权利要求：
1. A mounting system for a light fixture, the mounting system comprising:
a top hub;
an electrical connector coupled to the top hub;
an upper mounting arm coupled to the top hub;
a central hub coupled to the upper mounting arm;
a magnet positioned within the central hub;
a lower mounting arm coupled to the central hub; and
a bottom hub coupled to the lower mounting arm, the bottom hub configured to receive and secure an electronic device,
wherein the lower mounting arm is configured to slide through the central hub to adjust the mounting system from an extended configuration to a collapsed configuration to mount the mounting system to the light fixture, and
wherein the magnet is positioned within the central hub to apply magnetic force to at least one of the upper mounting arm or the lower mounting arm, to control movement of the lower mounting arm through the central hub.
2. The mounting system of claim 1, wherein the electrical connector comprises a male light bulb socket.
3. The mounting system of claim 1, wherein the central hub comprises a housing cavity, and wherein the magnet is positioned within the housing cavity.
4. The mounting system of claim 1, wherein the housing cavity further comprises first and second mounting arm slots, wherein the upper mounting arm is secured to the first mounting arm slot, and wherein the lower mounting arm is positioned such that it can slide through the second mounting arm slot.
5. The mounting system of claim 1, wherein the magnet comprises a cylindrical shape having first and second opposite, parallel, planar faces, and wherein the magnet is positioned within the central hub such that the first planar face is parallel to a planar surface of the lower mounting arm.
6. The mounting system of claim 1, wherein the magnet is positioned between the upper mounting arm and the lower mounting arm.
7. The mounting system of claim 1, wherein the magnet comprises one or more of a neodymium magnet or a printed poly-magnet.
8. The mounting system of claim 1, wherein the magnet comprises one or more of a friction layer, a rubber material, a silicone material, a plastic material, a polymer coating, or an encapsulation.
9. The mounting system of claim 1, wherein the electronic device comprises at least one of a light, an LED panel light, a microphone, a speaker, an audio component, a light fixture, a motor, a pump, a fan, a thermostat, a radio, a wireless transmitter, a wireless receiver, a Bluetooth device, a communications hub, a phone, a router, a switch, or a display.
10. The mounting system of claim 1, wherein a space defined by the top hub, the upper arm, and the central hub, is configured to hold an electronic circuit.
11. The mounting system of claim 10, wherein the electronic circuit is a light emitting diode (LED) driver.
12. A method for a light fixture, the method comprising the steps of:
providing a mounting system comprising:
a top hub;
an electrical connector coupled to the top hub;
an upper mounting arm coupled to the top hub;
a central hub coupled to the upper mounting arm;
a lower mounting arm coupled to the central hub, wherein the lower mounting arm is configured to slide through the central hub to adjust the mounting system from an extended configuration to a collapsed configuration;
a bottom hub coupled to the lower mounting arm, the bottom hub configured to receive and secure an electronic device; and
a magnet positioned within the central hub, wherein the magnet is configured to apply a magnetic force to at least one of the upper mounting arm or the lower mounting arm to control movement of the lower mounting arm through the central hub;
securing the electronic device to the bottom hub; and
coupling the electrical connector to the light fixture.
13. The method of claim 12, wherein the electrical connector comprises a male light bulb socket.
14. The method of claim 12, wherein a space defined by the top hub, the upper arm, and the central hub, is configured to hold an electronic circuit.
15. The method of claim 12, wherein the central hub comprises a housing cavity, and wherein the magnet is positioned within the housing cavity.
16. The method of claim 12, wherein the housing cavity further comprises first and second mounting arm slots, wherein the upper mounting arm is secured to the first mounting arm slot, and wherein the lower mounting arm is positioned such that it can slide through the second mounting arm slot.
17. The method of claim 12, wherein the magnet comprises a cylindrical shape having first and second opposite, parallel, planar faces, and wherein the magnet is positioned within the central hub such that the first planar face is parallel to a planar surface of the lower mounting arm.
18. The method of claim 12, wherein the magnet is positioned between the upper mounting arm and the lower mounting arm.
19. The method of claim 12, wherein the magnet comprises one or more of a friction layer, a rubber coating, a polymer coating, or an encapsulation.
20. The method of claim 12, wherein the electronic device comprises at least one of a light, an LED panel light, a microphone, a speaker, an audio component, a light fixture, a motor, a pump, a fan, a thermostat, a radio, a wireless transmitter, a wireless receiver, a Bluetooth device, a communications hub, a phone, a router, a switch, or a display.
