Device with direct mounting system

Abstract

A direct-mount lighting device includes a heat sink and a compression spring positioned around the heat sink. The direct-mount lighting device may further include a mounting sleeve that includes a sleeve body and mounting arms extending out from the sleeve body. The sleeve body is slidably positioned around the heat sink. The mounting sleeve is slidable to compress the compression spring. The mounting arms extend laterally farther from the heat sink when the mounting sleeve is in a retention position than when the mounting sleeve is in an insertion position, where the compression spring is compressed by the sleeve body when the mounting sleeve is in the insertion position.

Description

[0001] 2024PF80356

[0002] 1

[0003] DEVICE WITH DIRECT MOUNTING SYSTEM

[0004] TECHNICAL FIELD

[0005] The present disclosure relates generally to lighting and related solutions, and in particular to lighting and other devices, such as light fixtures and other devices, that are directly mounted to a mounting structure such as a ceiling or a wall.

[0006] BACKGROUND

[0007] Some devices are directly mounted to ceilings and walls. For example, a light fixture that does not have a can housing may be inserted into a light fixture opening of a ceiling and mounted to the ceiling using mounting devices. Mounting direct-mount light fixtures to a mounting structure (e.g., a ceiling) from a room side of the mounting structure may be challenging for a number of reasons. For example, some mounting devices may require a lighting device to have a relatively smaller size heat sink than desired. To illustrate, the size of the heat sink may be relatively small to provide adequate space for the placement of the mounting devices. Some mounting devices may also be challenging to position behind a ceiling through a relatively small mounting opening of the ceiling. For example, some direct-mount light fixtures may be compact in size (e.g., 1 inch in diameter) and may require a relatively small ceiling opening. Passing some mounting devices through such small ceiling openings may be challenging. Some mounting devices may also require access through the ceiling opening to place the mounting structures in a mounting position and such access may be challenging. Thus, a solution that simplifies the installation of direct-mount devices to a mounting structure such as a ceiling or a wall may be desirable.

[0008] CN109163259 relates to a downlights, including lamp cap and light bulb, lamp cap and the junction fixed-axis rotation of light bulb are socketed with pivoted housing, a lantern ring is fixed at the upper port of pivoted housing, it is coaxially fixed at inner annular edge with externally threaded sleeve on lantern ring, the sleeve is coaxially socketed in the annular groove opened up on light bulb side wall, annulate lamella is threadedly coupled on sleeve, the outer ring edge of ring flat-plate is hinged with multiple compression bars by pin shaft and wind spring, the annular groove upper surface of light bulb is fixed with guide rod 2024PF80356

[0009] 2 corresponding with compression bar, and the lower end of guide rod is fixed with bending section.

[0010] US2009 / 258524 relates to an electrical fixture connection assembly comprising a socket assembly, a plug assembly, and first and second fixing arms. A socket plate defines first and second socket apertures. Live and neutral electrical terminals are provided on the internal face of the socket plate. An earth terminal is provided within the socket housing at the distal end of a spring. The first and second fixing arms are provided on a carrier member and are movable between an open position in which the fixing arms extend out through fixing apertures in the socket housing and a closed position in which they are received within the socket housing. A resilient spring acts to bias the fixing arms in the open position. A live contact, a neutral contact, and an earth contact are provided on first, second and third plug arms of the plug assembly.

[0011] SUMMARY

[0012] The present disclosure relates generally to lighting and related solutions, and in particular to lighting and other devices, such as light fixtures and other devices, that are directly mounted to a mounting structure such as a ceiling or a wall. In an example embodiment, a direct-mount lighting device includes a heat sink and a compression spring positioned around the heat sink. The direct-mount lighting device may further include a mounting sleeve that includes a sleeve body and mounting arms extending out from the sleeve body. The sleeve body is slidably positioned around the heat sink. The mounting sleeve is slidable to compress the compression spring. The mounting arms extend laterally farther from the heat sink when the mounting sleeve is in a retention position than when the mounting sleeve is in an insertion position, where the compression spring is compressed by the sleeve body when the mounting sleeve is in the insertion position.

[0013] These and other aspects, objects, features, and embodiments will be apparent from the following description and the appended claims.

[0014] BRIEF DESCRIPTION OF THE FIGURES

[0015] Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0016] Figs. 1 A-1D illustrate different views of a lighting device having a direct mounting system according to an example embodiment; 2024PF80356

[0017] 3

[0018] Figs. 2A-2D illustrate different views of the lighting device of Figs. 1 A-1D with the direct mounting system in an insertion position according to an example embodiment;

[0019] Figs. 3 A-3C illustrate different views of the heat sink of the lighting device of Figs. 1 A-1D according to an example embodiment;

[0020] Figs. 4A-4C illustrate different views of the mounting sleeve of the direct mounting system of the lighting device of Figs. 1A-1D according to an example embodiment;

[0021] Fig. 5 illustrates a mounting sleeve of the direct mounting system of the lighting device of Figs. 1A-1D according to another example embodiment;

[0022] Figs. 6A and 6B illustrate the light module housing of the lighting device of Figs. 1 A-1D according to an example embodiment;

[0023] Fig. 7 illustrates the lighting device of Figs. 2A-2D during installation in a mounting structure according to another example embodiment;

[0024] Figs. 8A and 8B illustrate the lighting device of Figs. 1 A-1D mounted to the mounting structure according to an example embodiment; and

[0025] Figs. 9A and 9B illustrate cross-sectional views of the lighting device of Figs. 1 A-1D mounted to the mounting structure according to an example embodiment.

[0026] The drawings illustrate only example embodiments and are therefore not to be considered limiting in scope. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Additionally, certain dimensions or placements may be exaggerated to help visually convey such principles. In the figures, the same reference numerals used in different figures may designate like or corresponding and not necessarily identical elements.

[0027] DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

[0028] In the following paragraphs, particular embodiments will be described in further detail by way of example with reference to the figures. In the description, well known components, methods, and / or processing techniques are omitted or briefly described. Furthermore, reference to various feature(s) of the embodiments is not to suggest that all embodiments must include the referenced feature(s).

