH MOUNT LIGHTING FIXTURE
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of Canadian application No. 2,979,652, which
clams
priority from U.S. Patent Application No. 15/272,645 filed September 22, 2016.
BACKGROUND
Flat panel lighting fixtures are a convenient lighting option as they can be
mounted to
a mounting surface and have 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.
BRIEF SUMMARY
Generally described, various embodiments of the present invention comprise an
LED
lighting fixture comprising an LED flat panel lighting device and a mounting
bracket
configured for mounting the LED flat panel lighting device to a mounting
surface. For example,
the mounting bracket may be configured to flush mount the LED flat panel
lighting device to
a junction box within a ceiling, wall, or other mounting surface. In example
embodiments, the
LED flat panel lighting device may comprise a tether configured to suspend the
lighting device
from the mounting bracket during at least a portion of the process of
installing the LED lighting
fixture. In an example embodiment, the mounting bracket is a T-bar mounting
bracket
configured to flush mount an LED flat panel lighting device to a junction box
within a mounting
surface.
According to one aspect of the present invention, a lighting fixture is
provided. In an
example embodiment, the lighting fixture comprises a light emitting diode
(LED) flat panel
lighting device and a mounting bracket. The LED flat panel lighting device
comprises a front
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cover, a back cover, a frame, and at least one LED mounted within the interior
of the LED flat
panel light. The frame has an interior edge. The interior edge is in contact
with a perimeter of
the front cover and a perimeter of the back cover. The front cover, the back
cover, and the
frame define an interior of the LED flat panel light. At least one of the
frame and the back
cover comprises one or more attachment mechanisms. The mounting bracket
comprises a
junction box mounting element configured for securing the mounting bracket to
a junction box
or a mounting surface, and one or more attachment mechanism mating elements
configured to
mate with the one or more attachment mechanisms when the LED flat panel
lighting device is
rotated within the mounting bracket to secure the LED flat panel lighting
device into the
mounting bracket.
According to another aspect of the present invention, a lighting device is
provided. In
example embodiments, the lighting device comprises a front cover, a back
cover, and a frame.
The frame has an interior edge which is in contact with a perimeter of the
front cover and a
perimeter of the back cover. The front cover, the back cover, and the frame
define an interior
of the lighting device. The lighting device further comprises a flexible
tether. The tether
comprises a cord member and a clip member. A first end of the cord member is
fixedly secured
to the lighting device and an opposite end of the cord member secured to the
clip member. At
least one of the frame and the back cover comprises one or more attachment
mechanisms
configured to mount the lighting device within a mounting bracket.
According to yet another aspect of the present invention, a lighting kit for
installing a
lighting fixture is provided. In example embodiments, the lighting kit
comprises a lighting
device and a mounting bracket. In example embodiments, the lighting device
comprises a front
cover, a back cover, and a frame having an interior edge. The interior edge is
in contact with a
perimeter of the front cover and a perimeter of the back cover. The front
cover, the back cover,
and the frame define an interior of the lighting device. The lighting device
further comprises a
flexible tether. The tether comprises a cord member and a clip member. A first
end of the cord
member is fixedly secured to the lighting device and an opposite end of the
cord member is
secured to the clip member. At least one of the frame and the back cover
comprises one or more
attachment mechanisms. In example embodiments, the mounting bracket comprises
a junction
box mounting element configured for securing the lighting fixture to a
junction box, one or
more attachment mechanism mating elements configured to mate with the one or
more
attachment mechanisms when the lighting device is rotated within the mounting
bracket to
secure the lighting device into the mounting bracket, and a receiving member
configured to
secure the tether to the mounting bracket by the clip.
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According to still another aspect of the present invention, a mounting bracket
for flush
mounting a lighting device is provided. In example embodiments, the mounting
bracket
comprises a first element and a second element. The first element comprises a
first planar
member, one or two first transverse members disposed at opposite ends of the
first planar
member, and one or two first attachment mechanism mating elements each
disposed on an end
of one of the one or two first transverse members opposite the first planar
member. The second
element comprises a second planar member, one or two second transverse
members, and one
or two second attachment mechanism mating elements each disposed on an end of
one of the
one or two second transverse members opposite the second planar member. The
first element
is secured to the second element such that a first plane defined by the first
planar member is
generally parallel with a second plane defined by the second planar member and
a first major
axis defined by the first planar member is askew with respect to a second
major axis defined
by the second planar member. The one or two first attachment mechanism mating
elements and
the one or two second attachment mechanism mating elements are configured to
rotatably mate
with corresponding attachment mechanisms disposed on the lighting device to
secure the
lighting device to the mounting bracket.
