[0001] The present disclosure relates generally to linear luminaires and more specifically to a linear luminaire including a light inset inserted in a channel.

BACKGROUND

[0002] Linear luminaires can be mounted directly to a ceiling or wall or can be supported on a pendant.

SUMMARY

[0003] A linear luminaire is provided that includes a linear channel defining an interior space and a linear light inset configured for being inserted into the channel in the interior space. The light inset includes a cover and a printed circuit board fixed to the cover. The printed circuit board supports a plurality of light emitting diodes. The cover base wall includes a translucent portion. The light emitting diodes are arranged for emitting light through the translucent portion. The cover includes two cover connectors, each configured for being snapped into the channel to hold the cover in the interior space. The cover connectors are on an opposite side of the printed circuit board as the translucent portion.

[0004] A linear luminaire is provided that includes a linear channel defining an interior space and a linear light inset configured for being inserted into the channel in the interior space. The light inset includes a cover and a printed circuit board fixed to the cover. The printed circuit board supports a plurality of light emitting diodes. The cover base wall includes a translucent portion. The light emitting diodes are arranged for emitting light through the translucent portion. The cover includes a first support section supporting the printed circuit board and a second support section configured for supporting a further printed circuit board. The second support section and the first support section are different distances from the translucent portion.

[0005] A linear luminaire is provided that includes a linear channel defining an interior space and a linear light inset configured for being inserted into the channel in the interior space. The light inset includes a cover and a printed circuit board fixed to the cover. The printed circuit board supports a plurality of light emitting diodes. The cover base wall includes a translucent portion. The light emitting diodes are arranged for emitting light through the translucent portion. The cover includes two cover connectors each configured for being connected to the channel to hold the cover in the interior space. The linear luminaire further includes a fall down protection fastener fixed to printed circuit board and configured for being fixed to the channel base wall to prevent the cover and printed circuit board from being disconnected from the channel upon failure of a connection of the cover connectors to the channel.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present invention is described below by reference to the following drawings, in which:

[0007] Fig. la shows a cross-sectional longitudinally facing view of a linear luminaire configured to be mounted directly to a ceiling or wall or can be supported on a pendant;

[0008] Fig. lb shows an enlarged view of a portion of Fig. la illustrating the connectors;

[0009] Fig. 2 shows an exploded view of the linear luminaire shown in Figs, la and lb;

[0010] Fig. 3 shows a perspective view of a longitudinal end of the linear luminaire shown in Figs, la to 2;

[0011] Figs. 4a and 4b respectively show a downward facing and an upward facing perspective view of the linear luminaire shown in Figs, la to 3;

[0012] Fig. 5 shows a side exploded view of a portion of the linear luminaire shown in Figs, la to 4b; and

[0013] Fig. 6 shows a cross-sectional lateral facing view of the luminaire shown in Figs, la to 5, illustrating a longitudinal overlap two printed circuit boards.

DETAILED DESCRIPTION [0014] Fig. la shows a cross-sectional longitudinally facing view of a linear luminaire 10 configured to be mounted directly to a ceiling or wall, recessed in a ceiling or wall or can be supported on a pendant, and Fig. 2 shows an exploded view of linear luminaire 10. Terms used herein, including vertically, horizontally, higher, lower, above and below, unless otherwise stated, are used in reference to the orientation present when the luminaire 10 is mounted to the ceiling as an overhead light, or in the ceiling as a recessed light. Luminaire 10 includes a linear channel 12 and a linear light inset 14. Linear channel 12 includes a channel base wall 16 and two channel side walls 18, 20 extending away from base wall 16. When luminaire 10 is mounted to the ceiling as an overhead light, channel base wall 16 constitutes the top of the luminaire 10. Channel 12 may be formed by a single piece of a metal. In one example, channel 12 is formed of aluminum. In particular, channel 12 may be formed of extruded aluminum. In other examples, channel 12 may be formed as sheet metal parts that are welded together - i.e., with walls 16, 18, 20 as separate sheet metal parts that are welded together. In other examples, channel may also be formed of plastic.

[0015] Linear light inset 14 is configured for being inserted into channel 12 in a space 22 between the two channel side walls 18, 20. Light inset 14 includes a cover 24 and two printed circuit boards (PCBs) 26, 28 fixed to cover 24. PCBs 26, 28 each support a plurality of light sources in the form of light emitting diodes 30 to emit light through cover 24.