[0029] Turning now to the drawings, example embodiments are described. Figs. 1 A- 1D illustrate different views of a lighting device 100 having a direct mounting system according to an example embodiment. Figs. 1 A and IB show side views of the lighting 2024PF80356

[0030] 4 device 100, Fig. 1C shows a top perspective view of the lighting device 100, and Fig. ID shows a bottom perspective view of the lighting device 100. In some example embodiments, the lighting device 100 includes a heat sink 102 and a light module housing 104. The lighting device 100 may also include a light module 130 (e.g., printed circuit board with a light emitting diode) positioned in a cavity of the light module housing 104. The light module housing 104 may be attached to the heat sink 102, for example, by one or more fasteners that may also attach the light module 130 to the light module housing 104. Alternatively or in addition, the light module 130 may be attached to the light module housing 104 by other means, such as an adhesive, as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure.

[0031] In some example embodiments, the light module housing 104 includes a flange section 106 that extends outwardly from a cavity section of the light module housing 104. For example, the flange section 106 may abut against a ceiling from below the ceiling when the lighting device 100 is mounted to the ceiling.

[0032] In some example embodiments, the lighting device 100 may include a direct mounting system that includes a compression spring 108 and a mounting sleeve 110. The lighting device 100 may be mounted to a mounting structure such as a ceiling or a wall by the mounting sleeve 110 as explained below in more detail.

[0033] In some example embodiments, the compression spring 108 is positioned around the heat sink 102. The mounting sleeve 110 may also be positioned around the heat sink 102. The mounting sleeve 110 may be slidably positioned around the heat sink 102 such that the mounting sleeve 110 can axially compress the compression spring 108. To illustrate, the lighting device 100 may include a spring stop structure 118 at an end portion of the heat sink 102, and the compression spring 108 may be positioned around the heat sink 102 between the mounting sleeve 110 and the spring stop structure 118. The spring stop structure 118 may be fixedly attached to or integrally formed with the heat sink 102, and the compression spring 108 may be compressed by the mounting sleeve 110 by sliding the mounting sleeve 110 relative to the heat sink 102 axially toward the spring stop structure 118.

[0034] For example, a person may use fingers of one or two hands to slide the mounting sleeve 110 to different sliding positions relative to the heat sink 102. The mounting sleeve 110 may be moved such that the mounting sleeve 110 fully or partially compresses the compression spring 108 against the spring stop structure 118. The compression spring 108 may also be uncompressed (e.g., fully or partially uncompressed) by sliding the mounting sleeve 110 axially away from the spring stop structure 118. When the compression spring 2024PF80356

[0035] 5

[0036] 108 is compressed by the mounting sleeve 110, a resistance force that is, for example, applied to the mounting sleeve 110 may maintain the mounting sleeve 110 in the same position, thereby maintaining the compression of the compression spring 108. If a force applied on the mounting sleeve 110 to compress the compression spring 108 is removed, the compression spring 108 that was compressed by the force may result in the mounting sleeve 110 sliding in an axial direction such that the compression spring 108 decompresses until the mounting sleeve 110 encounters an adequate force or resistance, for example, from a ceiling and / or from the flange section 106 that prevents further decompression of the compression spring 108.

[0037] In some example embodiments, the mounting sleeve 110 may include mounting arms 112, 114. The mounting arms 112, 114 may extend down from a sleeve body of the mounting sleeve 110. The mounting arms 112, 114 may be movable such that the mounting arms 112, 114 can elastically swing outwardly, for example, to the extended positions shown in Figs. 1 A-1D. The size of the separation S (shown in Fig. 1 A) between the mounting arms 112, 114 may depend on the lateral positions of the mounting arms 112, 114 with respect to the heat sink 102. In Figs. 1 A-1D, the mounting sleeve 110 may be in a retention position where the mounting arms 112, 114 are extended outwardly relative to the heat sink 102. To illustrate, in the extended positions of the mounting arms 112, 114 shown in Figs. 1 A-1D, the mounting arms 112, 114 may retain the lighting device 100 mounted to a ceiling as shown, for example, in Figs. 8A and 8B.

[0038] In some example embodiments, the mounting arms 112, 114 may elastically swing back from the extended positions shown in Figs. 1 A-1D toward the heat sink 102 depending on the axial position of the mounting sleeve 110 with respect to the heat sink 102. In general, the lateral / radial positions of the mounting arms 112, 114 (i.e., how far the mounting arms 112, 114 extend laterally from the heat sink 102) may depend on the axial position of the mounting sleeve 110 with respect to the heat sink 102. That is, the separation S between the mounting arms 112, 114 may depend on the sliding position of the mounting sleeve 110 relative to the heat sink 102.

[0039] In some example embodiments, the mounting sleeve 110 may include sleeve adjustment legs 116, 120 that extend down from the sleeve body of the mounting sleeve 110. In Figs. 1 A-1D, the mounting sleeve 110 may be axially positioned relative to the heat sink 102 such that the sleeve adjustment legs 116, 120 are on and in contact with the flange section 106 of the light module housing 104. In general, the sleeve adjustment legs 116, 120 may be used to slide the mounting sleeve 110 to different sliding positions relative to the heat 2024PF80356

[0040] 6 sink 102. For example, a person may push or press the sleeve adjustment legs 116, 120 against the light module housing 104 and may apply a force to slide the mounting sleeve 110 axially, for example, from the retention position of the mounting sleeve 110 shown in Figs. 1 A-1D to another sliding position such as an insertion position shown in Figs. 2A-2D. To illustrate, the sleeve adjustment legs 116 and 120 may include grip sections 122 and 124, respectively, that each have a textured surface. The texture surface of the grip sections 122, 124 may provide a relatively rough surface that enables an improved grip, for example, with a finger to apply a force to slide the mounting sleeve 110 axially against the decompression force of the compression spring 108.