According to yet another aspect of the present invention, a lighting kit for
installing a
lighting fixture is provided. In an example embodiment, the lighting kit
comprises a lighting
device and a mounting bracket. In example embodiments, the lighting device
comprises a
front cover, a back cover, and a frame having an interior edge. The interior
edge is in contact
with a perimeter of the front cover and a perimeter of the back cover. The
front cover, the
back cover, and the frame define an interior of the lighting device. At least
one of the frame
and the back cover comprises one or more attachment mechanisms. In example
embodiments,
the mounting bracket comprises a first element and a second element. The first
element
comprises a first planar member, one or two first transverse members disposed
at opposite
ends of the first planar member, and one or two first attachment mechanism
mating elements
each disposed on an end of one of the one or two first transverse members
opposite the first
planar member. The second element comprises a second planar member, one or two
second
transverse members, and one or two second attachment mechanism mating elements
each
disposed on an end of one of the one or two second transverse members opposite
the second
planar member. The first element is secured to the second element such that a
first plane
defined by the first planar member is generally parallel with a second plane
defined by the
second planar member and a first major axis defined by the first planar member
is askew with
respect to a second major axis defined by the second planar member. The one or
two first
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attachment mechanism mating elements and the one or two second attachment
mechanism
mating elements are configured to rotatably mate with corresponding ones of
the one or more
attachment mechanisms disposed on the lighting device to secure the lighting
device to the
mounting bracket.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
Having thus described various embodiments of the invention in general terms,
reference will now be made to the accompanying drawings, which are not
necessarily drawn
to scale, and wherein:
FIG. 1 is a cross-sectional view of an LED flat panel lighting device, in
accordance
with an embodiment of the present invention;
FIG. 2 is a perspective view of a mounting bracket secured to a mounting
surface, in
accordance with example embodiments;
FIG. 3 is a perspective view of an example LED flat panel lighting device
suspended
from a mounting bracket by a tether, in accordance with an example embodiment
of the
present invention;
FIG. 4 is another perspective view of an example LED flat panel lighting
device
suspended from a mounting bracket by a tether, in accordance with an example
embodiment
of the present invention;
FIG. 5 is a perspective view of aligning an LED flat panel lighting device
with a
mounting bracket, in accordance with an embodiment of the present invention;
FIG. 6 is a close up perspective view of aligning an LED flat panel lighting
device
with a mounting bracket, in accordance with an embodiment of the present
invention;
FIG. 7 is a perspective view of an LED flat panel lighting device being
secured to a
mounting bracket, in accordance with an embodiment of the present invention;
FIGs. 8A and 8B show different perspective views of an LED flat panel lighting
device and corresponding mounting bracket, in accordance with an embodiment of
the
present invention;
FIG. 9 is a perspective view of another embodiment of an LED flat panel
lighting
device and corresponding mounting bracket, in accordance with an embodiment of
the
present invention;
FIG. 10 is a perspective view of another embodiment of an LED flat panel
lighting
device and corresponding mounting bracket, in accordance with an embodiment of
the
present invention;
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FIG. 11A is top view of an example mounting bracket, in accordance with an
embodiment of the present invention;
FIG. 11B is a side view of the example mounting bracket shown in FIG. 11A;
FIG. 12 is a perspective view of a T-bar mounting bracket and corresponding
LED
flat panel lighting device, in accordance with an embodiment of the present
invention;
FIG. 13 is a perspective view of a flat panel lighting device attached to a T-
bar
mounting bracket by a tether, in accordance with an embodiment of the present
invention;
FIG. 14 is a close up perspective view of an example attachment mechanism and
attachment mechanism mate, in accordance with an example embodiment of the
present
invention;
FIG. 15 is a close up perspective view of the example attachment mechanism and
attachment mechanism of FIG. 14 in a mated position, in accordance with an
example
embodiment of the present invention; and
FIG. 16 is a flowchart illustrating various processes and procedures of
installing an
example LED lighting fixture, in accordance with example embodiments.
DETAILED DESCRIPTION
Various embodiments of the present invention now will be described more fully
hereinafter with reference to the accompanying drawings, in which some, but
not all
embodiments are shown. Indeed, the invention may be embodied in many different
forms
and should not be construed as limited to the various embodiments set forth
herein; rather, the
embodiments described herein are provided so that this disclosure will satisfy
applicable legal
requirements. Like numbers refer to like elements throughout.
Various embodiments of the present invention provide an LED lighting fixture 1
(see
Figures 3-10 and 12-15) configured to be flush mounted. In example
embodiments, LED
lighting fixture 1 comprises a lighting device 100 and a mounting bracket 200,
200'. In
example embodiments, the lighting device 100 is a light emitting diode (LED)
flat panel
lighting device. The LED flat panel lighting device 100 comprises at least one
attachment
mechanism 115. The mounting bracket 200 comprises at least one attachment
mechanism
mate 215 configured to mate with the one or more attachment mechanisms 115 of
the LED
flat panel lighting device 100 and thereby secure the LED flat panel lighting
device 100 into
the mounting bracket 200, 200'. Elements of various embodiments of the present
invention
will now be described in more detail herein.
CA 3015800 2018-08-29
I. LED Flat Panel Lighting Device 100
Figure 1 shows a cross-sectional view an LED flat panel lighting device 100.
The
LED flat panel lighting device 100 may include at least one LED package 130.
In various
embodiments, the at least one LED package 130 is mounted on a ring 140. The at
least one
LED may be mounted on the ring 140 such that the light emitted by the at least
one LED
package 130 is directed toward the center of the ring 140. The LED flat panel
lighting device
100 may include a light guide 150. The light guide 150 may be configured to
direct light
emitted by the at least one LED package 130 toward the front cover 120. In
various
embodiments, the LED flat panel lighting device 100 may also include a
reflector 160
disposed behind the light guide 150, a back cover 170 disposed behind the
light guide 150,
and/or driver circuitry 180. The reflector 160 may be configured to reflect
light toward the
front cover 120. The back cover 170 may be configured to seal the LED flat
panel lighting
device 100 from dirt and/or moisture, provide structural support to the LED
flat panel
lighting device 100, enclose the electrical components (e.g., the at least one
LED package
130 and/or the driver circuitry 180) of the LED flat panel lighting device
100, and/or the like.
In various embodiments, the LED flat panel lighting device 100 may also
include a driver
circuitry protective cover configured to enclose and/or protect the driver
circuitry 180. In
various embodiments, the ring 140 and/or reflector 160 may be configured to
act as a heat
sink for the electrical components (e.g., the at least one LED package 130
and/or the driver
circuitry 180) of the LED flat panel lighting device 100. In various
embodiments, the frame
110 may also act as the ring 140. In example embodiments, the LED flat panel
lighting
device 100 may further comprise a tether 195 configured to suspend the LED
flat panel
lighting device 100 therefrom.
