CA2029758A1 - Fluorescent pot light retrofit unit and method of making same - Google Patents
Fluorescent pot light retrofit unit and method of making sameInfo
- Publication number
- CA2029758A1 CA2029758A1 CA 2029758 CA2029758A CA2029758A1 CA 2029758 A1 CA2029758 A1 CA 2029758A1 CA 2029758 CA2029758 CA 2029758 CA 2029758 A CA2029758 A CA 2029758A CA 2029758 A1 CA2029758 A1 CA 2029758A1
- Authority
- CA
- Canada
- Prior art keywords
- unit
- lighting
- lighting system
- reflector unit
- fluorescent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000004519 manufacturing process Methods 0.000 title description 5
- 238000012986 modification Methods 0.000 claims abstract description 6
- 230000004048 modification Effects 0.000 claims abstract description 6
- 239000004593 Epoxy Substances 0.000 claims description 7
- 230000017525 heat dissipation Effects 0.000 claims description 5
- 239000007787 solid Substances 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 2
- 230000002459 sustained effect Effects 0.000 claims 1
- 238000009434 installation Methods 0.000 abstract description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 11
- 229910052782 aluminium Inorganic materials 0.000 description 9
- 239000011521 glass Substances 0.000 description 7
- 239000000463 material Substances 0.000 description 5
- 150000001875 compounds Chemical class 0.000 description 4
- 238000005538 encapsulation Methods 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 238000002310 reflectometry Methods 0.000 description 4
- 238000005286 illumination Methods 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- 230000001351 cycling effect Effects 0.000 description 2
- 238000009429 electrical wiring Methods 0.000 description 2
- 238000005265 energy consumption Methods 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 239000002932 luster Substances 0.000 description 2
- 230000002035 prolonged effect Effects 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 239000003599 detergent Substances 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000004922 lacquer Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000001465 metallisation Methods 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
Landscapes
- Non-Portable Lighting Devices Or Systems Thereof (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A fluorescent lighting system for use in commercial or residential recessed lighting applications as either a retrofit unit or as a unit of choice in new lighting applications. This lighting system is primarily designed for installation into standard recessed or pot light style lighting fixtures without requiring any modification to the lighting fixture, while providing equivalent light intensity to standard incandescent lighting units, and while consuming substantially less energy during operation. This lighting system also provides means for bulb replacement without requiring the entire lighting unit be replaced, as is the case with standard sealed incandescent lighting units typically employed in these or similar applications.
A fluorescent lighting system for use in commercial or residential recessed lighting applications as either a retrofit unit or as a unit of choice in new lighting applications. This lighting system is primarily designed for installation into standard recessed or pot light style lighting fixtures without requiring any modification to the lighting fixture, while providing equivalent light intensity to standard incandescent lighting units, and while consuming substantially less energy during operation. This lighting system also provides means for bulb replacement without requiring the entire lighting unit be replaced, as is the case with standard sealed incandescent lighting units typically employed in these or similar applications.
Description
' ` . .
Title: FLUORESCENT POT LIGHT RETROFIT UNIT AND METHOD
OF MAKING SAME
Inventor: Myroslav Mocherniak Assignee: Faplex Industries Inc.
BACKGROUND OF THE INVENTION
Field of the invention This invention relates to residential and commercial lighting fixtures, and in particular relates to fluorescent lighting units which are designed to replace standard incandescent ~:
bulbs employed in recessed lighting applications.
Description of the Prior Art Recessed lighting has become an increasingly common 15 element in both residential and commercial lighting applications `
over the past several years. In particular the use of the "pot light" type of recessed lighting fixture has increased . . .
dramatically.
Several factors have contributed to the increased use of these~types of fixtures, including relative ease of installation and maintenance and the fact that they are comparatively inexpensive to manufacture.
These types of fixtures typically employ sealed reflector and lens units in which an incandescent bulb is provided, and where .
" 2029758 the entire lighting unit is adapted to be threadedly received into the ceiling-mounted pot light fixture.
The use of incandescent bulbs in sealed reflector and lens units requires the disposal of the entire lighting unit and 5 replacement with a new unit upon failure or breakage of the incandescent bulb.