发明内容：
[0014]A mounting system is provided for use in securing a device, such as an LED light, a flat panel LED, or other electronic device, to a light fixture, such as an existing incandescent recessed light fixture. The electronic device can be any of a variety of devices, including, but not limited to, a light, an LED panel light, a microphone, a speaker, an audio component, a light fixture, a motor, a pump, a fan, a thermostat, a radio, a wireless transmitter, a wireless receiver, a Bluetooth device, a communications hub, a phone, a router, a switch, a display, etc. In various embodiments, the mounting system comprises a central hub, containing an adjusting magnet interposed between two metallic (e.g., steel) mounting arms. The top mounting arm has a male light bulb socket for physical and electrical connection to a female light bulb socket in an existing recessed lighting fixture. The bottom mounting arm has a mount for securing to an electronic device, such as an LED panel or any other electronic device.
[0015]In one embodiment, a mounting system adapted to secure an electronic device to a light fixture includes: a top hub; an electrical connector coupled to the top hub an tipper mounting arm coupled to the top hub; a central hub coupled to the upper arm; a magnet position within the central hub; a lower mounting arm coupled to the central hub; and a bottom hub adapted to be secured to an electronic device. The lower mounting arm is configured to slide through the central hub to adjust the mounting system from an extended configuration to a collapsed configuration, and the magnet applies magnetic three to at least one of the upper mounting arm or the lower mounting and to control movement of at least one of the upper mounting arm or the lower mounting arm through the central hub.
[0016]In one embodiment, the electrical connector includes a male lightbulb socket. In another embodiment a space defined by the top hub, the upper arm, and the central hub, is configured to hold an electronic circuit. In another embodiment the space is configured to hold an LED driver. In another embodiment the central hub comprises a housing cavity, and wherein the magnet is positioned within the housing cavity. In another embodiment the housing cavity further comprises first and second mounting arm slots, and the upper mounting arm is secured to the first mounting arm slot, and the lower mounting arm is positioned such that it can slide through the second mounting arm slot.
[0017]In another embodiment the magnet comprises a cylindrical shape having first and second opposite, parallel, planar faces, and the magnet is positioned within the central hub such that the first planar face is parallel to a planar surface of the lower mounting arm. In another embodiment the magnet is positioned between the upper mounting arm and the lower mounting arm. In another embodiment the magnet comprises one or more of a neodymium magnet or a printed poly-magnet. In another embodiment the magnet has a strength between N40 and N52. In another embodiment the magnet comprises one or more of a friction layer, a rubber material, a silicone material, a plastic material, a polymer material, or an encapsulation. In another embodiment the electronic device comprises one of more of a light, an LED panel light, a microphone, a speaker, an audio component, a light fixture, a motor, a pump, a fan, a thermostat, a radio, a wireless transmitter, a wireless receiver, a Bluetooth device, a communications hub, a phone, a router, a switch, or a display.
[0018]A method of securing an electronic device to a light fixture includes: providing a mounting system, wherein the mounting system comprises: a top hub; an electrical connector coupled to the top hub; an upper mounting arm coupled to the top hub; a central hub coupled to the upper arm; a magnet position within the central hub; a lower mounting arm coupled to the central hub; and a bottom hub adapted to be secured to an electronic device. The lower mounting arm is configured to slide through the central hub to adjust the mounting system from an extended configuration to a collapsed configuration, and the magnet applies magnetic force to at least one of the upper mounting arm or the lower mounting arm to control movement of at least one of the upper mounting arm or the lower mounting arm through the central hub. The method also includes securing an electronic device to the bottom hub; and coupling the top hub to a light fixture.
[0019]In another embodiment the electrical connector comprises a male lightbulb socket. In another embodiment a space defined by the top hub, the upper arm, and the central hub, is configured to hold an electronic circuit. In another embodiment the central hub comprises a housing cavity, and the magnet is positioned within the housing cavity. In another embodiment the housing cavity further comprises first and second mounting arm slots, the upper mounting arm is secured to the first mounting arm slot, and the lower mounting arm is positioned such that it can slide through the second mounting arm slot.
[0020]In another embodiment the magnet comprises a cylindrical shape having first and second opposite, parallel, planar faces, and the magnet is positioned within the central hub such that the first planar face is parallel to a planar surface of the lower mounting arm. In another embodiment the magnet is positioned between the upper mounting arm and the lower mounting arm. In another embodiment the magnet comprises one or more of a neodymium magnet or a printed poly-magnet. In another embodiment the magnet has a strength between N40 and N52. In another embodiment the magnet comprises one or more of a friction layer, a rubber material, a silicone material, a plastic material, a polymer material, or an encapsulation. In another embodiment the electronic device comprises one of more of a light, an LED panel light, a microphone, a speaker, an audio component, a light fixture, a motor, a pump, a fan, a thermostat, a radio, a wireless transmitter, a wireless receiver, a Bluetooth device, a communications hub, a phone, a router, a switch, or a display.