In various embodiments, the LED flat panel lighting device 100 may be square,
rectangular, circular, polygonal, and/or have any of a variety of other, even
possibly irregular,
shapes. In various embodiments, the shape of ring 140 may have approximately
the same
shape as the LED flat panel lighting device 100. The LED flat panel lighting
device 100 may
be configured to be thin. For example, the thickness of the LED flat panel
lighting device
100 may be approximately half an inch to one inch, or smaller. In some
embodiments, the
thickness of the LED flat panel lighting device 100 is approximately the same
thickness as an
average piece of dry wall or other wall covering material (e.g., shiplap,
paneling, etc.). For
example, the thickness of the LED flat panel lighting device 100 may be
approximately three-
eighths to five-eighths of an inch. In another embodiment, the thickness of
the LED flat
panel lighting device 100 may be approximately three-quarters of an inch. In
some
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embodiments, the thickness of the LED flat panel lighting device 100 may be
between one
and two inches. The LED flat panel lighting device 100 may be configured such
that the
LED flat panel lighting device 100 may be flush mounted to a junction box 500
(see e.g.,
Figures 3, 4, and 7). For example, the LED flat panel lighting device 100 may
be configured
to be flush mounted to a junction box by being secured into a mounting bracket
secured to
junction box.
A. Frame 110
The frame 110 is configured to provide structural support to the LED flat
panel
lighting device 100. In various embodiments, the frame 110 may be configured
to enclose the
edges of the LED flat panel lighting device 100 and/or define the outside
perimeter of the
LED flat panel lighting device 100. For example, an inner edge of the frame
110 may be in
contact with the perimeter of the front cover 120 and the perimeter of the
back cover 170 and
may act to enclose the space between the front cover 120 and the back cover
170. In another
embodiment, the perimeter of the front cover 120 may be enclosed within frame
110, such
that the perimeter of the front cover 120 is not visible to a user. In an
example embodiment,
the frame 110 and the back cover 170 may be integrally formed.
In various embodiments, an external edge of the frame 110 may include a lip
112
configured to allow the LED flat panel lighting device 100 to be mounted flush
within the
mounting bracket while providing an aesthetically pleasing finish. For
example, the external
edge of the frame 110 may define two diameters, a first diameter dl around the
back of the
frame 110 and a second diameter d2 around the front of the frame 110. The
second diameter .
may be larger than first diameter (d2 > dl). In various embodiments, the
second diameter d2
is approximately a quarter of an inch to an inch larger than the first
diameter dl.
In various embodiments, the frame 110 may be configured to secure the LED flat
panel lighting device 100 to a mounting frame 200 or 200' (shown in Figures 2,
11A, and
11B). For example, the LED flat panel lighting device 100 may comprise one or
more
attachment mechanisms 115 configured to be mated with one or more attachment
mechanism
mating elements (e.g., attachment mechanism mates 215 shown in Figures 2-6,
11A, 11B,
and 14 and described in more detail below) of the mounting bracket 200, 200'.
For example,
the frame 110 may comprise attachment mechanism 115 configured to secure the
LED flat
panel lighting device 100 into the mounting frame 200, 200'. In various
embodiments, the
frame 110 may comprise one or more attachment mechanisms 115. In a particular
embodiment, the frame 110 may comprise three or four attachment mechanisms 115
equally
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spaced around the exterior of the frame 110. In various embodiments the
attachment
mechanisms 115 may extend outwardly from the exterior of the frame 110. For
example, the
attachment mechanisms 115 may be knobs, t-posts, tabs, and/or the like
configured to be
secured into a corresponding notch on the mounting bracket 200, 200'. In
another example,
the attachment mechanisms 115 may be a notch or other receiving element
configured to
receive, retain, and/or lock a knob, t-post, tab, and/or the like therein. As
shown in Figures
14 and 15, in embodiments, wherein the attachment mechanism 115 is a notch or
other
receiving element, the frame 110 may further comprise one or more locking
mechanisms 220
configured to lock and/or retain a knob, t-post, tab and/or the like therein.
For example, as
shown in Figures 13 and 14, a notch and locking mechanism may be formed by
securing
receiving envelope 117 to the frame 110 using, for example, fasteners, rivets,
adhesive,
and/or the like. In example embodiments, the one or more attachment mechanisms
115 may
be disposed on the back cover 170 of the LED flat panel lighting device 100
rather than
and/or in addition to being disposed on the frame 110.
In various embodiments, the frame 110 may be made from a polymerized material,
metal (e.g., aluminum, and/or the like), as commonly known and understood in
the art. In
certain embodiments, the frame 110 may be made of plastic or any of a variety
of (or
combination of) other appropriate materials. In various embodiments, the frame
110 may be
approximately one inch thick or thinner. In some embodiments, the frame 110
may be one to
one and a half inches thick. In other embodiments, the frame 110 may be
thicker than one
and a half inches.
As discussed elsewhere herein, the LED flat panel lighting device 100 may have
any
shape. In some embodiments, the shape of the LED flat panel lighting device
100 may be
determined at least in part by the frame 110. For example, the front of the
frame 110 (e.g.,
the portion of the frame 110 adjacent the front cover 120) may be round,
square, rectangular,
polygonal, elliptical, or irregular. The back of the frame 110 (e.g., the
portion of the frame
110 adjacent the back cover 170), may be round or a shape different from the
front of the
frame 110. For example, the front of the frame 110 may be configured to
provide an
aesthetically pleasing and/or interesting appearance and the back portion of
the frame may be
configured for easily securing the LED flat panel lighting device 100 into the
mounting bracket
200, 200'.
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B. Front Cover 120
The front cover 120 may be configured such that at least some portion of the
light
emitted by the at least one LED package 130 can pass through the front cover
120. For
example, the front cover 120 may be transparent, translucent, or semi-
translucent. For
example, in various embodiments, the front cover 120 may be configured such
that at least
10% of the light emitted by the at least one LED package 130 can pass through
the front
cover 120. In some embodiments, the front cover 120 may be configured such
that a
significant fraction of the light emitted by the at least one LED package 130
can pass through
the front cover 120. For example, in certain various embodiments, the front
cover 120 may
be configured to permit 10-30%, 30-50%, or 60-80% of the light emitted by the
at least one
LED package 130 and incident upon the front cover 120 to pass through the
front cover 120.