It would therefore be desirable to have a lighting unit that could be utilized in conjunction with a pot light fixture that provided illumination by means of a replaceable fluorescent bulb. This 10 would provide the advantages known to fluorescent illumination, namely, reduced energy consumption and prolonged bulb life, while retaining the above described advantages associated with the usage of pot light style recessed lighting fixtures.
It is an object of the invention to provide a fluorescent lighting unit suitable for use in replacing the incandescent lighting units typically employed in recessed lighting applications.
It is a further object of the present invention to provide 20 a replacement lighting unit which may be fitted into a standard recessed lighting fixture without requiring any modification.
It is still a further object of the present invention to provide a fluorescent replacement lighting unit for use in recessed lighting applications which develops at least an equivalent amount of 25 light intensity as provided by standard incandescent lighting units, -` 2029758 while providing significantly reduced energy consumption characteristics.
It is still a further object of the present invention to provide such a lighting unit that is not a sealed unit thereby permitting the replacement of burnt out bulbs without necessitating the replacement of the entire lighting unit.
It is still a further object of the present invention to provide such a lighting unit having excellent reflective and diffractive characteristics and adequate means of heat dissipation.
10 Thus, in accordance with the present invention, there is provided a fluorescent lighting unit to be used in recessed lighting applications, as either a replacement for incandescent units or as the lighting unit of choice in new installation applications, such lighting unit comprising three main components, namely: an adapter, a reflector, and a fluorescent bulb.
The adapter is for~ed by joining an incandescent light socket to a ballast transformer and then to a fluorescent light socket. These three components are selected so as to result in an appropriately dimensioned adapter unit capable of fitting into the receptacle of a standard pot light fixture. The three components are then partially encapsulated in an epoxy based compound for structural rigidity and to provide a substructure on which to form threads to allow the adapter to be threadedly joined to the reflector.
The reflector is fabricated of spun aluminum and shaped and dimensioned so as to provide maximum reflectivity and optimum '' ' ' '; ~r ~ . . . ' . . ' ;
- ~ 20297~
diffractive characteristics. It is also coated with aluminum powder to further increase reflectivity. vents are provided for heat dissipation purposes. Threads are formed on one end of the reflector, which threads reciprocate with the threads formed on the outside diameter of the adapter thus providing for a secure mechanical connection that permits disassembly when bulb replacement is necessitated. A glass lens covers the larger diameter end of the reflector.
A miniature fluorescent bulb is employed as the means of providing illumination.
Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF_THE DRAWINGS
In order that the invention may be more clearly understood, the preferred embodiment thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:
; Fig. 1 is an exploded perspective view of the three components of the fluorescent lighting unit.
Fig. 2 is is a side cross-sectional view taken about the line AA of Figure 1.
DETAILED DESCRIPTION OF THE PREFERRED_EMBODIMENT
'',,.''' ,'"' ':~,''''''','''" ".'.'',.''''''' ; ' -` 2029758 ~
Referring to Fig. 1, there is shown a perspective view of the reflector unit 1, the adapter unit 2, and a miniature fluorescent bulb 3.
The reflector unit 1 is generally described as having two parts: a generally cone shaped body section 4, and a generally tube shaped neck section 5, being continuous with and extending from the narrower end of the body section 4.
Appropriately dimensioned vent holes 6 are incorporated into the neck 5 of the reflector unit 1 at a point near the juncture of the neck 5 and the body 4 of the reflector unit l. The number, size and exact positioning of these vent holes is variable and is dependant on several factors including the wattage of bulb employed and hence the varying resultant amount of heat generated. Ease of manufacturing and local regulatory restrictions also have to be taken into account.
In the described embodiment of the present invention four identical vent holes 6 are provided being equally spaced around the neck 5 of the reflector unit l. Said vent holes 6 are generally rectangular in shape and are positioned longitudinally on the neck 5, each being positioned approximately 1-10 mm from the juncture of the neck 5 and the body 4 of the reflector unit 1 and each having the approximate dimensions of 2-7mm in width and 10-30 mm in length.
Edison threads 7 are provided on the end of the neck portion 5 of the reflector unit 1 distal to the body portion 4. These threads 7 reciprocate with Edison threads 8 which are formed on the outside diameter of the adapter unit 2, and which reciprocating threads -~ 2~g~$~
together provide a non-permanent means of joining the reflector l and the adapter 2, which means permits separation of said components to facilitate bulb 3 replacement when required.