[0041] In some example embodiments, the heat sink 102 may be made from a metal, such as aluminum, using one or more methods such as die casting, milling, cutting, etc. In some example embodiments, the light module housing 104 may be made from plastic using methods such as injection molding, etc. In some example embodiments, the mounting sleeve 110 may be made from plastic using methods such as injection molding, etc. Alternatively, the mounting sleeve 110 may be made from a metal, such as aluminum, using one or more methods such as die casting, milling, cutting, etc. In some example embodiments, the compression spring 108 may be made from spring steel as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure. The compression spring 108 may be selected to have a spring rate based on the weight of the lighting device 100 as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure.

[0042] Figs. 2A-2D illustrate different views of the lighting device 100 of Figs. 1A- 1D with the direct mounting system in an insertion position according to an example embodiment, and Figs. 3A-3C illustrate different views of the heat sink 102 of the lighting device 100 of Figs. 1 A-1D according to an example embodiment. As described above, lighting device 100 may include the heat sink 102, the light module housing 104, the compression spring 108, and the mounting sleeve 110. The compression spring 108 may be positioned around the heat sink 102 between the spring stop structure 118 and the mounting sleeve 110 that is slidably positioned around the heat sink 102. In general, the lighting device 100 may be assembled by inserting the heat sink 102 through the center of the compression spring 108 and the center of the mounting sleeve 110 and attaching the light module housing 104 to the heat sink 102, for example, using fasteners. The fasteners that are used to attach the light module housing 104 to the heat sink 102 may also be used to attach the light module 130 to the light module housing 104 in cavity of the light module housing 104. 2024PF80356

[0043] 7

[0044] In some example embodiments, the mounting sleeve 110 may include mounting arms 112, 114 that may be laterally / radially in different positions relative to the heat sink 102 depending on the axial / sliding position of the compression spring 108 with respect to the heat sink 102. The separation S between the mounting arms 112, 114 in Figs. 2A-2D, which shows the mounting sleeve 110 in an example insertion position, may be smaller than in Figs. 1 A-1D, which shows the mounting sleeve 110 in an example retention position. In general, the mounting arms 112, 114 may extend laterally farther from the heat sink 102 when the sleeve is in the retention or default position shown in Figs. 1 A-1D than when the sleeve is in the insertion position shown in Figs. 2A-2D. The default position of the mounting sleeve 110 may refer to the axial position of the mounting sleeve 110 when a force is not actively applied by a person to retain the mounting sleeve 110 in the particular position, and a default position of the mounting sleeve 110 may also be a retention position of the mounting sleeve 110 where the mounting sleeve 110 is retaining the lighting device 100 mounted to a ceiling or a wall.

[0045] In some example embodiments, the mounting sleeve 110 may be slid to the insertion position shown in Figs. 2A-2D from the retention or default position shown in Figs. 1 A-1D by pushing / pressing / pinching the sleeve adjustment legs 116,120 toward each other, for example, at the grip sections 122, 124 and applying an upward force on the sleeve adjustment legs 116, 120 toward the compression spring 108. For example, a person may use fingers on one or two hands 208, 210 to slide the mounting sleeve 110 axially toward the compression spring 108, which results in fully or partially compressing the compression spring 108. Because the compression spring 108 is compressed when in the mounting sleeve 110 is in the insertion position shown in Figs. 2A-2D, a person may need to apply a force on the sleeve adjustment legs 116, 120 to maintain the compression of the compression spring 108 and the insertion position of mounting sleeve 110 where the mounting arms 112, 114 are positioned closer to the heat sink 102 than in the retention or default position of the mounting sleeve 110 shown in Figs. 1 A-1D. In general, when the insertion position of the mounting sleeve 110, the relatively smaller radial / lateral size of the mounting sleeve 110 may allow the lighting device 100 to be inserted into a mounting opening of a ceiling or a wall, and when the retention position of the mounting sleeve 110, the relatively larger radial / lateral size of the mounting sleeve 110 may allow the mounting sleeve 110 to mount the lighting device 100 to the ceiling.

[0046] To illustrate, when the mounting sleeve 110 is in the insertion position shown in Figs. 2A-2D, the mounting arm 112 is radially / laterally positioned such that a retention 2024PF80356

[0047] 8 section 212 of the mounting arm 112 is positioned in an arm cavity 202 of the heat sink 102, and the mounting arm 114 is radially / laterally positioned such that a retention section 206 of the mounting arm 114 is positioned in an arm cavity 204 of the heat sink 102. To illustrate, in Figs. 2A-2D, the mounting arms 112, 114 are swung inwards as compared to the outwardly swung radial / lateral positions of the mounting arms 112, 114 shown, for example, in Fig. 1 A, where the mounting sleeve 110 in Figs. 2A-2D has a smaller radial / lateral size than in Figs. 1A.

[0048] In some example embodiments, the heat sink 102 includes fins, such as fins 302, 304, 306, 308, that extend up from a base 320 of the heat sink 102. For example, the fins 302, 304 may be spaced from each other by a space 316, and the fins 306, 308 may be spaced from each other by a space 318. Other fins of the heat sink 102 may also be similarly spaced from each other. The fins and the spaces between the fins may be designed to dissipate heat generated by the light module 130 described above with respect to Figs. 1 A-1D.

[0049] In some example embodiments, the heat sink 102 may include the arm cavities 202, 204 that are formed, for example, in the fins of the heat sink 102. The arm cavities 202, 204 may be located diametrically opposite each other. The arm cavity 202 may have a ramp 312 that enables the mounting arm 112 to slide into and out of the arm cavity 202. For example, the retention section 212 of the mounting arm 112 may in contact with the ramp 312 as the retention section 212 slides into the arm cavity 202 during the movement / sliding of the mounting sleeve 110 from the retention or default position shown in Figs. 1 A-1D to the insertion position shown in Figs. 2A-2D. The arm cavity 204 may have a ramp 314 that enables the mounting arm 114 to slide into and out of the arm cavity 204. For example, the retention section 206 of the mounting arm 114 may in contact with the ramp 314 as the retention section 206 slides into the arm cavity 204 during the movement / sliding of the mounting sleeve 110 from the retention or default position shown in Figs. 1 A-1D to the insertion position shown in Figs. 2A-2D. In some alternative embodiments, the arm cavities 202, 204 may have a different shape than shown without departing from the scope of this disclosure. In some alternative embodiments, the arm cavities 202, 204 may be at different locations than shown without departing from the scope of this disclosure.