In some embodiments, the front cover 120 may be configured to permit at least
50% of the
light emitted by the at least one LED package 130 to pass through the front
cover 120. In
certain embodiments, the front cover 120 may be configured such that
substantially all of the
light emitted by the at least one LED package 130 and incident on the front
cover 120 may
pass through the front cover 120. For example, in some embodiments, the front
cover 120
may be configured to permit more than 80%, or in certain embodiments, more
than 90%, of
the light emitted by the at least one LED package 130 and incident upon the
front cover 120
to pass through front cover 120.
In various embodiments, the front cover 120 may be made from a polymerized
material, glass, alabaster, and/or the like, as commonly known and understood
in the art. In
certain embodiments, the front cover 120 may be made of plastic. In some
embodiments, the
front cover 120 may be made of an opaque material; however, in other
embodiments, the
front cover 120 may be made of any of a variety of translucent or semi-
translucent materials,
as may be commonly known and used in the art. Still further, according to
other
embodiments, the front cover 120 may be clear or frosted. In at least one
embodiment, the
front cover 120 may be made of Smart Glass, or some other material that can
transition from
clear to frosted and/or vice versa. In yet other embodiments, the front cover
120 may be
tinted with various colors. For example, in at least one embodiment, the front
cover 120 may
be tinted blue to give the light emitted by the LED lighting fixture 1 a blue
glow. Indeed, it
should be understood that the front cover 120 may be made from any of a
variety of
materials, as may be commonly known and used and readily available in the art,
provided
such possess the light transmission characteristics that are desirable for
particular applications.
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In various embodiments, the translucent or semi-translucent material may
permit
passage of at least some portion of the light emitted by the at least one LED
package 130 and
incident upon thc front cover 120 to pass through the front cover 120. In
certain
embodiments, the translucent or semi-translucent material may allow passage of
at least 10%
of the light emitted by the at least one LED package 130 to pass through the
front cover 120.
In at least one embodiment, the translucent or semi-translucent material may
permit passage
of 10-30% of the light emitted by the at least one LED package 130 and
incident upon the
cover to pass through the front cover 120. In other certain embodiments, the
translucent or
semi-translucent material may be configured to permit passage of 30-50% of the
light emitted
by the at least one LED package 130 to pass through the front cover 120. In
still other
embodiments the translucent or semi-translucent material may permit passage of
more than
50%, or, in certain various embodiments, more than 80%, of the light emitted
by the at least
one LED package 130 to pass through front cover 120. Alternatively, the
translucent or
semi-translucent material may permit passage of 60-80% of the light emitted by
at least one
LED package 130 to pass through the front cover 120. Indeed, it should be
understood that
according to various embodiments, the front cover 120 may be configured to
permit at least
some desired portion of the light emitted by the at least one LED package 130
and incident
upon the front cover 120 to pass through the front cover 120, however as may
be beneficial
for particular applications.
In example embodiments, the front cover 120 may comprise an alignment guide
122
(see Figure 5). In example embodiments, the alignment guide 122 is configured
to aid a user
in aligning one or more attachment mechanisms 115 with one or more attachment
mechanism
mates (or mating elements) of the mounting bracket 200, 200'. As discussed in
more detail
herein the one or more attachment mechanism mates of the mounting bracket 200,
200' may
be configured to receive an attachment mechanism 115 therein (or vice versa).
The LED flat
panel lighting device 100 and the mounting bracket 200, 200' may then be
rotated with
respect to one another to lock the attachment mechanisms 115 into the
corresponding
attachment mechanism mates of the mounting bracket 200, 200'. The alignment
guide 122
may further indicate a direction in which the LED flat panel lighting device
100 should be
rotated, with respect to the mounting bracket 200, 200' to cause the LED flat
panel lighting
device 100 to be secured into the mounting bracket 200, 200'. In example
embodiments, the
alignment guide 122 may indicate the degree of rotation the LED flat panel
lighting device
100 should be rotated, with respect to the mounting bracket 200, 200' to fully
secure, lock,
and/or the like the LED flat panel lighting device 100 into the mounting
bracket 200, 200'. In
CA 3015800 2018-08-29
example embodiments, the alignment guide 122 may be a removable sticker that
is attached to
the cover 120 (or frame 110), by an adhesive, static cling, and/or the like.
For example, the
alignment guide 122 may be removed after the LED lighting fixture 1 is
installed (e.g., after
the LED flat panel lighting device 100 is secured into the mounting bracket
200, 200').
C. Light Emitting Diode (LED) Package 130
As shown in Figure 1 the LED flat panel lighting device 100 also comprises at
least
one light emitting diode (LED) package 130. In example embodiments, an LED
package 130
comprises one or more LED chips, electrical contacts, and optionally phosphor
(e.g., to cause
the LED package to emit white light). The LED package 130 may further comprise
encapsulant to protect the one or more LED chips, wire bonds, and the
phosphor. In some
embodiments, the LED package 130 may further comprise one or more optical
elements. In
embodiments having more than one LED package, the LED packages 130 may have
different
wattages and/or different color temperatures. In various embodiments, the LED
flat panel
lighting device 100 is an edge-lit panel. For example, the one or more LED
packages 130
may be secured along the inside perimeter of the LED flat panel lighting
device 100 (e.g.,
along the inner edge of ring 140) such that the light emitted by the one or
more LED
packages 130 is emitted toward the middle of the ring 140. Also, various
embodiments of the
LED flat panel lighting device 100 may employ LED packages 130 that emit
different levels
of illumination at different color temperatures. The number of LED packages
130 used may
also be utilized to determine the level of illumination emitted by the LED
flat panel lighting
device 100.
D. Driver Circuitry 180
As illustrated in Figure 1, driver circuitry 180 is disposed within the LED
flat panel
lighting device 100. In example embodiments, the driver circuitry 180 is
configured to
provide a controllable current to the one or more LED packages 130. In various
embodiments, the driver circuitry 180 may comprise a circuit portion
configured to convert
the input alternating current (AC) line voltage to a direct current (DC)
voltage. In various
embodiments, the driver circuitry 180 may comprise a circuit portion
configured to control
the current being applied to the one or more LED packages 130. The driver
circuitry 180, in
various embodiments, may further comprise a circuit portion configured to
allow a user to
adjust the brightness of the light emitted from the LED flat panel lighting
device 100 through
the use of a dimmer switch. These circuitry portions are commonly known and
understood in
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the art, and thus will not be described in detail herein. In various
embodiments, the driver
circuitry 180 may include other circuitry portions and/or the circuitry
portions described
herein may not be distinct circuitry portions. For example, in some
embodiments, the
circuitry portion that converts the AC line voltage to a DC voltage may also
control the
current being applied to the one or more LED packages 130.