A diffusing means is incorporated into the larger diameter end of the body section 4 of the reflector unit 1. In the described embodiment of the present invention the diffusing means is provided by means of a known, commercially available glass lens 9, such as General Electric Par 30 or 38 type glass. A retaining lip 10 is provided on the edge of the larger diameter end of the body section 4, which retaining lip 10 provides a means to physically secure the glass lens 9 into place.
The reflector unit 1 is fabricated from commercial grade aluminum base plate, typically being provided in thicknesses of approximately 0.020-0.040 inches. The base aluminium is first mechanically spun to obtain the overall shape of the reflector unit 1. The vent holes 6 are then mechanically punched through the aluminum and the Edison threads 7 and the retaining lip lO are then mechanically rolled into place.
The base aluminum substrate is then chemically treated and washed with a solution of standard cleansing agents. Two coats of base lacquer are then applied to the surface of the aluminum substrate to improve the adhesion characteristics of the substrate and to improve d the luster, glossiness and reflectivity of the material. The aluminum reflector unit l is then placed into a vacuum chamber and covered with aluminum powder. This vacuum metallization process improves the 20297~8 reflective properties of the aluminum and eliminates the need to polish the aluminum to a high luster to obtain the high degree of reflectivity required.
The shaped, treated and coated reflector unit 1 is then returned to the mechanical spinning apparatus and the glass lens 9 is then rolled into the open end of the body 4 of the reflector unit 1 with a nylon roller which presses the retaining lip 10 over the edge of the glass lens 9 so as to form a permanent physical connection between the reflector unit 1 and the glass lens 9.
The size and shape of the reflector unit 1 is determined by empirical testing and varies with the different physical dimensions and output wattages of commercially available, standard miniature fluorescent bulbs.
Two preferred embodiments of the reflector unit 1 of the present invention are described, together which are capable for use with standard miniature fluorescent bulbs of either 7, 9 or 13 watts.
The larger reflector unit 1, which is suitable for use with the 13 watt fluorescent bulbs, has an outside diameter of approximately 4 3/4 inches at the wider end of the body section 4, and is consistently tapered throughout the body section 4 to a diameter of approximately 1-7/8 inches at the juncture of the body ~: section 4 and the neck section 5. A slight outward curvature is incorporated into the tapered body section 4 of the larger reflector unit 1. The diameter of the reflector unit 1 throughout the neck section 5 remains at approximately 1-7/B inches. The overall length 20297~8 of the larger reflector unit 1 is approximately 6 inches, and once the adapter unit is attached and the entire lighting unit is complete the overall length is approximately 8 1/4 inches.
The smaller reflector unit 1 has an outside diameter of approximately 3-7/8 inches at the wider end of the body section 4 is consistently tapered throughout the body section 4 to a diameter of approximately 1-7/8 inches at the juncture of the body section 4 and the neck section 5. Little or no curvature is incorporated into the tapered body section 4 of the smaller reflector unit 1. The diameter of the reflector unit 1 remains at approximately 1-7/8 inches throughout the length of the neck section 5. The overall length of the smaller reflector unit 1 is approximately 5-1/4 inches, and the overall length of the entire lighting unit employing the smaller reflector unit 1 is approximately 7 inches.
The adapter unit 2 is comprised of three components: a standard medium base incandescent light socket 11, a standard miniature open core and coil ballast transformer 12, and a standard miniature polycarbonate fluorescent light socket 13.
These three components are physically connected by electrical wiring 14 which is soldered using a high heat solder and a non-acidic soldering paste. The incandescent and fluorescent light sockets 11 and 13 are slightly modified to accept the ballast transformer 12 more readily and to provide some physical interlocking between these three components. Specifically, grooves of appropriate width and depth are cut into the plastic on the non-contacting end of : ':
.' ' ; ", ,' ~' ' ' " ;" ' ", . ' ""' : .; ' ' '' '" ' ' '- ` ~' , '. " ` . ' . ' ' --` 2~297~
the incandescent light socket 11 into which the edge of the ballast transformer 12 is set. The fluorescent light socket 13 is modified by partially or completely removing the shoulder of the non-contacting end of the socket, again to permit the edge of the ballast transformer 12 to be set in against the fluorescent light socket 13. The type and degree of modification to these components will vary with the physical configurations of the particular standard components employed.