[0050] In some example embodiments, heat sink 102 may include overhanging structures, such the structures 332, 334 that make that are parts of the spring stop structure 118. For example, the overhanging structures, including the structures 332, 334, of the spring stop structure 118 may radially extend from the fins of the heat sink 102 beyond the perimeter of a main body 336 of the heat sink 102. The overhanging structures, including the 2024PF80356

[0051] 9 structures 332, 334 may extend out such that the spring stop structure 118 prevents the compression spring 108 that is positioned around the main body 336 of the heat sink 102 from sliding off from the heat sink 102 at the top end portion of the heat sink 102. In some alternative embodiments, the overhanging structures, including the structures 332, 334, may be joined to form a single structure without departing from the scope of this disclosure. In some alternative embodiments, the overhanging structures, including the structures 332, 334, may be omitted without departing from the scope of this disclosure. For example, the spring stop structure 118 may be a single piece structure (e.g., a round or rectangular plate) that has a larger diameter and / or perimeter than the main body 336 and may be attached, for example, by a fastener to the heat sink 102 at the top end portion of the heat sink 102 to prevent the compression spring 108 from sliding of the heat sink 102.

[0052] In some example embodiments, the heat sink 102 includes rib slots 310, 322 that are sized and positioned to receive rib structures of the mounting sleeve 110. The positioning of the rib structures of the mounting sleeve 110 may prevent a rotation of the mounting sleeve 110 around the heat sink 102 while allowing the axial movement of the mounting sleeve 110 relative to the heat sink 102.

[0053] In some example embodiments, the heat sink 102 may include wire holes 324, 326 that may be used to route electrical wires therethrough. For example, electrical wires extending through the wire holes 324, 326 may be routed between adjacent fins for connection to a power supply such as an LED driver. To illustrate, the wire holes 324, 326 may be aligned with respective wire holes of the light module housing 104 such that electrical wires may be routed to / from the light module 130 shown in Fig. ID and a power source that is external to the lighting device 100. In some alternative embodiments, the wire holes 324, 326 may be omitted and electrical power may be provided to the light module 130 shown in Fig. ID in a different manner. In some alternative embodiments, the wire holes 324, 326 may be sized, shaped, and / or located differently than shown without departing from the scope of this disclosure.

[0054] In some example embodiments, the heat sink 102 may include fastener holes 328, 330 that may be used to attach the light module housing 104 to the heat sink 102 using fasteners such as screws. For example, the fastener holes 328, 330 may be aligned with respective fastener holes of the light module housing 104 such that the fasteners (e.g., screws) may be extended into the respective holes through the cavity of the light module housing 104. In some alternative embodiments, the fastener holes 328, 330 may be omitted, 2024PF80356

[0055] 10 and the light module housing 104 may be attached to the heat sink in a different manner without departing from the scope of this disclosure.

[0056] Figs. 4A-4C illustrate different views of the mounting sleeve 110 of the direct mounting system of the lighting device 100 of Figs. 1 A-1D according to an example embodiment. Figs. 4A and 4B show the mounting sleeve 110 with the mounting arms 112, 114 in radial / lateral positions shown in Fig. 1 A, and Fig. 4C shows the mounting sleeve 110 with the mounting arms 112, 114 in the radial / lateral positions shown in Fig. 2A. To be clear, the mounting arms 112, 114 stay in the default radial / lateral positions shown in Fig. 2A unless the mounting arms 112, 114 are forced to retention positions such as the radial / lateral positions shown in Fig. 2A.

[0057] Referring to Figs. 1 A-4C, in some example embodiments, the mounting sleeve 110 includes a sleeve body 406 and the mounting arms 112, 114 that extend down from the sleeve body 406. The sleeve body 406 may be slidably positioned around the heat sink 102 as shown in Figs. 1 A-2D. The mounting arms 112, 114 may extend down from the sleeve body 406 diagonally across from each other. The mounting arms 112, 114 may extend straight down from the sleeve body 406 as shown, for example, in Figs. 2A and 4C unless swung outwardly away from each other as shown, for example, in Figs. 1 A, 4A, and 4B. Indeed, the mounting arms 112, 114 may elastically return from the extended radial / lateral positions shown in 4A and 4B to the default radial / lateral positions shown in Fig. 4C unless the mounting arms 112, 114 are actively maintained in the extended radial / lateral positions.

[0058] In some example embodiments, the mounting arm 112 includes a main arm section 402 and the retention section 212, and the mounting arm 114 includes a main arm section 404 and the retention section 206. The main arm section 402 may extend down from the sleeve body 406, and the retention section 212 may angularly extend from the main arm section 402. For example, the retention section 212 may be angled or otherwise oriented generally inwardly relative to the main arm section 402. In general, the retention section 212 may be oriented / angled such that the retention section 212 can slide up and down the ramp 312 of the arm cavity 202 of the heat sink 102 shown in Figs. 1 A-2D depending in the direction of the axial movement of the mounting sleeve 110 relative to the heat sink 102. The retention section 212 may be positioned in the arm cavity 202 when the mounting sleeve 110 is in the insertion position shown, for example, in Figs. 2A-2D. The retention section 212 may be positioned outside of the arm cavity 202 when the mounting sleeve 110 is in the default or retention position shown, for example, in Figs. 1A-1D. The retention section 212 may be oriented / angled such that the retention section 212 slides up and down the ramp 312 2024PF80356

[0059] 11 of the arm cavity 202 of the heat sink 102 as the retention section 212 enters and exits, respectively, the arm cavity 202.