In various embodiments, the driver circuitry 180 is disposed within the
chamber
defined by the back cover 170 and the reflector 160. In some embodiments, the
driver
circuitry may be mounted on the back cover 170. In other embodiments, the
driver circuitry
may be mounted on the reflector 160. In certain embodiments, some components
of the
driver circuitry 180 may be mounted to the reflector 160 while other
components of the
driver circuitry 180 may be mounted to the back cover 170.
In various embodiments, the LED flat panel lighting device 100 comprises a
driver
circuitry protective cover. The driver circuitry protective cover may be
configured to enclose
at least a portion of the driver circuitry 180. For example, the driver
circuitry protective cover
may be configured to seal the driver circuitry 180 from dust, dirt, moisture
and/or the like. In
some embodiments, the LED flat panel lighting device 100 may comprise a driver
circuitry
protective cover 185 in addition to and/or in place of a back cover 170.
E. Light Guide 150
In various embodiments, the LED flat panel lighting device 100 may comprise a
light
guide 150. In various embodiments, the light guide 150 may be configured to
direct the light
emitted by the one or more LED packages 130 toward the front cover 120. For
example, the
light emitted by the one or more LED packages 130 may travel through the light
guide 150
until reaching a particular point wherein the light guide 150 directs at least
a portion of the
light (e.g., via scattering, diffraction, internal reflection, and/or the
like) toward the front
cover 120. In various embodiments, a reflector 160 may be positioned behind
the light guide
150 such that light directed away from the front cover 120 may be reflected
back toward the
front cover 120. A variety of light guides are known and understood in the art
and may be
employed herein for various applications. In example embodiments, the light
guide 150 may
comprise various secondary optics for conditioning the light emitted by the
one or more LED
packages 130 before the light is emitted from the LED flat panel lighting
device 100. In
various embodiments, the light guide 150 may be made of polymeric material as
is known in
the art, glass, and/or other translucent and/or partially translucent
material, as appropriate for
the application.
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F. Back Cover 170
In various embodiments, the LED flat panel lighting device 100 may comprise a
back
cover 170. The back cover 170 may be configured to seal the interior of the
LED flat panel
lighting device 100 from dust, dirt, moisture and/or the like; enclose the
electrical
components (e.g., the at least one LED package 130 and/or the driver circuitry
180) of the
LED flat panel lighting device 100; provide structural support for the LED
flat panel lighting
device 100; and/or the like. In some embodiments, the back cover 170 may
comprise wire
conduit 175. The wire conduit 175 may be a hole or passage through the back
cover such
that a wire carrying line voltage may be connected to the driver circuitry 180
and/or other
electrical component of LED flat panel lighting device 100. For example, in
one embodiment,
connecting wires 190 (e.g., see Figures 3 and 4) may be connected to the
driver circuitry 180
and pass through the wire conduit 175 such that the connecting wires 190 may
be connected
to line voltage wires 520 (see Figure 2). In various embodiments, the wire
conduit 175 may
be configured to provide a seal around the connecting wires 190 to prevent
dust, dirt, and/or
moisture from entering the interior of the LED flat panel lighting device 100.
In various
embodiments, electrical connecting wires 190 may be secured to the driver
circuitry 180 or
other electrical component of the LED flat panel lighting device 100. The
electrical
connecting wires 190 may pass through the wire conduit 175 and be configured
to connect
the electrical components (e.g., driver circuitry 180, the at least one LED
package 130, and/or
the like) of the LED flat panel lighting device 100 with line voltage and/or
other electrical
power.
In example embodiments, a tether 195 may pass through the back cover 170. For
example, component configured to retract at least a portion of the tether 195
and/or to secure
a first end of the tether 195 may be positioned between the back cover 170 and
the reflector
160. The first end of the tether 195 may be securely affixed to the LED flat
panel lighting
device 100.
In example embodiments, the back cover 170 may comprise one or more attachment
mechanisms 115 configured to secure the LED flat panel lighting device 100
into the
mounting frame 200, 200'. In various embodiments, the frame 110 may comprise
one or
more attachment mechanisms 115. In a particular embodiment, the frame 110 may
comprise
three or four attachment mechanisms 115 equally spaced around the exterior of
the frame
110. In various embodiments the attachment mechanisms 115 may extend outwardly
from
the exterior of the frame 110. For example, the attachment mechanisms 115 may
be knobs, t-
posts, tabs, and/or the like configured to be secured into a corresponding
notch on the
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mounting bracket 200, 200'. In another example, the attachment mechanisms 115
may be a
notch or other receiving element configured to receive, retain, and/or lock a
knob, t-post, tab,
and/or the like therein. As shown in Figures 14 and 15, in embodiments,
wherein the
attachment mechanism 115 is a notch or other receiving element, the frame 110
may further
comprise one or more locking mechanisms 220 configured to lock and/or retain a
knob, t-
post, tab and/or the like therein. For example, as shown in Figures 13 and 14,
a notch and
locking mechanism may be formed by securing receiving envelope 117 to the back
cover 170
using, for example, fasteners, rivets, adhesive, and/or the like. As should be
understood, the
LED flat panel lighting device 100 described herein provides various examples
of LED flat
panel lights that may be mounted via the various methods described herein.