[0016] Cover 24 includes a cover base wall 32 and two cover side walls 34, 36 extending away from the cover base wall 32. PCBs 26, 28 are each fixed to the two cover side walls 34, 36. Cover base wall 32 forms a translucent portion, and LEDs 30 arranged for emitting light through cover base wall 32. Light inset 14 defines an interior space 14a between walls 32, 34, 36 and PCBs 26, 28 through which light travels before passing through cover base wall 32.

[0017] Cover 24 also includes two cover connectors 38, 40, and each of cover connectors

38, 40 is fixed to a respective one of the two cover side walls 34, 36. Cover connectors

38, 40 are configured for being snapped into the channel 12 to hold the cover 24 in the space 22 between the two channel side walls 18, 20. The connection by connectors 38, 40 to channel 12 prevents light insert 14 from falling downward from channel 12 through an opening 42 defined at lower ends 18a, 20a of channel side walls 18, 20.

[0018] Cover connectors 38, 40 are positioned above an upward facing side 26a of upper PCB 26 - i.e., the side facing channel base wall 16, which is opposite a downward facing side 26b of upper PCB 26 - i.e., the side facing cover base wall 32. LEDs 30 are fixed to downward facing side 26b of PCB 26. Each of cover connectors 38, 40 is formed integrally as a single piece with an end of the respective cover side wall 34, 36. Further, cover side walls 34, 36 are formed integrally as a single piece with cover base wall 32. In other words, cover base wall 32, cover side walls 34, 36 and cover connectors 38, 40 are formed integrally as a single piece to constitute cover 24. In one advantageous example, cover 24 may be formed of plastic and may have an opal color such that it is translucent, but not transparent. In other examples, cover 24 may be translucent and transparent or cover 24 may be translucent and colored.

[0019] Each of the two channel side walls 18, 20 includes a channel connector 44, 46. Each of cover connectors 38, 40 is configured for being snapped onto one of the channel connectors 44, 46 to create a form fit connection between the channel 12 and the cover.

[0020] Fig. lb shows an enlarged section of a portion of Fig. la including cover connectors 40 and channel connector 46. The following discussion of connectors 40, 46 also applies to connectors 38, 44. Referring to Figs, la and lb together, each of cover connectors 38, 40 includes an outwardly extending section 39a extending horizontally away from a longitudinal center plane CCR of cover 24. Longitudinal center plane CCR of cover 24 extends along a length of cover 24. Outwardly extending sections 39a are each configured for contacting a securing surface 45a of the respective channel connector 44, 46 to prevent the cover 24 from falling out of the linear channel 12 and away from the channel base wall 16. More specifically, outer downwardly facing surfaces 41a of outwardly extending sections 39a contact securing surfaces 45a, respectively, to prevent the cover 24 from falling out of the linear channel 12 and away from the channel base wall 16. Outer downwardly facing surfaces 41a are inclined with respect to longitudinal center plane CCR such that surfaces 41a face away from longitudinal center plane CCR and also face downwardly toward the respective side wall 34, 36. In other words, outer downwardly facing surfaces 41a extend both vertically and horizontally. Securing surfaces 45a face upward toward the channel base wall 16 and also angle toward center plane CCR, such that surfaces 45a also extend vertically while extending horizontally.

[0021] Each of cover connectors 38, 40 also includes an inwardly extending section 39b extending horizontally away from the respective cover side wall 34, 36 and toward the longitudinal center plane CCR of cover 24. Inwardly extending sections 39b are each configured for contacting a respective abutment surface 45b of the respective channel connector 44, 46 to prevent the cover 24 from being forced further into the linear channel 12 toward the channel base wall 16. More specifically, upwardly facing surfaces 41b of inwardly extending sections 39b are each configured for contacting a respective abutment surface 45b to prevent the cover 24 from being forced further into the linear channel 12 toward the channel base wall 16. Abutment surfaces 45b extend horizontally and face downwardly away from the channel base wall 16. Inwardly extending sections 39b also include horizontally extending downwardly facing surfaces 41e contacting or are at least directly facing surface 26a of PCB 26. Each of the inwardly extending sections 39b is formed integrally with an upper end 34b, 36b of the respective cover side wall 34, 36.