Once these modifications are complete and the connecting electrical wires are soldered, the three components are partially encapsulated with a high-heat, fast-setting epoxy compound.
The combined incandescent light socket 11, the ballast transformer 12, and the fluorescent light socket 13 are encapsulated so that the ballast transformer 12 is completely enclosed as are all of the electrical connections between the ballast transformer 12 and the adjacent light sockets. As a result the length of the formed epoxy structure will vary and is primarily dependent on the dimensions of the particular ballast transformer 12 employed. The diameter of the formed epoxy structure is determined again primarily by the dimensions of the ballast transformer 12. The ballast transformer 12 should generally be chosen so that it can be totally encapsulated by a structure having an outside diameter of no more than 2 inches.
An maximum outside diameter for the entire assembled lighting unit of 2 inches or less is typically necessary in order to permit the entire lighting unit to be retro-fitted into a standard - 2029~S8 recessed, pot light fixture without requiring any modification to the fixture.
In the preferred embodiment of the present invention the material used for encapsulating the sockets and transformer is a high heat, fast setting epoxy compound, which is formed in a solid mass around the relevant components as described. Any material however that offers excellent heat dissipation properties, electrical insulative properties, high impact resistance and resistance to deterioration from temperature cycling, ie. repeated heating and cooling, may be employed.
It is also possible to encapsulate the components in a shell like structure as opposed to a solid mass, if the resultant shell like structure can offer a satisfactory level of performance in relation to the above described characteristics. Injection molded ABS shell like structures, which are less expensive to manufacture, were found to be subject to some degradation and weakening due to the temperature cycling which eventually imparted a brittleness to the material, and which occasionally resulted in failure of the encapsulation structure.
Solid mass encapsulation seems preferable and also imparts an increased rigidity and additional structural strength to the adapter unit 2, as well as offering physical protection to the electrical components and electrical wiring connections.
Any suitable epoxy compound may be employed in the encapsulation process. The essential characteristic of the resultant solid mass is that it be able to withstand prolonged exposure to the 20297~8 temperatures typically generated in the enclosed pot light fixture environment. Performance criteria of appropriate standards writing organizations or regulatory bodies may also have to be satisfied.
Fillers and catalysts will be typically employed to reduce the cost of the materials employed in the process, as well as to reduce setting times.
The mold for the encapsulation process is formed so as to provide for Edison threads 8 on the outside diameter of the adapter unit 2. These threads reciprocate with the Edison threads 7 on the end of the neck section 5 of the reflector unit 1. The Edison threads 8 on the outside of the adapter unit 2 are positioned so as to permit only a predetermined amount of the fluorescent bulb 3 to project into the body section 4 of the reflector unit 1. The optimum depth to which the fluorescent bulb 3 should be inserted into the reflector unit 1 is a function of the characteristic light output of the functioning lighting unit, and is determined by observing maximum lumen output and diffraction pattern characteristics at varying degrees of bulb projectlon into the reflector unit 1. Once the optimum depth is determined a stop ring means is provided in the Edison threads 8 at the appropriate position so as to ensure accurate depth alignment between the bulb 3 and the reflector unit 1. This stop ring means also prevents possible damage to the threads 7 or 8 caused by overscrewing or overtighteninq between the reflector unit 1 and the adapter unit 2, and also prevents bulb breakage from overturning the adapter unit 2 into the reflector unit 1 and causing the bulb to break from ~ 11 ~, . . , . ,, .. ~ . . .. . . . .... . .. . .
-20297~8 pressure resulting from contacting the inner surface of the diffusing means 10.
The entire lighting unit is assembled by inserting a standard miniature fluorescent bulb 3 into the fluorescent light socket 13 provided on the adapter unit 2. The combined adapter unit 2 and bulb 3 are then inserted into the open neck section 5 of the reflector unit 1 being mechanically joined in a non-permanent manner ~
by the reciprocating Edison threads 7 and 8, and having correct depth .
alignment being provided by the stop ring means. : - .