[0060] In some example embodiments, the main arm section 404 of the mounting arm 114 may extend down from the sleeve body 406, and the retention section 206 may angularly extend from the main arm section 404. For example, the retention section 206 may be angled or otherwise oriented generally inwardly relative to the main arm section 404. In general, the retention section 206 may be oriented / angled such that the retention section 206 can slide up and down the ramp 314 of the arm cavity 204 of the heat sink 102 shown in Figs. 1 A-2D depending in the direction of the axial movement of the mounting sleeve 110 relative to the heat sink 102. The retention section 206 may be positioned in the arm cavity 204 when the mounting sleeve 110 is in the insertion position shown, for example, in Figs. 2A-2D. The retention section 206 may be positioned outside of the arm cavity 204 when the mounting sleeve 110 is in the default or retention position shown, for example, in Figs. 1 A-1D. The retention section 206 may be oriented / angled such that the retention section 206 slides up and down the ramp 314 of the arm cavity 204 of the heat sink 102 as the retention section 206 enters and exits, respectively, the arm cavity 204.

[0061] In some example embodiments, the mounting sleeve 110 includes the sleeve adjustment legs 116, 120 that extend down from the sleeve body 406. The sleeve adjustment leg 116, 120 may be diagonally across from each other. The sleeve adjustment leg 116 may include the grip section 122 that has a textured surface. The sleeve adjustment leg 120 may include the grip section 124 that has a textured surface. The texture surfaces of the grip sections 122, 124 may provide a slip-resistant surface for applying an axial force, for example, with a finger to slide the mounting sleeve 110 axially against the decompression force of the compression spring 108 to the insertion position of the mounting sleeve 110 shown in Figs. 2A-2D from the default position shown, for example, in Figs. 1 A-1D.

[0062] In some example embodiments, the mounting sleeve 110 may include rib structures 412, 414 as shown in Figs. 4A-4C. For example, the rib structures 412, 414 may be located on the inside of the sleeve body 406, for example, across from each other. The rib structures 412, 414 may be sized and located to be inserted into respective rib slots of the heat sink 102 shown, for example, in Figs. 3A-3C. To illustrate, the rib structure 412 may be positioned in the rib slot 310, and the rib structure 414 may be positioned in the rib slot 322. The positioning of the rib structures 412, 414 in the rib slots 310, 322, respectively, may prevent the rotation of the mounting sleeve 110 around the heat sink 102. 2024PF80356

[0063] 12

[0064] As described above with respect to Figs. 1 A-2D, the mounting sleeve 110 be positioned around the heat sink 102 such that the mounting sleeve 110 compresses the compression spring 108. To illustrate, the mounting sleeve 110 may be positioned around the heat sink 102 such that a perimeter edge 410 of the mounting sleeve 110 is in contact with the compression spring 108. The mounting sleeve 110 may be slidingly moved axially toward the compression spring 108 that applies a decompression force against the mounting sleeve 110 as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure.

[0065] In some alternative embodiments, the mounting sleeve 110 may have a different shape than shown without departing from the scope of this disclosure. For example, the sleeve body 406 of the mounting sleeve 110 may have a rectangular box shape instead of the cylindrical shape. In some alternative embodiments, the mounting sleeve 110 may include more mounting arms than shown without departing from the scope of this disclosure. In some alternative embodiments, the mounting arms 112, 114 may be at different locations than shown without departing from the scope of this disclosure. In some alternative embodiments, the mounting arms 112, 114 may each have a different shape than shown without departing from the scope of this disclosure. For example, the mounting arms 112, 114 may each have other sections in addition to the respective main arm section and retention section. As another example, the retention sections 212, 206 of the mounting arms 112, 114, respectively, may be oriented differently (e.g., more or less angled) than shown without departing from the scope of this disclosure. As another example, the mounting arms 112, 114 may each be or may include a curved section without departing from the scope of this disclosure. In some alternative embodiments, the sleeve adjustment legs 116, 120 may each have a different shape than shown without departing from the scope of this disclosure. In some alternative embodiments, the grip sections 122, 124 may have a different texture than shown without departing from the scope of this disclosure. In some alternative embodiments, the mounting arms 112, 114 may be separate structures that are each attached to the sleeve body 406 by one or more fasteners. In some alternative embodiments, the sleeve adjustment legs 116, 120 may be separate structures that are each attached to the sleeve body 406 by one or more fasteners.

[0066] Fig. 5 illustrates a mounting sleeve 500 of the direct mounting system of the lighting device 100 of Figs. 1 A-1D according to another example embodiment. In general, the mounting sleeve 500 may be used in the same manner as described herein with respect to the mounting sleeve 110 shown, for example, in Figs. 4A-4C. In some example 2024PF80356

[0067] 13 embodiments, the mounting sleeve 500 may include a sleeve body 502, mounting arms corresponding to the mounting arms 112, 114 of the mounting sleeve 110 shown in Figs. 4A- 4C, and sleeve adjustment legs 508, 510 that extend down from the sleeve body 502. The mounting sleeve 500 may also include rib structures 512, 514 that correspond to the rib structures 412, 414 of the mounting sleeve 110 shown in Figs. 4A-4C and that may be used in the same manner to prevent the rotation of the mounting sleeve 500 around the heat sink 102 shown in Figs. 3A-3C.

[0068] In some example embodiments, the mounting arms of the mounting sleeve 500 may be separate structures that are attached to the sleeve body 502, for example, using fasteners. For example, a mounting arm 504 of the mounting sleeve 500 may be attached to the sleeve body 502 by a fastener (e.g., a rivet), and another mounting arm of the mounting sleeve 500 that may be diagonally across from the mounting arm 504 may be attached to the sleeve body 502 by another fastener (e.g., a rivet). The areas of the sleeve body 502 at which the mounting arm 504 and another mounting arm are attached may be indented to maintain an outer diameter that corresponds to the outer diameter of the sleeve body 406 of the mounting sleeve 110 shown in Figs. 4A-4C. In general, the mounting arms of the mounting sleeve 500 may be used in the same manner as the mounting arms 112, 114 shown in Figs. 4A-4C.