G. Tether 195
As shown in Figures 3, 4, and 13, an LED flat panel lighting device 100 may
comprise a tether 195. In example embodiments, a tether comprises a cord
member 196 and a
clip member 197. In example embodiments, the cord member 196 comprises a
length of wire,
string, cording, cable, and/or other flexible material having appropriate
tensile strength. For
example, the cord member 196 may comprise a length of braided, twisted, and/or
coated
aluminum or steel cable. In example embodiments, the cord member 196 may be
flexible,
thereby providing a flexible tether 195. In example embodiments, the cord
member 196
and/or the tether 195 may stretchable. In example embodiments, the cord member
196 and/or
the tether 195 may be spring-loaded. In example embodiments the maximum length
that the
cord member 196 may extend out from the back cover 170 approximately six
inches (e.g.,
within manufacturing constraints of six inches). In other embodiments, the
maximum length
that the cord member 196 may extend out from the back cover 170 six inches to
one foot. In
example embodiments, the maximum length that the cord member 196 may extend
out from
the back cover 170 is half an inch to six inches. In an example embodiment,
the tether 195 is
between two and nine inches long. In particular, a first end of the cord
member 196 may be
secured, fastened, affixed, and/or the like within the LED flat panel lighting
device 100 (e.g.,
between the back cover 170 and the reflector 160) or to the back cover 170. In
some
embodiments, the cord member 196 is secured, fastened, affixed, and/or the
like to the LED
flat panel lighting device 100 by a retracting element that is secured,
fastened, affixed, and/or
the like to the LED flat panel lighting device 100. Thus, the length of the
cord member 196
that extends out of the back cover 170 may be adjustable up to the maximum
length. The clip
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member 197 may be configured such that the clip member 197 may not be
retracted into the
LED flat panel lighting device 100.
In example embodiments, a first end of the cord member 196 is securely
fastened,
affixed and/or the like to the LED flat panel lighting device 100. For
example, the tether 195
may be securely fastened, affixed, and/or the like to a securing element
and/or a retracting
element disposed between the back cover 170 and the reflector 160 of the LED
flat panel
lighting device 100. For example, a retracting element disposed between the
back cover 170
and the reflector 160 may be configured to retract at least a portion of the
cord member 196
into the space between the back cover 170 and the reflector 160 when the
tether 195 is not
actively in use.
In example embodiments, a clip member 197 is secured, fastened, affixed and/or
the
like to a second end of the cord member 196 that is opposite the first end of
the cord member
196. For example, the second end of the cord member 196 may comprise a loop
that loops
through the clip member 197, thereby securing the clip member 197 to the cord
member 196.
The clip member 197 may be configured to be clipped onto, attached to, and/or
the like a
receiving member 244 of the mounting bracket 200, 200'. In example
embodiments, the clip
member 197 may be made of metal (e.g., aluminum, steel, and/or the like), a
polymeric
material (e.g., plastic), or other material having appropriate tensile
strength. In example
embodiments, the clip member 197 may be configured to be connected to the
receiving
member 244 of the mounting bracket 200, 200' after the mounting bracket is
secured,
fastened, affixed, and/or the like to a junction box and/or mounting surface
such that the LED
flat panel lighting device 100 may be suspended from the mounting bracket 200,
200' by the
tether 195 while the electrical connections between the electrical connecting
wires 190 and
the line voltage wires 520 are made. In some embodiments, the clip member 197
may remain
clipped onto, attached to, and/or the like the mounting bracket 200, 200'
while the LED flat
panel lighting device 100 is being secured into the mounting bracket 200, 200'
and after
installation of the LED flat panel lighting device 100 is completed. Thus, the
clip member
197 is configured to fit within the space between the LED flat panel lighting
device 100 (e.g.,
the back cover 170 thereof) and the mounting bracket 200, 200' and/or the
mounting surface
505.
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11. Mounting Bracket 200
Figure 2 illustrates a mounting bracket 200 in accordance with an embodiment
of the
present invention. The illustrated mounting bracket is secured to a junction
box 510 within a
mounting surface 505. The mounting bracket 200 may be configured to be secured
to the
LED flat panel lighting device 100. For example, the illustrated mounting
bracket 200
comprises a bracket frame 210 comprising attachment mechanism mates 215 (also
referred to
herein as attachment mechanism mating elements) for mating with the attachment
mechanism(s) 115 for securing the LED flat panel lighting device 100 into the
mounting
bracket 200. For example, the attachment mechanisms 115 may be knobs, t-posts,
tabs,
and/or the like and the attachment mechanism mates 215 may comprise notches
configured to
receive a knob, t-post, tab, and/or the like therein. Such notches may be
matched and/or
aligned with locking mechanism 220 configured to retain the knob, t-post, tab,
and/or the like
secured to the mounting bracket 200. In another example, the attachment
mechanisms 115
may be a notch or other receiving element and the one or more attachment
mechanism mates
215 may be one or more knobs, t-posts, tabs, and/or the like configured to be
received,
retained, and/or locked into the attachment mechanism(s) 115. For example, the
attachment
mechanism mate 215 may be configured such that each attachment mechanism mate
215 may
receive an attachment mechanism 115 therein; the mounting bracket 200 and the
LED flat
panel lighting device 100 may then be rotated with respect to each other such
that each
attachment mechanism 115 is secured to the mounting bracket 200 via the
locking
mechanism 220. For example, the locking mechanism 220 may be configured to
retain an
attachment mechanism 115 (e.g., a rounded portion of a knob, a free end of a t-
post, a locking
portion of a tab, and/or the like) therein. Of course, any of a variety of
interlocking
mechanisms may be incorporated, in part, as may be desirable for particular
applications
without departing from the spirit of the present invention.
The mounting bracket 200 may further comprise a junction mount 240. For
example,
the junction mount 240 may be secured to the mounting bracket 200 via screws,
a twist and
lock element, rivets, welding, and/or other securing mechanism. The junction
mount 240
may be configured to flush mount the LED flat panel lighting device 100 to a
junction box
510 located in a wall, ceiling, and/or other mounting surface 505. In example
embodiments,
the junction mount 240 may comprise one or more mounting holes 242 configured
to receive
a fastener there through to secure, mount, affix, and/or the like the junction
mount 240 to the
junction box 510 and/or mounting surface 505.