It will be appreciated that the above description related to the preferred embodiment by way of example only. Many variations on the invention will be obvious to those knowledgeable in the field, -~
and such obvious variations are within the scope of the invention as described and claimed, whether or not expressly described.
i~
.
' ' .
.:
. .
.
~: .
Title: FLUORESCENT POT LIGHT RETROFIT UNIT AND METHOD
OF MAKING SAME
Inventor: Myroslav Mocherniak Assignee: Faplex Industries Inc.
BACKGROUND OF THE INVENTION
Field of the invention This invention relates to residential and commercial lighting fixtures, and in particular relates to fluorescent lighting units which are designed to replace standard incandescent ~:
bulbs employed in recessed lighting applications.
Description of the Prior Art Recessed lighting has become an increasingly common 15 element in both residential and commercial lighting applications `
over the past several years. In particular the use of the "pot light" type of recessed lighting fixture has increased . . .
dramatically.
Several factors have contributed to the increased use of these~types of fixtures, including relative ease of installation and maintenance and the fact that they are comparatively inexpensive to manufacture.
These types of fixtures typically employ sealed reflector and lens units in which an incandescent bulb is provided, and where .
" 2029758 the entire lighting unit is adapted to be threadedly received into the ceiling-mounted pot light fixture.
The use of incandescent bulbs in sealed reflector and lens units requires the disposal of the entire lighting unit and 5 replacement with a new unit upon failure or breakage of the incandescent bulb.
It would therefore be desirable to have a lighting unit that could be utilized in conjunction with a pot light fixture that provided illumination by means of a replaceable fluorescent bulb. This 10 would provide the advantages known to fluorescent illumination, namely, reduced energy consumption and prolonged bulb life, while retaining the above described advantages associated with the usage of pot light style recessed lighting fixtures.
It is an object of the invention to provide a fluorescent lighting unit suitable for use in replacing the incandescent lighting units typically employed in recessed lighting applications.
It is a further object of the present invention to provide 20 a replacement lighting unit which may be fitted into a standard recessed lighting fixture without requiring any modification.
It is still a further object of the present invention to provide a fluorescent replacement lighting unit for use in recessed lighting applications which develops at least an equivalent amount of 25 light intensity as provided by standard incandescent lighting units, -` 2029758 while providing significantly reduced energy consumption characteristics.
It is still a further object of the present invention to provide such a lighting unit that is not a sealed unit thereby permitting the replacement of burnt out bulbs without necessitating the replacement of the entire lighting unit.
It is still a further object of the present invention to provide such a lighting unit having excellent reflective and diffractive characteristics and adequate means of heat dissipation.
10 Thus, in accordance with the present invention, there is provided a fluorescent lighting unit to be used in recessed lighting applications, as either a replacement for incandescent units or as the lighting unit of choice in new installation applications, such lighting unit comprising three main components, namely: an adapter, a reflector, and a fluorescent bulb.
The adapter is for~ed by joining an incandescent light socket to a ballast transformer and then to a fluorescent light socket. These three components are selected so as to result in an appropriately dimensioned adapter unit capable of fitting into the receptacle of a standard pot light fixture. The three components are then partially encapsulated in an epoxy based compound for structural rigidity and to provide a substructure on which to form threads to allow the adapter to be threadedly joined to the reflector.
The reflector is fabricated of spun aluminum and shaped and dimensioned so as to provide maximum reflectivity and optimum '' ' ' '; ~r ~ . . . ' . . ' ;
- ~ 20297~
diffractive characteristics. It is also coated with aluminum powder to further increase reflectivity. vents are provided for heat dissipation purposes. Threads are formed on one end of the reflector, which threads reciprocate with the threads formed on the outside diameter of the adapter thus providing for a secure mechanical connection that permits disassembly when bulb replacement is necessitated. A glass lens covers the larger diameter end of the reflector.
A miniature fluorescent bulb is employed as the means of providing illumination.
Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF_THE DRAWINGS
In order that the invention may be more clearly understood, the preferred embodiment thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:
; Fig. 1 is an exploded perspective view of the three components of the fluorescent lighting unit.
Fig. 2 is is a side cross-sectional view taken about the line AA of Figure 1.