[0069] In some example embodiments, the mounting sleeve 500 including the mounting arms may be made from plastic using methods such as injection molding, cutting, etc. Alternatively, the mounting sleeve 500 including the mounting arms may be made from a metal (e.g., aluminum) using methods such as die casting, milling, cutting, bending, etc. In some example embodiments, the mounting arms of the mounting sleeve 500 including the mounting arm 504 may be made from a different material from the material used to make the rest of the mounting sleeve 500.

[0070] Figs. 6A and 6B illustrate the light module housing 104 of the lighting device 100 of Figs. 1 A-1D according to an example embodiment. Referring to Figs. 1 A-3C, 6A, and 6B, in some example embodiments, the light module housing 104 includes a cavity section 602 that has a cavity 614. For example, the light module 130 shown in Fig. ID may be positioned in the cavity 614. The light module housing 104 may also include the flange section 106 that extends outwardly from the cavity section 602, for example, proximal to an opening 616 of the cavity section 602. When the lighting device 100 is mounted to a mounting structure such as a ceiling or a wall, the flange section 106 may be on the room side of the mounting structure while the cavity section 602 extends through a mounting 2024PF80356

[0071] 14 opening in the mounting structure. The light module 130 may provide a light to a room or another space through the opening 616. In general, the flange section 106 may have a larger size (e.g., the outer diameter) than the size (e.g., the diameter) of the mounting opening of a ceiling or a wall as well as the size (e.g., the diameter) of the cavity section 602.

[0072] In some example embodiments, the light module housing 104 includes a back cover 612 that may be abutted against the heat sink 102. The back cover 612 may have wire holes 604, 606 that may be aligned with the wire holes 324, 326, respectively, of the heat sink 102. Electrical wires that are connected to the light module 130 and to a power supply (e.g., a driver) may be routed through the wire holes 324, 326, 604, 606 and may be used to provide electrical power to the light module 130.

[0073] In some example embodiments, the back cover 612 may have fastener holes 608, 610 that may be aligned with the fastener holes 328, 330, respectively, of the heat sink 102. Screws may be extended through the fastener holes 608, 610 and the fastener holes 328, 330 to securely attach the light module housing 104 to the heat sink 102. For example, the light module housing 104 may be attached to the heat sink 102 after the compression spring 108 and the mounting sleeve 110 are positioned around the heat sink 102.

[0074] In some example embodiments, the flange section 106 may retain the mounting sleeve 110 attached to the heat sink 102 by preventing the mounting sleeve 110 from slipping off from the heat sink 102. To illustrate, the sleeve adjustment legs 116, 120 may be positioned on the flange section 106 when the compression spring 108 is in the default or retention position as shown, for example, in Figs. 1 A-1D. As such, by retaining the mounting sleeve 110 attached around the heat sink 102, the flange section 106 helps retain the compression spring 108 attached around the heat sink 102.

[0075] In some alternative embodiments, the light module housing 104 may have a different shape than shown without departing from the scope of this disclosure. For example, the light module housing 104 may have a rectangular or box shape or another shape without departing from the scope of this disclosure. In some alternative embodiments, the wire holes 604, 606 and / or the fastener holes 608, 610 may be at different locations than shown without departing from the scope of this disclosure. In some alternative embodiments, the wire holes 604, 606 and / or the fastener holes 608, 610 may be a different shape than shown without departing from the scope of this disclosure. In some alternative embodiments, the light module housing 104 may include fewer or more wires holes and / or fastener holes than shown without departing from the scope of this disclosure. 2024PF80356

[0076] 15

[0077] Fig. 7 illustrates the lighting device 100 of Figs. 2A-2D during installation in a mounting structure 702 according to another example embodiment. In Fig. 7, the mounting sleeve 110 of the lighting device 100 may be in the insertion position shown in Figs. 2A-2D. In some example embodiments, a person may slide the mounting sleeve 110 to the retention position, for example, from the default position shown in Figs. 1 A-1D by pressing or pushing on the sleeve adjustment legs 116, 120 inwardly and applying a force to axially slide the mounting sleeve 110 upward (in the orientations shown in Figs. 1 A-2D and 7) until the mounting sleeve 110 is in the insertion position shown in Figs. 2A-2D and 7. Because the axially upward movement of the mounting sleeve 110 compresses the compression spring 108, the force applied on the sleeve adjustment legs 116, 120 to slide the mounting sleeve 110 upward needs to overcome the resistance / decompression force of the compression spring 108.

[0078] In Fig. 7, the lighting device 100 has been moved close to the mounting structure 702 to insert the lighting device into a mounting opening 704 of mounting structure 702. The lighting device 100 is oriented such that the heat sink 102 can be inserted into the mounting opening 704 where the light module 130 is positioned to emit a light toward a space to be illuminated. The mounting opening 704 may have a backside perimeter edge 706 and a room side perimeter edge 708. The diameter D of the mounting opening 704 is sized such that the flange section 106 of the light module housing 104 covers the room side perimeter edge 708 after the lighting device 100 is mounted to the mounting structure 702. In general, the mounting structure 702 may be a section of a ceiling (e.g., a ceiling tile) or a section of a wall. The thickness of the mounting structure 702 may be, for example, 1 inch. Alternatively, the mounting structure 702 may be thicker or thinner than 1 inch. The diameter D of the mounting opening 704 may be, for example, 1.05 inch. Alternatively, the diameter D of the mounting opening 704 may be smaller or larger than 1.05 inch. In general, the lighting device 100, including the compression spring 108 and the mounting sleeve 110, can be sized for mounting to the mounting structure 702 where the mounting opening 704 or another mounting opening is larger or smaller (e.g., in diameter or width) than 1.05 inch.