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In example embodiments, the mounting bracket 200 may comprise an alignment
guide 222. For example, the alignment guide 222 may be a marking, sticker,
and/or the like
on the mounting bracket 200 configured to aid the user in aligning the
attachment
mechanism(s) 115 with the corresponding attachment mechanism mate(s) 215. For
example,
the alignment guide 122 on the LED flat panel lighting device 100 may be
visually aligned
with the alignment guide 222 to place the attachment mechanism(s) 115 in
appropriate
alignment with the corresponding attachment mechanism mate(s) 215 such that
the LED flat
panel lighting device 100 may be rotated relative to the mounting bracket 200
to cause the
attachment mechanism(s) 115 and the corresponding attachment mechanism mate(s)
215 to
engage in a secure mating manner. Figures 8A, 8B, and 9 illustrate some
example
embodiments of LED flat panel lighting devices 100 having attachment
mechanism(s) 115
configured to engage corresponding attachment mechanism mate(s) 215 to engage
in a secure
mating manner when the LED flat panel lighting device 100 is rotated relative
to the
mounting bracket 200.
In an example embodiment, the LED flat panel lighting device 100 may be moved
translationally (e.g., vertically, horizontally, or a combination thereof)
with respect to the
mounting bracket 200 to cause the attachment mechanism(s) 155 and the
corresponding
attachment mechanism mate(s) 215 to engage in a secure mating manner. An
example
embodiment in which the LED flat panel lighting device 100 may be moved
translationally
with respect to the mounting bracket 200 to secure the lighting device 100 to
the mounting
bracket 200 is shown in Figure 10.
In example embodiments, as shown in Figure 4, the junction mount 240 further
comprises receiving member 244 configured to receiving the clip member 197 of
the tether
195. For example, the junction mount 240 (or bracket frame 210) may comprise a
receiving
member 244 that separates a pair of adjacent receiving holes 244a, 244b. The
clip member
197 may be passed through a first receiving hole 244a, across the receiving
member 244, and
a portion of the clip member 197 may then be passed through a second receiving
hole 244b,
effectively clipping, fastening, securing, affixing, and/or the like the clip
member 197 to the
receiving member 244. In an example embodiment, at least one of the first and
second
receiving holes 244a, 244b may be a mounting hole 242.
In various embodiments, the mounting bracket 200 may be made of a polymeric
material or metal as is known in the art. For example, the mounting bracket
200 may be
made of plastic, aluminum, and/or the like. In various embodiments, the
mounting bracket
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200 may be made of any material appropriate for the application. In example
embodiments,
the junction mount is made out of the same material as the bracket frame 210.
III. T-bar Mounting Bracket 200'
In example embodiments, the mounting bracket of the LED lighting fixture 1 may
be
a T-bar mounting bracket. Figures 11A, 11B, and 12-15 provide various views of
an example
T-bar mounting bracket 200'. In example embodiments, a T-bar mounting bracket
200'
comprises a first element 212 and a second element 214. The first element 212
and the
second element 214 may be secured to each other to form a T-bar mounting
bracket 200'.
Each of the first element 212 and the second element 214 may comprise one or
more
attachment mechanism mates 215 configured to be mated with one or more
attachment
mechanisms 115 of the LED flat panel lighting device 100. The T-bar mounting
bracket 200'
may further comprise one or more mounting holes 242 configured to receive a
fastener there
through to secure, mount, affix, and/or the like the T-bar mounting bracket
200' to the
junction box 510 and/or mounting surface 505. In example embodiments, the T-
bar mounting
bracket 200' comprises a receiving member 244 for securing, clipping,
fastening, affixing,
and/or the like a clip member 197 of a tether 195 to the T-bar mounting
bracket 200'. In
example embodiments, the T-bar mounting bracket 200' may further comprise a
central
opening 175 configured to allow the electrical connecting wires 190 to pass
there through.
In example embodiments, the first element 212 comprise a generally planar
member
216. For example, the planar member 216 may define a plane, that when the T-
bar mounting
bracket 200' is secured to a mounting surface 505, is generally parallel with
a plane defined
by the mounting surface 505. In an example embodiment, the planar member 216
may define
a major axis 216a that is generally parallel to the length of the planar
member 216 and a
minor axis 216b that is generally parallel to the width of the planar member
216. The planar
member 216 may have a length (along the major axis 216a) that is generally the
length of the
diameter of the back cover 170 (e.g., dl). The planar member 216 may have a
width (along
the minor axis 216b) that is generally less than two inches. For example, the
planar member
216 may have a width of one inch to half an inch. The planar member 216 may
comprise one
or more mounting holes 242 there through. For example, two or four mounting
holes 242
may be positioned along the length of the planar member 216. The planar member
216 may
further comprise one or more receiving elements 244. Additionally, the planar
member 216
may comprise a central opening 275 for receiving the electrical connecting
wires 190 there
through.
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In example embodiments, the first element 212 may further comprise one or more
attachment mechanism mates 215. For example, the attachment mechanism mates
215 may
be tabs disposed on either end of the planar member 216. For example, a first
attachment
mechanism mate 215 may be disposed on a first end of the planar member 216 and
a second
attachment mechanism mate 215 may be disposed on a second end of the planar
member 216,
wherein the first end and the second end of the planar member 216 are
separated by the
length of the planar member 216. The one or more attachment mechanism mates
215 may be
connected to the planar member 216 by a transverse member 217 that extends out
of the
plane defined by the planar member 216. In example embodiments, the transverse
member
217 extends out of the plane defined by the planar member 216 at a 90 degree
angle. In
various embodiments, the transverse member 217 is approximately and/or is
determined
based on the thickness d of the LED flat panel lighting device 100. In example
embodiments,
the planar member 216, transverse member(s) 217, and attachment mechanism
mate(s) 215
may be integrally fon-ned. For example, the planar member 216, transverse
member 217, and
attachment mechanism mate(s) 215 may be formed by bending an appropriately
sized piece
of metal (e.g., aluminum or steel) or by molding a first element 212 from
metal, plastic,
and/or the like. For example, the first element 212 may be a single piece that
comprises the
planar member 216, one or two transverse members 217, and one or two
attachment
mechanism mates 215.