DETAILED DESCRIPTION OF THE PREFERRED_EMBODIMENT
'',,.''' ,'"' ':~,''''''','''" ".'.'',.''''''' ; ' -` 2029758 ~
Referring to Fig. 1, there is shown a perspective view of the reflector unit 1, the adapter unit 2, and a miniature fluorescent bulb 3.
The reflector unit 1 is generally described as having two parts: a generally cone shaped body section 4, and a generally tube shaped neck section 5, being continuous with and extending from the narrower end of the body section 4.
Appropriately dimensioned vent holes 6 are incorporated into the neck 5 of the reflector unit 1 at a point near the juncture of the neck 5 and the body 4 of the reflector unit l. The number, size and exact positioning of these vent holes is variable and is dependant on several factors including the wattage of bulb employed and hence the varying resultant amount of heat generated. Ease of manufacturing and local regulatory restrictions also have to be taken into account.
In the described embodiment of the present invention four identical vent holes 6 are provided being equally spaced around the neck 5 of the reflector unit l. Said vent holes 6 are generally rectangular in shape and are positioned longitudinally on the neck 5, each being positioned approximately 1-10 mm from the juncture of the neck 5 and the body 4 of the reflector unit 1 and each having the approximate dimensions of 2-7mm in width and 10-30 mm in length.
Edison threads 7 are provided on the end of the neck portion 5 of the reflector unit 1 distal to the body portion 4. These threads 7 reciprocate with Edison threads 8 which are formed on the outside diameter of the adapter unit 2, and which reciprocating threads -~ 2~g~$~
together provide a non-permanent means of joining the reflector l and the adapter 2, which means permits separation of said components to facilitate bulb 3 replacement when required.
A diffusing means is incorporated into the larger diameter end of the body section 4 of the reflector unit 1. In the described embodiment of the present invention the diffusing means is provided by means of a known, commercially available glass lens 9, such as General Electric Par 30 or 38 type glass. A retaining lip 10 is provided on the edge of the larger diameter end of the body section 4, which retaining lip 10 provides a means to physically secure the glass lens 9 into place.
The reflector unit 1 is fabricated from commercial grade aluminum base plate, typically being provided in thicknesses of approximately 0.020-0.040 inches. The base aluminium is first mechanically spun to obtain the overall shape of the reflector unit 1. The vent holes 6 are then mechanically punched through the aluminum and the Edison threads 7 and the retaining lip lO are then mechanically rolled into place.
The base aluminum substrate is then chemically treated and washed with a solution of standard cleansing agents. Two coats of base lacquer are then applied to the surface of the aluminum substrate to improve the adhesion characteristics of the substrate and to improve d the luster, glossiness and reflectivity of the material. The aluminum reflector unit l is then placed into a vacuum chamber and covered with aluminum powder. This vacuum metallization process improves the 20297~8 reflective properties of the aluminum and eliminates the need to polish the aluminum to a high luster to obtain the high degree of reflectivity required.
The shaped, treated and coated reflector unit 1 is then returned to the mechanical spinning apparatus and the glass lens 9 is then rolled into the open end of the body 4 of the reflector unit 1 with a nylon roller which presses the retaining lip 10 over the edge of the glass lens 9 so as to form a permanent physical connection between the reflector unit 1 and the glass lens 9.
The size and shape of the reflector unit 1 is determined by empirical testing and varies with the different physical dimensions and output wattages of commercially available, standard miniature fluorescent bulbs.
Two preferred embodiments of the reflector unit 1 of the present invention are described, together which are capable for use with standard miniature fluorescent bulbs of either 7, 9 or 13 watts.
The larger reflector unit 1, which is suitable for use with the 13 watt fluorescent bulbs, has an outside diameter of approximately 4 3/4 inches at the wider end of the body section 4, and is consistently tapered throughout the body section 4 to a diameter of approximately 1-7/8 inches at the juncture of the body ~: section 4 and the neck section 5. A slight outward curvature is incorporated into the tapered body section 4 of the larger reflector unit 1. The diameter of the reflector unit 1 throughout the neck section 5 remains at approximately 1-7/B inches. The overall length 20297~8 of the larger reflector unit 1 is approximately 6 inches, and once the adapter unit is attached and the entire lighting unit is complete the overall length is approximately 8 1/4 inches.