[0079] Referring to Figs. 2A-2D and 7, the retention section 212 of the mounting arm 112 is positioned in the arm cavity 202 of the heat sink 102, and the retention section 206 of the mounting arm 114 is positioned in the arm cavity 204 of the heat sink 102. The mounting arms 112, 114 may be at default positions where the separation S (labeled in Fig. 2 A) between the mounting arms 112, 114 is less than the diameter D of the mounting opening 704 of the mounting structure 702. In general, when the mounting sleeve 110 is in the insertion 2024PF80356

[0080] 16 position, the lighting device 100 including the heat sink 102 and the mounting sleeve 110 including the retention section 206, 212 can enter and / or pass through the mounting opening 704. As described above with respect to Figs. 2A-2D, the mounting sleeve 110 may be held in the retention position shown in Figs. 2A-2D and 7 by applying a force on the sleeve adjustment legs 116, 120. For example, a person may use fingers on one hand or both hands 208, 210 to press, push, or pinch the sleeve adjustment legs 116, 120 against the heat sink 102.

[0081] In some example embodiments, a person may insert the lighting device 100 into the mounting opening 704 while maintaining the mounting sleeve 110 in the insertion position by applying a force (e.g., pressing or pinching) the sleeve adjustment legs 116, 120 radially inwardly, for example, against the heat sink 102. For example, after the retention sections 206 and 212 of the mounting arms 114 and 112, respectively, have at least partially moved past the backside perimeter edge 706, the person may release the sleeve adjustment legs 116, 120. Upon the person releasing the sleeve adjustment legs 116, 120, the decompression force of the compression spring 108 may result in the light module housing 104 being suck up into the mounting opening 704 such that the cavity section 602 of the light module housing 104 is positioned in the device cavity 704 and such that the flange section 106 is abutted against the mounting structure 702 on an opposite side of the mounting structure 702 from the heat sink 102.

[0082] Figs. 8A and 8B illustrate the lighting device 100 of Figs. 1 A-1D mounted to the mounting structure 702 according to an example embodiment, and Figs. 9A and 9B illustrate cross-sectional views of the lighting device 100 of Figs. 1 A-1D mounted to the mounting structure 702 according to an example embodiment. Fig. 9A shows a vertical cross- sectional view of the lighting device 100 of Fig. 8B looking into the page, and Fig. 9A is a vertical cross-sectional view of the lighting device 100 of Fig. 8B toward the left side of the lighting device 100.

[0083] In general, when the sleeve is in a retention position as shown in Figs. 1 A-1D and 8A-9B, the mounting arms 112, 114 are positioned extending / swung beyond the backside perimeter edge 706 of the mounting opening 704 of the mounting structure 702 such that the mounting arms 112, 114 mount the lighting device 100 to the mounting structure 702. When the mounting sleeve 110 is in an insertion position as shown in Figs. 2A-2D and 7, the mounting arms 112, 114 are positioned to pass through the mounting opening 704 of a mounting structure 702. For example, the separation S between the mounting arms 112, 114 in Figs. 2A-2D and 7 may be 1 inch, the diameter D of the mounting opening 704 may be 2024PF80356

[0084] 17

[0085] 1.05 inch, and the separation S between the mounting arms 112, 114 in Figs. 1A-1D and SA- OB may be 1.2 inch. In some example embodiments, the separation S between the mounting arms 112, 114 and the diameter D of the mounting opening 704 may have larger or smaller without departing from the scope of this disclosure.

[0086] As shown in Figs. 8A-9B, in some example embodiments, the lighting device 100 may be mounted to the mounting structure 702 by the direct mounting system that includes the compression spring 108 and the mounting sleeve 110. In Figs. 8A-9B, the mounting sleeve 110 is in a retention position where the mounting arms 112, 114 are extended / swung farther from the heat sink 102 than when the mounting sleeve 110 is in the insertion position shown in Figs. 2A-2D and 7. For example, the retention position of the mounting sleeve 110 in Figs. 8A-9B may correspond to the retention or default position of the mounting sleeve 110 shown in Figs. 1 A-1D.

[0087] In some example embodiments, when the mounting sleeve 110 is in the retention position, the retention section 212, 206 of the mounting arms 112, 114, respectively, are outside of the arm cavities 202, 204 as more clearly shown in Fig. 9A. To illustrate, in Figs. 8A-9B, the mounting arms 112, 114 may have been swung radially / laterally outwardly such that the retention section 206, 212 are positioned against the backside perimeter edge 706, thereby mounting the lighting device 100 to the mounting structure 702. In the radial / lateral positions of the mounting arms 112, 114 shown in Figs. 8A-9B, the compression spring 108 may push the retention section 206, 212 against the backside perimeter edge 706 of the mounting opening 704 of the mounting structure 702, which helps retain the lighting device 100 mounted to the mounting structure 702. The tips of the retention section 212, 206 may also rest against the light module housing 104 or the heat sink 102.

[0088] In some example embodiments, when the lighting device 100 is mounted to the mounting structure 702 as shown in Figs. 8A-9B, the heat sink 102 may be entirely on the back side of the mounting structure 702 and the flange section 106 may be abutted against the mounting structure 702 on an opposite side of the mounting structure 702 from the heat sink 102.. When the lighting device 100 is mounted to the mounting structure 702 as shown in Figs. 8A-9B, the sleeve adjustment legs 116, 120 of the mounting sleeve 110 may be positioned close to or in contact with the flange section 106 of the light module housing 104. When the lighting device 100 is mounted to the mounting structure 702 as shown in Figs. 8A-9B, the light module 130 positioned in the cavity 614 of the light module housing 104 may be oriented to illuminate the area in front of (e.g., below) the mounting structure 702. As 2024PF80356

[0089] 18 more clearly shown in Fig. 9A, the light module housing 104 is attached to the heat sink 102 by fasteners 902, 904 (e.g., screws).