In example embodiments, the second element 214 may be identical to the first
element 212. In some embodiments, the second element 214 may be similar to the
first
element 212 but may lack one or more mounting holes 242 and/or a receiving
element 244. In
example embodiments, the layout of the one or more mounting holes 242 through
the second
element 214 may be different from the layout of the one or more mounting holes
242 through
the first element 212. Generally, the second element 214 may comprise a planar
member 216,
one or two transverse members 217, and one or two attachment mechanism mates
215,
similar to the first element 212.
In example embodiments, the middle of the first element 212 is secured to the
middle
of the second element 214. For example, the first element 212 may be welded,
riveted, glued,
and/or the like to the second element 214. In some embodiments, the first
element 212 and
the second element 214 are integrally formed (e.g., molded, cut, bent, and/or
the like from a
single piece of plastic, metal, and/or the like). For example, the first
element 212 and the
second element 214 may be secured to one another such that the central opening
275 of the
first element 212 is generally aligned with the central opening 275 of the
second element 214.
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CA 3015800 2018-08-29
In example embodiments, the first element 212 and the second element 214 are
askew with
respect to one another. For example, the planar member 216 of the first
element 212 may
define a first plane and the planar member 2016 of the second element 214 may
define a
second plane. The first element 212 is secured to the second element 214 such
that the first
plane and the second plane are parallel. However, the first element 212 is
secured to the
second element 214 such that the major axis 216a of the first element 212 are
not parallel to
the major axis 216a of the second element 214. In example embodiments, the
first element
212 is secured to the second element 214 such that the major axis 216a of the
first element
212 is perpendicular to the major axis 216a of the second element 214.
IV. Exemplary Methods of Installing an LED Lighting Fixture 1
Figure 16 provides a flowchart illustrating processes and procedures for
installing an
LED lighting fixture 1, in accordance with example embodiments of the present
invention.
Starting at block 302, the mounting bracket 200, 200' may be secured to the
junction box
510. For example, one or more fasteners may be used to secure the mounting
bracket 200,
200' to the junction box 510 by passing the one or more fasteners (e.g.,
screws) through
mounting holes 242 of the junction mount 240 or the T-bar mounting bracket
200' and
securing the fasteners to the junction box 510. For example, as shown in
Figure 2, the
mounting bracket 200 may be secured to the junction box 510.
Continuing with Figure 16, at block 304, the mounting bracket 200, 200' may
optionally be secured to the mounting surface 505. For example, one or more
fasteners may
be used to secure the mounting bracket 200, 200' to the mounting surface 505
may passing
the one or more fasteners (e.g., screws) through mounting holes 242 of the
junction mount
240 or the T-bar mounting bracket 200' and securing the fasteners to the
junction box 510. In
example embodiments, dry-wall anchors and/or the like may be installed into
the mounting
surface 505 for receiving and retaining the fasteners therein.
At block 306, the tether 195 of the LED flat panel lighting device 100 is
attached to
the mounting bracket 200, 200'. For example, the clip member 197 may be passed
through a
first receiving hole 244a, passed behind a receiving member 244, and a portion
of the clip
member 197 may be passed through the second receiving hole 244b such that the
clip
member 197 is clipped about the receiving member 244. For example, the LED
flat panel
lighting device 100 may be attached to the mounting bracket 200, 200' as shown
in Figures 3
and 15. The LED flat panel lighting device 100 may then be allowed to hang
from the tether
195 as the electrical connections between the LED flat panel lighting device
100 and the
CA 3015800 2018-08-29
junction box 510 are made at block 308 of Figure 16. For example, the
electrical connecting
wires 190 may be secured into electrical connection with the corresponding
line voltage wires
520. For example, a first electrical connecting wire 190 may be secured into
electrical
connection with a corresponding line voltage wire 520 using a wire nut, and/or
the like, as
shown in Figure 4.
Continuing with Figure 16, at block 310, the LED flat panel lighting device
100 is
aligned with the mounting bracket 200, 200'. For example, the alignment guide
122 of the
LED flat panel lighting device 100 may be aligned with an alignment guide 222
of the
mounting bracket 200, 200'. For example, Figures 5, 6, and 12 illustrate an
LED flat panel
lighting device 100 being aligned with the mounting bracket 200, 200'. At
block 312 of
Figure 16, the LED flat panel lighting device 100 may be secured into the
mounting bracket
200, 200'. For example, Figures 7 and 15 illustrate the LED flat panel
lighting device 100
secured into the mounting bracket 200, 200'. For example, the LED flat panel
lighting device
100 may be rotated with respect to the mounting bracket 200, 200'. As the LED
flat panel
lighting device 100 is rotated with respect to the mounting bracket 200, 200',
the attachment
mechanisms 115 may mate with the corresponding attachment mechanism mates 215.
In
example embodiments, the mating of the attachment mechanisms 115 and the
corresponding
attachment mechanism mates 215 may fixedly secure, mount, affix, and/or the
like the LED
flat panel lighting device 100 into the mounting bracket 200, 200'.
Thus, example embodiments of the present invention provide improved lighting
fixtures. For example, example embodiments provide a lighting device that may
be wired to a
junction box by a single installer. For example, the tether 195 may be
configured to suspend
the lighting device from the mounting bracket such that the electrical
connections may be
made without the lighting device needing to be held next to the mounting
bracket by hand. In
another example, example embodiments, provide lighting fixtures that may be
flush mounted
to junction boxes such that additional room is not required, for example,
above a ceiling to
accommodate the lighting fixture. In yet another example, example embodiments
provide a
T-bar mounting bracket 200' for flush mounting a lighting device to a junction
box. The T-
bar mounting bracket 200' is configured to securely mount the lighting device
and to provide
for an easy installation.
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V. Conclusion
Many modifications and other embodiments of the invention set forth herein
will
come to mind to one skilled in the art to which this 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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