The smaller reflector unit 1 has an outside diameter of approximately 3-7/8 inches at the wider end of the body section 4 is consistently tapered throughout the body section 4 to a diameter of approximately 1-7/8 inches at the juncture of the body section 4 and the neck section 5. Little or no curvature is incorporated into the tapered body section 4 of the smaller reflector unit 1. The diameter of the reflector unit 1 remains at approximately 1-7/8 inches throughout the length of the neck section 5. The overall length of the smaller reflector unit 1 is approximately 5-1/4 inches, and the overall length of the entire lighting unit employing the smaller reflector unit 1 is approximately 7 inches.
The adapter unit 2 is comprised of three components: a standard medium base incandescent light socket 11, a standard miniature open core and coil ballast transformer 12, and a standard miniature polycarbonate fluorescent light socket 13.
These three components are physically connected by electrical wiring 14 which is soldered using a high heat solder and a non-acidic soldering paste. The incandescent and fluorescent light sockets 11 and 13 are slightly modified to accept the ballast transformer 12 more readily and to provide some physical interlocking between these three components. Specifically, grooves of appropriate width and depth are cut into the plastic on the non-contacting end of : ':
.' ' ; ", ,' ~' ' ' " ;" ' ", . ' ""' : .; ' ' '' '" ' ' '- ` ~' , '. " ` . ' . ' ' --` 2~297~
the incandescent light socket 11 into which the edge of the ballast transformer 12 is set. The fluorescent light socket 13 is modified by partially or completely removing the shoulder of the non-contacting end of the socket, again to permit the edge of the ballast transformer 12 to be set in against the fluorescent light socket 13. The type and degree of modification to these components will vary with the physical configurations of the particular standard components employed.
Once these modifications are complete and the connecting electrical wires are soldered, the three components are partially encapsulated with a high-heat, fast-setting epoxy compound.
The combined incandescent light socket 11, the ballast transformer 12, and the fluorescent light socket 13 are encapsulated so that the ballast transformer 12 is completely enclosed as are all of the electrical connections between the ballast transformer 12 and the adjacent light sockets. As a result the length of the formed epoxy structure will vary and is primarily dependent on the dimensions of the particular ballast transformer 12 employed. The diameter of the formed epoxy structure is determined again primarily by the dimensions of the ballast transformer 12. The ballast transformer 12 should generally be chosen so that it can be totally encapsulated by a structure having an outside diameter of no more than 2 inches.
An maximum outside diameter for the entire assembled lighting unit of 2 inches or less is typically necessary in order to permit the entire lighting unit to be retro-fitted into a standard - 2029~S8 recessed, pot light fixture without requiring any modification to the fixture.
In the preferred embodiment of the present invention the material used for encapsulating the sockets and transformer is a high heat, fast setting epoxy compound, which is formed in a solid mass around the relevant components as described. Any material however that offers excellent heat dissipation properties, electrical insulative properties, high impact resistance and resistance to deterioration from temperature cycling, ie. repeated heating and cooling, may be employed.
It is also possible to encapsulate the components in a shell like structure as opposed to a solid mass, if the resultant shell like structure can offer a satisfactory level of performance in relation to the above described characteristics. Injection molded ABS shell like structures, which are less expensive to manufacture, were found to be subject to some degradation and weakening due to the temperature cycling which eventually imparted a brittleness to the material, and which occasionally resulted in failure of the encapsulation structure.
Solid mass encapsulation seems preferable and also imparts an increased rigidity and additional structural strength to the adapter unit 2, as well as offering physical protection to the electrical components and electrical wiring connections.
Any suitable epoxy compound may be employed in the encapsulation process. The essential characteristic of the resultant solid mass is that it be able to withstand prolonged exposure to the 20297~8 temperatures typically generated in the enclosed pot light fixture environment. Performance criteria of appropriate standards writing organizations or regulatory bodies may also have to be satisfied.
Fillers and catalysts will be typically employed to reduce the cost of the materials employed in the process, as well as to reduce setting times.