[0090] By using the compression spring 108 and the mounting sleeve 110, the lighting device 100, which may be a direct-mount lighting device, may be mounted the mounting structure 702 with minimal effort by an installer. For example, depending on the size of the lighting device 100, a person may use one hand to install the lighting device 100 in the mounting structure 702. As described above, a person may place the mounting sleeve 110 in a retention position, such as the retention position shown in Figs. 2A-2D and 7, and may insert lighting device 100 into the mounting opening 704 while retaining the mounting sleeve 110 in the retention position using the sleeve adjustment legs 116, 120. The person may release the sleeve adjustment legs 116, 120 after the mounting arms 112, 114 are inserted into the mounting opening 704, which results in the lighting device 100 being further pulled through the mounting opening 704 such that the lighting device 100 is mounted to the mounting structure 702 by the mounting sleeve 110.

[0091] Referring to Figs. 1 A-9B, in some example embodiments, the direct mounting system that includes the compression spring 108 and the mounting sleeve 110 can be used to mount devices other than or in addition to direct-mount lighting devices without departing from the scope of this disclosure. For example, the compression spring 108 and the mounting sleeve 110 may be used to mount a sensor device or another device in the same manner as described with respect to the lighting device 100. To illustrate, instead of the heat sink 102, a sensor device may have a housing that has arm cavities with ramps corresponding to the arm cavities 202, 204 shown, for example, in Figs. 3B and 3C. In some alternative embodiments, the compression spring 108 and the mounting sleeve 110 may be used to mount other types of lighting devices than shown without departing from the scope of this disclosure. In general, one or more components of the lighting device 100 including the heat sink 102 and the light module housing 104 may have a different shape than shown without departing from the scope of this disclosure.

[0092] Although particular embodiments have been described herein in detail, the descriptions are by way of example. The features of the embodiments described herein are representative and, in alternative embodiments, certain features, elements, and / or steps may be added or omitted. Additionally, modifications to aspects of the embodiments described herein may be made by those skilled in the art without departing from the scope of the following claims, the scope of which are to be accorded the broadest interpretation so as to encompass modifications and equivalent structures.

Claims

2024PF8035619CLAIMS:

1. A direct-mount lighting device (100), comprising: a heat sink (102); a compression spring (108) positioned around the heat sink; and a mounting sleeve (110) comprising a sleeve body (406) and mounting arms(112, 114) extending out from the sleeve body, wherein the sleeve body is slidably positioned around the heat sink, wherein the mounting sleeve is slidable to compress the compression spring, wherein the mounting arms extend laterally farther from the heat sink when the mounting sleeve is in a retention position than when the mounting sleeve is in an insertion position, and wherein the compression spring is compressed by the sleeve body when the mounting sleeve is in the insertion position; and wherein the mounting sleeve (110) includes sleeve adjustment legs (116, 120) extending down from the sleeve body (406) and wherein the mounting sleeve is slidable to the insertion position by applying a force to the sleeve adjustment legs.

2. The direct-mount lighting device of claim 1, wherein, when the mounting sleeve (110) is in the insertion position, the mounting arms (112, 114) are laterally positioned to pass through a mounting opening (704) of a mounting structure (702) and wherein, when the mounting sleeve is in the retention position, the mounting arms are positioned to extend beyond a perimeter edge (706) of the mounting opening (704) of the mounting structure such that the mounting arms mount the lighting device to the mounting structure.

3. The direct-mount lighting device of claim 1, further comprising a spring stop structure (118), wherein the compression spring (108) is positioned around the heat sink (102) between the mounting sleeve (110) and the spring stop structure (118).

4. The direct-mount lighting device of claim 3, wherein the spring stop structure (118) includes overhanging sections (332, 334) of the heat sink.2024PF80356205. The direct-mount lighting device of claim 1, wherein the heat sink comprises arm cavities (202, 204) and wherein a retention section (212, 206) of each mounting arm of the mounting arms (112, 114) is positioned in a respective arm cavity of the arm cavities (202, 204) when the mounting sleeve is in the insertion position.

6. The direct-mount lighting device of claim 5, wherein the retention section (212, 206) of each mounting arm of the mounting arms (112, 114) is positioned outside of the respective arm cavity of the arm cavities (202, 204) when the mounting sleeve is in the retention position.

7. The direct-mount lighting device of claim 5, wherein each mounting arm of the mounting arms (112, 114) includes a main arm section (402, 404) that extends down from the sleeve body (406) and wherein the retention section (212, 206) of each mounting arm of the mounting arms (112, 114) extends angularly from the main arm section (402, 404) toward the heat sink 102.

8. The direct-mount lighting device of claim 5, wherein the retention section (212, 206) of each mounting arm of the mounting arms (112, 114) slides against a ramp (312, 314) of a respective arm cavity of the arm cavities (202, 204) during insertions and exits of the mounting arms from the arm cavities.

9. The direct-mount lighting device of claim 1, further comprising a light module housing (104) and a light module (130) positioned in a cavity (614) of the light module housing, wherein the light module housing is attached to the heat sink.

10. The direct-mount lighting device of claim 9, wherein the light module housing (104) includes a cavity section (602) and a flange section (106), wherein the flange section extends outwardly around the cavity section such that the flange section is positioned below a mount structure (702) when the cavity section is positioned through a mounting opening (704) of the mount structure.

11. The direct-mount lighting device of claim 1, wherein the heat sink includes one or more rib slots (310, 322) and wherein the mounting sleeve includes one or more rib2024PF8035621 structures (412, 414) that are positioned in the one or more rib slots to prevent a rotation of the mounting sleeve around the heat sink.

12. The direct-mount lighting device of claim 1, wherein each sleeve adjustment leg of the sleeve adjustment legs includes a grip section (122, 124) that has a textured surface.

13. The direct-mount lighting device of claim 1, wherein the mounting arms (112, 114) are attached to the sleeve body (406) such that the mounting arms are positioned swung away from the heat sink when the mounting sleeve is in the retention position and wherein the mounting arms are attached to the sleeve body such that the mounting arms are closest to the heat sink when the mounting sleeve is in the insertion position.

14. The direct-mount lighting device of claim 1, wherein the mounting arms (504) are attached to the sleeve body (502) by fasteners (506).

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