具体实施方式：
[0069]A mounting system is provided for use in securing an electronic device 100 (see FIGS. 4-6), such as an LED light, flat panel LED, or other electronic device, to a light fixture, such as an existing incandescent recessed light fixture. As used in the industry and herein, a recessed light fixture is also referred to as a “can light fixture.” Although many of the embodiments are described in terms of mounting an LED light, such as a flat panel LED or other LED light, it should be understood that any electronic device 100, including but not limited to the particular electronic devices described above, may be mounted using any of the devices or methods described herein. For example, the electronic device 100 can be any of a variety of electronic devices, including, but not limited to, a light, an LED panel light, a microphone, a speaker, an audio component, a light fixture, a motor, a pump, a fan, a thermostat, a radio, a wireless transmitter, a wireless receiver, a Bluetooth device, a communications hub, a phone, a router, a switch, a display, etc.
[0070]As depicted in FIGS. 1-19, the mounting system 10 generally includes a central hub 12, a top mounting arm 14, with a top hub 16, and a bottom mounting arm 18, with a bottom hub 20. The three hubs 12, 16, 20 of the mounting system are generally sized to fit comfortably within the diameter and circumference of a can light fixtures. A container space 22 is also provided to house electronics or other components, such as an LED driver and other electronic components. In some embodiments, the top mounting arm 14 comprises an arm 24 and a top hub component 26. A male lightbulb socket 28 is affixed to project upwardly from the top hub component 26. The male lightbulb socket 28 may have electrical connection wires, not shown, extending downwardly therefrom, for connection to an electronic device 100 (e.g., an LED driver, an LED panel, or other electronic device). The top mounting arm 14 is affixed to the central hub 12. The bottom mounting arm 18 is movably attached to the central hub 12 by an arm 25 (see FIGS. 1-2), enabling the bottom mounting arm 18 to be moved longitudinally toward or away from the central hub 12.
[0071]In one embodiment, the bottom mounting arm 18 may be moved between an extended position, as shown in FIG. 1, and a compressed position as shown in FIG. 2. Moreover, in one embodiment, the range of motion is continuous between the extended position and compressed position, such that the bottom mounting arm 18 can be moved or adjusted to any position between the fully extended position and the fully retracted position, and is not limited any particular increments of adjustment. This continuous adjustability of the length of the mounting system allows it to be easily used in can light fixtures of various lengths, as the bottom mounting arm 18 of the mounting system may be quickly and easily moved to secure the electronic device 100 (such as an LED light) tightly against the bottom of the can light fixture and the surrounding ceiling structure, when installed. The bottom mounting arm 18 further comprises a bottom hub 20 coupled to the arm 25 for attachment to an electronic device 100, such as an LED panel light. The arms 24, 25 of the mounting arms 14, 18 respectively may be formed of metal and referred to herein as metal arms 24, 25
[0072]In use, the mounting system 10 is attached to a light fixture, such as an incandescent can light fixture, by screwing the male light bulb socket 28 of the top hub 16 into a female light bulb socket of the incandescent can light fixture (not shown). The mounting system 10 is attached to an electronic device, such as an LED panel (not shown) at the bottom hub 20 of the bottom mounting arm 18. In one embodiment, the bottom hub 20 affixes to a mounting ring 32 affixed to the electronic device (e.g., LED panel light (not shown)). In some embodiments, the bottom hub 20 includes one or more magnets (not shown), which magnetically secures to the metal underside of the electronic device (e.g., LED panel light). In some embodiments, the bottom hub 20 can be secured to an electronic device by screws, glue or other readily understood fastening means. The central hub 12 can include two hub components 40, 42, embodiments of which are discussed below. The mounting system 10 can also include a mounting ring 32, as discussed below.