The mold for the encapsulation process is formed so as to provide for Edison threads 8 on the outside diameter of the adapter unit 2. These threads reciprocate with the Edison threads 7 on the end of the neck section 5 of the reflector unit 1. The Edison threads 8 on the outside of the adapter unit 2 are positioned so as to permit only a predetermined amount of the fluorescent bulb 3 to project into the body section 4 of the reflector unit 1. The optimum depth to which the fluorescent bulb 3 should be inserted into the reflector unit 1 is a function of the characteristic light output of the functioning lighting unit, and is determined by observing maximum lumen output and diffraction pattern characteristics at varying degrees of bulb projectlon into the reflector unit 1. Once the optimum depth is determined a stop ring means is provided in the Edison threads 8 at the appropriate position so as to ensure accurate depth alignment between the bulb 3 and the reflector unit 1. This stop ring means also prevents possible damage to the threads 7 or 8 caused by overscrewing or overtighteninq between the reflector unit 1 and the adapter unit 2, and also prevents bulb breakage from overturning the adapter unit 2 into the reflector unit 1 and causing the bulb to break from ~ 11 ~, . . , . ,, .. ~ . . .. . . . .... . .. . .
-20297~8 pressure resulting from contacting the inner surface of the diffusing means 10.
The entire lighting unit is assembled by inserting a standard miniature fluorescent bulb 3 into the fluorescent light socket 13 provided on the adapter unit 2. The combined adapter unit 2 and bulb 3 are then inserted into the open neck section 5 of the reflector unit 1 being mechanically joined in a non-permanent manner ~
by the reciprocating Edison threads 7 and 8, and having correct depth .
alignment being provided by the stop ring means. : - .
It will be appreciated that the above description related to the preferred embodiment by way of example only. Many variations on the invention will be obvious to those knowledgeable in the field, -~
and such obvious variations are within the scope of the invention as described and claimed, whether or not expressly described.
i~
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.:
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Claims (8)
1. In combination, a fluorescent lighting system for use in recessed lighting applications, comprising:
(a) an open ended reflector unit incorporating a permanently affixed diffusing means;
(b) an adapter unit, having means of being threadedly received and non-permanently joined to the reflector unit, which adapter unit consists of a incandescent light socket, a miniature open core and coil ballast transformer, and a miniature fluorescent light socket, together being partially encapsulated in a solid mass of epoxy; and (c) a miniature fluorescent bulb.
(a) an open ended reflector unit incorporating a permanently affixed diffusing means;
(b) an adapter unit, having means of being threadedly received and non-permanently joined to the reflector unit, which adapter unit consists of a incandescent light socket, a miniature open core and coil ballast transformer, and a miniature fluorescent light socket, together being partially encapsulated in a solid mass of epoxy; and (c) a miniature fluorescent bulb.
2. A lighting system as claimed in claim 1, wherein said lighting system is provided such that it can be retro-fitted into a standard recessed lighting fixture without the requirement of modification to the recessed lighting fixture.
3. The lighting system of claim 1, said lighting system including appropriate heat dissipation means for cooling purposes.
4. The lighting system of claim 1, wherein said heat dissipation means is vent holes provided in the reflector unit.
5. An adapter unit of claim 1, such adapter unit being capable of sustained operation at temperatures in excess of 115 degrees Celsius.
6. The lighting system of claim 1, wherein means for preventing overtightening or overscrewing of the adapter unit into the reflector unit are provided, such means also providing the means of correct depth and directional alignment of the bulb in the reflector unit.
7. The lighting system of claim 7, wherein the alignment means and means to prevent overtightening or overscrewing is a dead ring or stop ring incorporated into the Edison threads provided on the adapter unit.
8. The lighting system of claim 1, wherein the lighting system is provided in an overall length not exceeding 8 1/2 inches for the system employing the larger reflector unit, and an overall length not exceeding 7 1/2 inches for the system employing the smaller reflector unit.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2029758 CA2029758A1 (en) | 1990-11-13 | 1990-11-13 | Fluorescent pot light retrofit unit and method of making same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2029758 CA2029758A1 (en) | 1990-11-13 | 1990-11-13 | Fluorescent pot light retrofit unit and method of making same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2029758A1 true CA2029758A1 (en) | 1992-05-14 |
Family
ID=4146401
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2029758 Abandoned CA2029758A1 (en) | 1990-11-13 | 1990-11-13 | Fluorescent pot light retrofit unit and method of making same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2029758A1 (en) |
-
1990
- 1990-11-13 CA CA 2029758 patent/CA2029758A1/en not_active Abandoned
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| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |