US 2022/0018522 A1Published application

Round metal housing for a lighting system

AssigneeDMF, Inc.

InventorsFrederick William Kopitzke, Ken Czech, Bao Khoa Vinh, Amir Lotfi, Morteza Nejad

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Abstract

A housing assembly for a lighting system includes a single metal housing that functions as a can housing and a junction box and has a round geometry to improve ease of installation and support trims with smaller flanges. The housing includes a top component and one or more sidewall components. The sidewall component defines the desired round shape of the housing while the top component provides one or more flat surfaces to support one or more knockout features. For a remodel installation, the housing assembly further includes a spring clip assembly with a mounting ring and multiple spring clamps to securely couple the housing assembly to a drywall panel of a ceiling. For a new construction installation, the housing assembly further includes a bar hanger assembly to couple the housing to one or more support structures within the ceiling.

Claims21

Dependent claims

A housing for a lighting system, the housing comprising:

a sidewall that defines at least a portion of a cavity, the sidewall comprising:
a top end;
and
a bottom end, disposed opposite to the top end, defining a bottom opening into the cavity;
and
a top component, coupled to the sidewall, having one or more knockouts, the top component comprising:
a base section, abutting at least a portion of the top end of the sidewall, to cover the top end, the base section being flat in shape with an outer edge aligned with an exterior edge of the top end;
a first tab extending from the base section;
and
a second tab extending from the base section,
wherein:
at least a portion of the sidewall has a curved shape;
a bottom portion of the cavity proximate to the bottom opening has a first cross-sectional shape that is circular;
a top exterior portion of the housing proximate to the top end has a second cross-sectional shape comprising a circular section corresponding to the sidewall, a first straight section corresponding to the first tab, and a second straight section corresponding to the second tab;
and
each of the sidewall and the top component is formed from steel.

13 more elements

A housing for a lighting system, the housing comprising:

a sidewall component shaped as a cylindrical tube, the sidewall component comprising:
a first end defining a first opening;
and
a second end, disposed opposite to the first end, defining a second opening, a first notch that extends from the second opening towards the first end, and a second notch that extends from the second opening towards the first end, the second notch being disposed diametrically opposite to the first notch;
and
a top component coupled to the sidewall component, the top component comprising:
a base section, abutting at least a portion of the second end of the sidewall component, to substantially cover the second opening, the base section being flat in shape;
a first tab, extending from the base section and oriented at a right angle with respect to the base section, to substantially cover the first notch, the first tab being flat in shape such that a first gap is formed between the first tab and the sidewall component;
a first end portion, extending from the first tab, to cover the first gap;
a second tab, extending from the base section and oriented at a right angle with respect to the base section, to substantially cover the second notch, the second tab being flat in shape such that a second gap is formed between the second tab and the sidewall component;
a second end portion, extending from the second tab, to cover the second gap;
at least one knockout disposed on at least one of the base section, the first tab, or the second tab,
wherein:
each of the sidewall component and the top component is formed as a single component;
and
each of the sidewall component and the top component is formed from steel having a uniform thickness that ranges between 0.6 mm and 2.0 mm.

13 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/378,214Filed 16 Jul 2021
Priority: 16 Jul 2020
Published: 20 Jan 2022
Term ends: Not estimatedThe source records don’t support an estimate.

Classification7 codes

F21V 15/01
Protecting lighting devices from damage: housings, e.g. material or assembling of housing parts
F21S 8/04
Lighting devices intended for fixed installation: intended only for mounting on a ceiling or the like overhead structures
H02G 3/12
Distribution boxes; Connection or junction boxes: for flush mounting
F21S 8/026
Of recess-mounted type, e.g. downlighters: intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling

Family

Application63/052,915Us provisional application · filed 16 Jul 2020
Application63/061,160Us provisional application · filed 4 Aug 2020
Application63/123,334Us provisional application · filed 9 Dec 2020
US 12,203,631 B2Related patent
US 2022/0018522 A1This patent

From the US filing history. Foreign family members aren’t listed.