[0073]FIGS. 3-7 show an embodiment of the mounting system 10 in further detail. The mounting system central hub 12 is comprised of two interlocking central hub components 40, 42. In some embodiments, each of the central hub components 40, 42 is identical to the other hub component. Each of the central hub components 40, 42 has a generally circular circumference. On one side of each of the central hub components 40, 42, a cut-away 44 has been made to create space for the insertion of an LED driver component or other electronics as illustrated in FIGS. 1-2. Each of the central hub components 40, 42 also comprises a detent sphere 46 and a detent cavity 48. The detent sphere 46 is a partial-sphere projecting upwardly from the left side of the inside face of the bottom central hub component 40, and likewise, projecting downwardly from the inside face of the right side of the top central hub component 42. When assembled, the two central hub components 40, 42, are pressed tightly against one another, causing the detent sphere 46 of each central hub component to project into and tightly engage the detent cavity 48 of the other central hub component. When the two hub central components 40, 42 are in close-fit relationship and secured, the interaction of the detent sphere 46 and detent cavity 48 serve to prevent rotation of one central hub component 40 with respect to the other central hub component 42, thus resulting in a substantially secured central hub 12. The interaction of the respective detent sphere 46 and detent cavity 48 of each of the central hub components 40, 42, provides a strong lock between the central hub components 40, 42, and therefore substantial ability to resist twisting, turning or torsion on the central hub 12 caused by screwing the mounting system 10 into the recessed light fixture. In some embodiments, other rotation-preventing structures are provided instead of detent spheres. For example, one or more pins, tabs, projections or other interlocking structure may be provided. The top central hub component 42 can be affixed to the bottom central hub component 40 by glue at any point on the detent sphere 46, the detent cavity 48 or the inner face 50 of the respective central hub component. The two central hub components 40, 42 can also be affixed to one another by screws, pins, zip ties or wires through pre-formed or pre-drilled holes 52 (which are optionally provided). In one embodiment, the two central hub components 40, 42, as well as the top hub component 16 and bottom hub component 20, are formed from a sturdy plastic, such as phenolic plastic, but can also be formed from polyurethane, polystyrene, polypropylene, polyvinyl chloride, polycarbonate, PLA, nylon, ABS, or carbon fiber. In some embodiments, the mounting system 10 further includes a stopping cavity 82 (see FIGS. 3-4) a hole 90 (see FIGS. 4, 6, 7) and magnet mount cavity 85 (see FIGS. 4-6), as further described below.
[0074]FIGS. 8-16 show an embodiment of the central hub component in further detail, illustrating features discussed above. Each central hub component 40, 42 includes a housing cavity 60 (see FIGS. 10-12, 15) and a pre-formed hole 62 (see FIGS. 9, 14) for attachment to the top mounting arm 14. The central housing cavity 60 has two mounting arm slots 64, 66 (see FIGS. 10-13, 15) formed there-through. Each of the mounting arm slots 64, 66 is configured to be the same size as the width and thickness of its respective mounting arm, or sized to receive a mounting arm such that the mounting arm can slide therethrough. As discussed further below, in one embodiment, each mounting arm is a flat steel lever arm approximately ⅛ inch thick by ¾ inch wide, with a variable length for different can sizes. The central housing cavity 60 also has a center support 68 (see FIGS. 10-12, 15) forming the inside edges of the mounting slots 64, 66.
[0075]In one embodiment, the center support 68 forms a half-cylindrical ledge, most clearly shown in FIGS. 12 and 15. The half-cylindrical ledge is configured to have the same half-circumference and radius of curve as an adjusting magnet 70 (see FIGS. 6-7, and 19). In one embodiment, the adjusting magnet is a flat cylindrical magnet. At assembly, the adjusting magnet 70 is placed in the central housing cavity 60 such that the adjusting magnet 70 is oriented so that the curve of the magnet's cylinder circumference is supported by and generally touching the half-cylindrical ledges of the center supports 68 of both the respective bottom central hub component 40 and the top central hub component 42. Thus oriented, the flat sides of the adjusting magnet 70 are positioned toward the inside edges of the mounting slots 64, 66. The adjusting magnet 70 may be secured in place on the half-cylindrical ledges of the center supports 68 with glue, but such securement is not required, as a tight close-fit relationship is achieved by minimizing tolerance between the curved edge of the adjusting magnet 70 and the half-cylindrical ledges of the center support 68 each of the respective top and bottom central hub components 40, 42. Further, when assembled, a top mounting arm 14 and bottom mounting arm 18 are inserted through each of the mounting arm slots 64, 66, thereby placing the wide flat metal portion of each metal arm 24, 25 in proximity to and, in some embodiments, in contact with, either side of the secured adjusting magnet 70. This placement, and in some embodiments, contact, results in a strong magnetic attraction between the adjusting magnet 70 and each of the respective metal arms 24, 25 of the mounting arms 14, 18.
[0076]In some embodiments, the magnet 70 includes a friction layer, such as rubber or polymer covering. For example, the magnet 70 may be encapsulated within or otherwise include a rubber, silicone, plastic, or other polymer material to increase the friction forces applied to the mounting arms 14, 18. In some embodiments, the magnet 70 attracts and pulls the elongated metal slide 308 into the friction layer, which increases resistance of movement of the mounting arms 14, 18.
[0077]In one embodiment, each of the mounting arms 14, 18 is made from steel. However, it will be understood by one of skill in the art that the mounting arms may be composed of any ferrous metal, so that the adjusting magnet may magnetically adhere to or attract the mounting aims 14, 18.
