# US 11,898,720 B2 · Downlight fixture housing fabrication > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,898,720 B2 - Document ID: US11898720B2 - Status: Granted - Kind: B2 - Application number: 17/150,700 - Filed: 2021-01-15 - Published: 2021-07-15 - Granted: 2024-02-13 - Earliest claimed: 2020-01-15 - Assignees: Man-D-Tec, Inc. - Applicants: Man-D-Tec, Inc. - Inventors: Terry Roy Mandy; Zhang Jun; Dalton John Mandy - Web page: https://patentgrep.com/patent/US11898720B2 ## CPC - F21S 8/026: {intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling} - F21V 15/01: Housings, e.g. material or assembling of housing parts (F21V15/02 takes precedence {housings forming signs or letters G09F13/04}) - F21V 17/101: {permanently, e.g. welding, gluing or riveting} - F21V 17/12: by screwing - F21V 21/041: {Mounting arrangements specially adapted for false ceiling panels or partition walls made of plates (F21V21/047 takes precedence)} - F21V 21/047: {Mounting arrangements with fastening means engaging the inner surface of a hole in a ceiling or wall, e.g. for solid walls or for blind holes} - F21S: NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS - F21V: FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR ## Abstract A downlight fixture housing fabrication method in which upper and lower downlight fixture housing portions are formed in separate steps and joined by press-fitting, a bonding agent, pinning, and/or threaded engagement. ## Claims ### Claim 1 A downlight fixture housing fabrication method comprising the steps of: fabricating a lower portion of a downlight fixture housing; fabricating an upper portion of the downlight fixture housing; and joining the upper and lower portions to form a single downlight fixture housing by connecting the lower and upper portions together by at least one of press fitting and/or the use of a bonding agent; and mounting the downlight to a ceiling by supporting the upper housing portion on the ceiling in a position where the lower portion of the downlight fixture housing extends through an opening in the ceiling. ### Claim 2 (depends on 1) The method of claim 1 including the additional step of forming a recess around the upper end of the lower portion and/or a recess around the lower end of the upper portion, the recess or recesses being configured to allow one of the upper or lower portions to fit within at least part of the other of the upper or lower portions. ### Claim 3 (depends on 1) The method of claim 1 in which the step of fabricating a lower portion of a downlight fixture housing includes extruding the lower portion of the downlight fixture housing. ### Claim 4 (depends on 1) The method of claim 1 in which the step of fabricating a lower portion of a downlight fixture housing includes adding design elements to the lower housing portion via machining. ### Claim 5 (depends on 1) The method of claim 1 in which the step of fabricating an upper portion of the downlight fixture housing includes die casting the upper portion of the downlight fixture housing and the step of fabricating a lower portion of the downlight fixture housing includes adding an aesthetic finish. ### Claim 6 (depends on 5) The method of claim 5 in which the step of fabricating an upper portion of the downlight fixture housing includes die casting the upper portion of the downlight fixture housing to include an at least partially closed upper end. ### Claim 7 (depends on 1) The method of claim 1 in which the step of mounting the downlight to a ceiling includes mounting the downlight to an elevator drop ceiling; and in which the method includes the additional steps of: attaching a downlight mount to the upper portion of the downlight fixture housing; and mounting the downlight in the elevator drop ceiling by supporting the downlight mount on the elevator drop ceiling in a position that permits the removal of the lower portion of the housing from the upper portion of the housing through the opening in the elevator drop ceiling without dismounting the upper portion of the housing from the elevator drop ceiling. ### Claim 8 (depends on 1) The method of claim 1 in which: the step of fabricating the upper portion of the downlight fixture housing additionally comprises forming a lamp mount within the upper portion, the lamp mount being shaped to removably receive a lamp; and the step of fabricating the lower portion of the downlight fixture housing additionally comprises forming the lower portion for attachment to and detachment from the upper portion after the lamp has been received by the lamp mount in the upper portion. ### Claim 9 A downlight fixture housing fabrication method comprising the steps of: fabricating a lower portion of a downlight fixture housing; fabricating an upper portion of the downlight fixture housing; joining the upper and lower portions to form a single downlight fixture housing by connecting the lower and upper portions using a mechanical attachment system; and mounting the downlight to a ceiling by attaching the upper housing portion to the ceiling in a position where the lower portion of the downlight fixture housing extends through an opening in the ceiling. ### Claim 10 (depends on 9) The method of claim 9 including the additional step of forming a recess around the upper end of the lower portion and/or a recess around the lower end of the upper portion, the recess or recesses being configured to allow one of the upper or lower portions to fit within at least part of the other of the upper or lower portions. ### Claim 11 (depends on 9) The method of claim 9 in which the step of fabricating a lower portion of a downlight fixture housing includes extruding the lower portion of the downlight fixture housing. ### Claim 12 (depends on 9) The method of claim 9 in which the step of fabricating a lower portion of a downlight fixture housing includes adding design elements to the lower housing portion via machining. ### Claim 13 (depends on 9) The method of claim 9 in which the step of fabricating an upper portion of the downlight fixture housing includes die casting the upper portion of the downlight fixture housing and the step of fabricating a lower portion of the downlight fixture housing includes adding an aesthetic finish. ### Claim 14 (depends on 11) The method of claim 11 in which the step of fabricating an upper portion of the downlight fixture housing includes die casting the upper portion of the downlight fixture housing to include an at least partially closed upper end. ### Claim 15 (depends on 9) The method of claim 9 in which the step of connecting the upper and lower portions comprises: providing a mechanical attachment system comprising a pin and a pinhole formed in at least one of the upper and lower portions of the downlight fixture housing where insertion of the pin in the pinhole will resist separation of the upper and lower portions from one another; and inserting the pin at least partially into the pinhole. ### Claim 16 (depends on 9) The method of claim 9 in which the step of connecting the upper and lower portions comprises: providing a mechanical attachment system comprising interior threads formed in an inner circumferential surface of one of the upper and lower portions of the downlight fixture housing, and exterior threads formed in an outer circumferential surface of the other of the upper and lower portions of the downlight fixture housing; and threadedly engaging the interior threads with the exterior threads. ### Claim 17 (depends on 9) The method of claim 9 in which the step of mounting the downlight to a ceiling includes mounting the downlight to an elevator drop ceiling; and in which the method including the additional steps of: attaching a downlight mount to the upper portion of the downlight fixture housing; and mounting the downlight to the elevator drop ceiling by supporting the downlight mount on the elevator drop ceiling in a position where the upper portion of the downlight fixture housing extends above the drop ceiling and the lower portion of the downlight fixture lies flush or proud of a bottom of the drop ceiling, the housing extending through an opening in the drop ceiling, and permitting the removal of the lower portion of the housing from the upper portion of the housing through the opening in the elevator surface without dismounting the upper portion of the housing from the elevator surface. ### Claim 18 (depends on 9) The method of claim 9 in which the step of fabricating the upper portion of the downlight fixture housing additionally comprises providing a lamp mount within the upper portion, the lamp mount being shaped to removably receive and retain a lamp in the upper portion. ### Claim 19 (depends on 18) The method of claim 18 in which the step of fabricating the lower portion of the downlight fixture housing additionally comprises forming the lower portion to include lower and upper openings through which a lamp can pass and be received by, or removed from, the lamp mount in the upper portion without detaching the upper portion from the lower portion. ### Claim 20 (depends on 18) The method of claim 18 in which the step of fabricating the lower portion of the downlight fixture housing additionally comprises forming the lower portion for attachment to and detachment from the upper portion after the lamp has been received by the lamp mount in the upper portion, and without removing the lamp mount and the upper portion.