[0078]The adjusting magnet 70 may be any suitably strong magnet to hold the weight of the electronic device (e.g., LED panel) in a steady position, but still allow the bottom mounting arm 18 to slide with respect to the adjusting magnet 70 when a suitable force is applied. Such motion enables the bottom mounting arm 18 to be adjusted upwardly when the mounting system 10 is screwed into a can light fixture. In one embodiment, the adjusting magnet 70 is a neodymium magnet, of strength ranging from N40 to N52. The adjusting magnet 70 may also be a so-called printed poly-magnet, which is a type of neodymium magnet that is magnetized in a selected pattern. It will be appreciated that the adjusting magnet 70 must be able to be strongly attracting to the two metal arms 24, 25 of the respective mounting arms 14, 18 in order to hold the weight of the electronic device and prevent the bottom mounting arm 18 from sliding downward under the weight of the electronic device, while at the same time enabling the bottom mounting arm 18 to slide against the adjusting magnet 70 when a user presses the mounting arm 18 upward in order to secure an electronic device against the bottom of the can light fixture and ceiling.
[0079]The bottom component 40 of the central hub 12 may be secured to the top mounting arm 14 by a screw or pin (or other fastener) inserted through the pre-formed hole 62 on the side of the bottom component 40 of the central hub 12. This securement fixes the position of top mounting arm 14 with respect to the central hub 12. In contrast, the bottom mounting aim 18 is moveable, between an extended position and a compressed position in any desired increment, due to the bottom mounting arm 18 sliding within the mounting slot and against the adjusting magnet 70. In one embodiment, the top end of the bottom mounting arm 18 has a small projecting pin 80 (see FIG. 2), screw or hook (or other motion limiting structure) that catches on the top hub component 42 of the central hub 12, in order to prevent the bottom mounting arm 18 from being pulled completely through and out of the bottom of the mounting slot 64. In one embodiment, the top hub component 42 of the central hub 12 has a stopping cavity 82 (see FIGS. 3, 4, 13) formed in the bottom side of the hub component (which is therefore oriented upwardly when the top hub component is in place) such that the small projecting pin 80 may enter and then engage the bottom of the stopping cavity 82, thereby stopping and preventing further downward motion of the bottom mounting arm.
[0080]As illustrated in FIG. 17, the top hub component 26 is affixed to the top mounting arm 14 by a screw or pin inserted through a pre-formed hole 90 in the side of the top hub component 26 and into a pre-drilled hole in the metal top mounting arm. A male light bulb socket 28 is affixed to the upper side of the top hub component 26, using glue screws or pins or other fastening technique. The male light bulb socket 28 has positive and negative electrical connections as normally found in conventional male light bulb sockets. However, the male light bulb socket 28 does not have any bulb or filament, and instead the positive and negative connections are connected to electrical wires (not shown) that can be directed through the bottom or sides of the top hub component 26 through pre-formed holes (not shown) and into the electronic device (e.g., LED driver in the LED driver compartment, or if the driver is mounted to the LED panel itself directly downward to the driver mounted to the LED panel). These electrical connections and wires serve to provide power to the electronic device for operation (e.g., to the LED driver so that the LED panel can be illuminated) when the mounting system is screwed into a conventional recessed light fixture.
[0081]As illustrated in FIG. 18, the bottom hub 20 is affixed to the bottom mounting arm 18 by a screw or pin or other fastener inserted through a pre-formed hole 90 in the side of the bottom hub 20 and into a pre-drilled hole or cavity in the metal bottom mounting arm. In one embodiment, the bottom hub 20 has a magnet mount cavity 85 in the bottom of the bottom hub 20. A flat cylindrical attachment magnet 93 is mounted into the magnet mount cavity 85. In some embodiments, the attachment magnet 93 is also a neodymium magnet similar to the adjustment magnet 70 discussed above. The attachment magnet 93 may be secured to the bottom hub 20 by either glue, or a tight, close-fit relationship (e.g., compression fit) between the magnet mount cavity 85 edges and the edges of the attachment magnet 93. The attachment magnet 93 is magnetically strong enough to strongly attract the metal base of the electronic device (e.g., the LED panel) and hold its weight in place when the mounting system is screwed into a can light and sufficient to resist sliding or spinning when screwed in place. The bottom hub 20 may also have a separate ring mounting cavity 95 configured to receive a mounting ring 32, with round stops 97, that is affixed to the electronic device so that the close-fit relationship of the round stops 97 of the mounting ring 32 and the ring mounting cavity 95 serve to prevent rotation of the electronic device when it is mounted and screwed into place in a can light fixture.
[0082]Finally, as shown in FIG. 19, the bottom mounting arm 18 may include a simple flange mount that can be glued to, or secured by screws to, the electronic device (e.g., an LED panel plate).
[0083]As for manufacture and assembly, it will be appreciated, based on the foregoing disclosure and drawings, that the design of the two central hub components as identical and interlocking will simplify manufacture and assembly of the device. It will also be appreciated that the plastic hub components of the mounting system can be manufactured using a variety of known techniques, including injection molding. The described hub components can also be readily manufactured with 3-D printing. The metal and magnetic parts can be easily and quickly assembled by low-skill assembly workers or machinery.
[0084]When used, a user attaches the electronic device (e.g., LED panel) to the bottom mount using the mounting ring, a mounting magnet, or both. The user then attaches the LED driver (when used) or other electrical connections to the electronic device, typically by a simple male-female plugging-in action. The user then extends the bottom mounting arm downward to its fullest extended position. Then user then screws the male light bulb socket of the top mounting hub 16 into a female light bulb socket (e.g., in a can light fixture) by rotating the whole mounting system, with electronic device (e.g., LED panel) attached. This action is similar in nature to the twisting action consumers are familiar with to replace existing light bulbs, and requires no wire cutting, wire splicing, drilling or turning off of the power at the circuit breaker. Then, the user pushes the LED panel upward, thereby causing the bottom mounting arm 18 to slide upward relative to the adjusting magnet 70 and the central hub 12, until the electronic device (e.g., LED panel) is snugly fit against the trim or ceiling as desired.
[0085]In other embodiments, the bottom mounting arm 18 is rigidly affixed to the central and bottom hubs 12, 20, and the central hub 12 slides along the upper arm 23 to expand or compress the mounting system 10. The adjustment magnet 70 provides sufficient pulling force against one or both mounting arms 14, 18 to allow the user to push or pull the electronic device upwardly or downwardly with respect to the top hub 16 to adjust the overall length of the mounting system 10, while also providing enough holding force to prevent the electronic device from moving downwardly under the force of gravity once installed. The adjustment magnet strength and/or encapsulation may be selected to provide the appropriate balance of movement and resistance based upon the weight of the electronic device attached to the mounting system 10. The encapsulation material, thickness, texture, etc. may also be selected (when encapsulation is provided with the adjustment magnet 70) to provide the balance of movement and resistance, as well.
[0086]Referring now to FIGS. 20-40, in various embodiments a mounting system is provided for use in securing an electronic device (e.g., any of the electronic devices discussed above, an LED light, such as a flat panel LED, including but not limited to an “edge-lit” LED panel, or any other electronic device), to a light fixture, such as an incandescent recessed light fixture. As used in the industry and herein, a recessed light fixture is also referred to as a “can light fixture.” As depicted in FIGS. 20-40, the mounting system 110 generally includes a barrel 112, a mounting sleeve 114, a locking ring 116, a top cap 118, and an upwardly projecting male light bulb socket 120. The male light bulb socket 120 is affixed to, or secured by, the top cap 118. The mounting system 110 is generally sized to fit within the diameter and circumference of can light fixtures. The male lightbulb socket 120 may have electrical connection wires, not shown, extending downwardly therefrom, for connection to electronics, such as an LED driver or LED panel, or other electronics. These electrical connection wires pass through the barrel 112. In one embodiment, the electronics (e.g., LED driver) is located within the barrel 112, and additional electrical connection wires pass from the electronics down through the mounting sleeve 114 and into another electronic device (e.g., an LED panel light). In another embodiment, in which the LED driver is located on the LED panel, the electrical connection wires may pass through the mounting sleeve 114 for connection outside of the mounting system 110. In one embodiment, in which the LED driver is located on the LED panel, and the LED panel has a standard male light bulb socket already in place (not shown) the electrical connection wires are connected directly between the male light bulb socket 120 and a female light bulb socket 122 (see FIGS. 22-23) that is rigidly affixed inside of the bottom portion of the mounting sleeve 114. Although the following discussion describes the electronic device as an LED panel light, the following embodiments may be applied to any electronic device, including any electronic device described above with respect to FIGS. 1-19.
[0087]The mounting sleeve 114 fits within the barrel 112 and is moveable between an extended position as show in FIG. 20 and a compressed position as shown in FIG. 21. In one embodiment, the mounting sleeve 114 may be set to a plurality of intermediate positions between the fully extended and fully compressed positions shown in FIGS. 20 and 21. As described further below, the locking ring 116 is removable. When in place, the locking ring 116 engages both the barrel 112 and the mounting sleeve 114. As described further below, the locking ring uses a ratchet and pawl type structure that allows the mounting sleeve to be moved upwardly, toward the compressed position, but prevents the mounting sleeve from moving downwardly toward the extended position. This one-way adjustability of the length of the mounting system allows it to be easily used in can light fixtures of various lengths, as the bottom of the mounting sleeve 114 may be quickly and easily attached to an LED panel light, and then, when the mounting system 110 has been secured to the can light fixture, the mounting sleeve 114 may be moved upwardly using its one-way adjustability to secure the LED panel light tightly against the bottom of the can light fixture and the surrounding ceiling structure.
[0088]In use, the mounting system 110 is attached to an incandescent can light fixture by screwing the male light bulb socket 120 into a female light bulb socket of the incandescent can light fixture (not shown). The mounting system 110 is attached to an LED panel at the bottom of the mounting sleeve 114. In one embodiment, a female light bulb socket 122 is rigidly affixed inside the mounting sleeve 114. An LED panel light (not shown) that has an upwardly projecting male light bulb socket can be simply screwed into the female light bulb socket 122.
[0089]Alternatively, the bottom edge of the mounting sleeve 114 can be secured to an LED panel light by screws, a mounting bracket, glue, or other readily understood fastening means.
[0090]FIGS. 22-37 show an embodiment of the mounting system 110 in further detail, both in assembled and disassembled views. In the embodiment shown, the barrel 112, mounting sleeve 114 and locking ring 116 interact to enable the mounting system 110 to hold very heavy loads, likely up to 120 pounds, but still allow the mounting sleeve, and any LED panel or other component attached to it, to be adjusted upwardly, using the one-way adjustability feature resulting from the structure described further as follows.
[0091]The barrel 112 is generally hollow. The inside diameter of the barrel 112 includes two opposed shoulders 124, 126, on the left and right sides of the barrel 112, thus forming two opposed interior grooves 128, 130 on the back and front insides of the barrel 112. The inside diameter of the barrel 112 also includes a projecting stop 132. The barrel 112 also has an engagement window 134 on the front side of the barrel 112. The engagement window 134 is centered on a locking groove 136, which is formed into a locking bulge 138, on the outer face of the barrel 112. The barrel 112 also has an orientation tab 140 projecting outwardly from the top of the locking bulge 138. The barrel 112 also has a plurality of, and in some embodiments, three, top cap orientation tabs 142, 144, 146.
[0092]The mounting sleeve 114 is generally hollow. The mounting sleeve 114 has a top 148 and bottom 150. Near the bottom 150 of the mounting sleeve 114, a female light bulb socket 122 is affixed into the interior diameter of the mounting sleeve 114. The female light bulb socket 122 may be affixed by generally known means, such as glue or press-mounting. In one embodiment, the interior diameter of the bottom of the mounting sleeve 114 has a lip or flange that engages the edge of the female light bulb socket 122 to hold the female light bulb socket 122 in place and prevent it from moving downwardly. The back side of the mounting sleeve 114 has two lands 152, 154, running the full length of the mounting sleeve 114. These lands 152, 154 are split by a slot 156 running from the bottom 150 of the mounting sleeve 114 most of the way to the top 148 of the sleeve. However, a horizontal top land 158 is present at the top 148 of the mounting sleeve 114, cutting off the slot 156. The front of the mounting sleeve 114 has a front land 160 running the full length of the mounting sleeve 114. The front land 160 has, indented into it, a plurality of laddered ratchet teeth 162. Each of the laddered ratchet teeth 162 is angled at approximately 45 degrees with respect to the length of the mounting sleeve 114. Further, each of the laddered ratchet teeth has a top face 164 and a bottom face 166. The top face 164 of each of the laddered ratchet teeth 162 is angled inwardly and upwardly toward the top 148 of the mounting sleeve 114 at approximately 45 degrees. The bottom face 166 of each of the laddered ratchet teeth 162 is angled inwardly, but not downwardly, making the bottom face 166 of each of the laddered ratchet teeth 162 perpendicular to the plane of the front land 160.
[0093]This configuration of the laddered ratchet teeth 162 on the front land 160 is illustrated throughout the drawings, but with particular detail in FIGS. 24 and 26.
[0094]As illustrated throughout the drawings, but most particularly in FIGS. 32-33, the locking ring 116 comprises a semi-circular ring that has a radius of curvature of approximately the same radius of curvature as the locking bulge 138 of the barrel 112. In the embodiment shown, the locking ring 116 has a circumference of three-quarters of the circumference of locking bulge 138 of the barrel 112. The remaining one-quarter circumference of the locking ring 116 is left open, to enable the locking ring 116 to be locked onto, and removed from, the locking bulge 138. As explained further below, while this one-quarter to three-quarters ratio is, in one embodiment, the locking ring 116 may be either a more complete semi-circle, or a little as slightly over half a circle. The locking ring 116 has a rounded land 168 projecting outwardly from and encircling most of the inner diameter of the locking ring 116. In one embodiment, the inside diameter of the locking ring 116 is sloped inwardly on the top and bottom sides 170, 172 of the rounded land 168. The locking ring also has an engagement block 174 projecting inwardly from the inside diameter. The engagement block 174 is approximately the same shape and size as the engagement window 134 of the barrel 112. The engagement block 174 further comprises a plurality of engagement teeth 176 projecting inwardly from the inside face 178 of the engagement block 174. The engagement teeth 176 each have a top face 178 and a bottom face 180. The bottom face 180 of each of the engagement teeth 176 is angled inwardly and downwardly toward the bottom 182 of the engagement block 174 at approximately 45 degrees. The top face 178 of each of the engagement teeth 176 is angled inwardly, but not downwardly, making the top face 178 of each of the engagement teeth 176 perpendicular to the plane of the inside face 178 of the engagement block 174. Above the engagement block 174, the locking ring 116 has an orientation cut-out 184. The locking ring 116 also has, at each end, a gripping tab 186. Each gripping tab 186 has a tie-off cut-out 190, 192 at the same relative height, respectively.
[0095]As illustrated throughout the drawings, but most particularly in FIGS. 20, 22, 36, and 37, the top cap 118 is configured to fit over the top of the barrel 112 and secure the male light bulb socket 120 in place. The top cap 118 has an inside diameter that is slightly greater than the outside diameter of the barrel 112, so that the top cap 118 can fit over and be secured to the outside of the barrel 112. The top cap 118 has a plurality, and in one embodiment, three, orientation slots 196, 198, 200. Each top cap orientation slot 196, 198, 200 is sized and placed to accommodate a top cap orientation tab 142, 144, 146 of the barrel 112. The interaction of the top cap orientation tabs 142, 144, 146 and slots 196, 198, 200, when engaged with one another, prevents rotation of the top cap 118, and therefore prevents rotation of the male light bulb socket 120, when the mounting system 110 is in use. As explained further below, the interaction of the top cap orientation tabs 142, 144, 146 and slots 196, 198, 200 also serves to aid assembly of the mounting system 110 by properly positioning the top cap 118. It will be appreciated that other structures and techniques may be used to secure the male light bulb socket 120 in place with respect to the barrel, including crimping machines, glue, screws or pins. The top cap 118 also has, at its inside diameter, a front orientation tab 208.
[0096]As illustrated throughout the drawings, but most particularly in FIGS. 22, 34, and 35, the support ring 210 serves the function of holding the male light bulb socket 120 in the barrel 112 and preventing it from moving downwardly in the barrel 112. The support ring 210 has an outside diameter that is slightly smaller than the inside diameter of the barrel 112. When the mounting system 110 is assembled, the support ring 210 contacts and rests on the two opposed shoulders 124, 126 of the inside diameter of the barrel 112. As such, the support ring 210 cannot move downward into the barrel 112. The bottom end of the male light bulb socket 120, when placed against the top of the support ring, will likewise not be able to move downward into the barrel 112. The support ring 210 also has an inset orientation shelf 212 on the front of the support ring 210.
[0097]When the mounting system 110 is assembled for use, the mounting sleeve 114 is movably positioned inside the barrel 112. In assembly, the mounting sleeve 114 should be inserted into the top of the barrel 112. The mounting sleeve 114 is oriented inside the barrel 112 so that the two lands 152, 154 and slot 156 on the back of the mounting sleeve 114 are aligned with the back interior groove 128 of the barrel 112. The projecting stop 132 of the barrel 112 fits within the slot 156 of the mounting sleeve 114. Also with this orientation, the front land 160 of the mounting sleeve 114 is aligned with the front interior groove 130 of the barrel. This alignment further positions the laddered ratchet teeth 162 toward the engagement window 134. When free, the mounting sleeve 114 can slide downwardly in the barrel 112 until the top horizontal land 158 of the mounting sleeve 114 contacts the projecting stop 132 of the barrel 112. The top horizontal land 158, in contact with the projecting stop 132 of the barrel 112, also serves as a fail-safe to prevent the mounting sleeve 114 from failing out of the bottom of the barrel, in the event that the laddered ratchet teeth 162 or engagement teeth 176 fail. It will be noted that, due to the configuration of the lands 152, 154, slot 156 and front land 160 of the mounting sleeve 114, and the interior grooves 128, 130 and projecting stop 132 of the barrel 112, the mounting sleeve 114 cannot be inserted incorrectly into the barrel 112. For example, if an assembler should try to insert the mounting sleeve 114 upside down, the horizontal top land 158 will not pass the projecting stop 132. Likewise, if an assembler should try to insert the mounting sleeve 114 backwards, the front land 160, with its laddered ratchet teeth 162, will also not pass the projecting stop 1