[0022] Each of cover connectors 38, 40 further includes an intermediate section 39c connecting inwardly extending section 39b to outwardly extending section 39a. Each of intermediate sections 39c is configured for laterally contacting an alignment surface 45c of the respective channel connector 38, 40 to center the cover 24 within the channel 12. Alignment surfaces 45c face toward each other. More specifically, each alignment surface 45c faces toward longitudinal center plane CCR and away from the respective channel side wall 18, 20 and extends vertically upward from the respective abutment surface 45b to the respective securing surface 45a.

[0023] Each of cover connectors 38, 40 additionally includes an insertion section 39d tapering inward from outwardly extending section 39a by extending horizontally toward longitudinal center plane CCR and horizontally away from the respective cover side wall 34, 36 while extending vertically toward channel base wall 16 and away from PCB 26. More specifically, each insertion section 39d includes an inclined surface 41d that extends horizontally and vertically away from surface 41a toward longitudinal center plane CCR.

[0024] Each of cover side walls 34, 36 is also provided with two circuit board support sections including an upper support section 48 and a lower support section 50. Sections 48, 50 extend along an entire length of cover 24. Upper support section 48 vertically supports upper PCB 26 and lower support section 50 vertically supports lower PCB 28. Cover side walls 34, 36 include outer surfaces 35a facing away from light inset interior space 14a and toward the respective channel side walls 18, 20 and inner surfaces 35b facing toward interior space 14a and away from the respective side walls 18, 20. Support sections 48, 50 protrude horizontally inward from the respective inner surface 35b toward longitudinal center plane CCR. Each of support sections 48, 50 includes a respective horizontally extending support surface 48a, 50a for contacting the lower surface 26b, 28b of the respective PCB 26, 28. Lateral ends 28c of PCB 28 are received in gaps 52a formed vertically between the respective support surface 50a and a respective lower horizontally extending surface 48b of support section 48, and lateral ends 26c of PCB 26 are received in gaps 52b formed vertically between the respective support surface 48a and the horizontally extending downwardly facing surfaces 41e of the respective cover connector 38, 40.

[0025] As shown in Figs. 4a and 6, providing two different support sections 48, 50 at two different vertical positions provides flexibility during the installation of luminaire 10. In particular, for example, if a plurality of standard length PCBs 26 or 28 are used and luminaire is not an integer multiple of this standard length, PCBs 26, 28 can overlap with each other in the longitudinal direction. As an illustrative example, if each of PCBs 26, 28 are ten inches long, and luminaire has a length of forty-five inches, four different PCBs 26 can be provided on upper support sections 48 and a fifth PCB 28 can be provided on lower support sections 50 overlapped in the longitudinal direction by five inches with one of upper PCBs. Fig. 6 shows a cross-sectional lateral facing view of luminaire 10, illustrating a longitudinal overlap LO of an upper PCB 26 and a lower PCB 28.

[0026] As shown in Figs, la, 2, 4a, 4b and 5, luminaire 10 further includes a fall down protection fastener 54 configured for being connected to channel base wall 16 on a first end 54a thereof and to one of PCB s 26, 28 at a second end 54b thereof. Fall down protection fastener 54 includes a cord 56 extending from a first end connector 58 to a second end connector 60. First end connector 58 is configured for being removably connected to channel base wall 16 and second end connector 60 is configured for being removably connected to one of PCBs 26, 28. End connector 58 includes a threaded section 59a for being screwed to threaded section 16a of channel base wall 16 and end connector 60 includes a threaded section 59b for being screwed to threaded section 27 of PCBs 26, 28. In the illustrated example, threaded sections 59a, 59b are formed as male connectors including external threads and threaded sections 16a, 59b are formed as female connectors including internal threads, but this arrangement can be reversed. The connection of fastener 54 to channel base wall 16 and PCB 26 or 28 prevents light inset 14 from being disconnected from channel 12 and falling to the ground in the event that connectors 38, 40 fail. In other embodiments, instead of a screw connection, the connectors 58, 60 can be welded or riveted to the channel base wall 16 and PCB 26, 28, respectively.

[0027] Luminaire 10 further includes an electrical driver 62 received in space 22 inside of channel 12. Electrical driver 62 connects to channel base wall 16 and electrically connects to PCBs 26, 28 to provide electricity to LEDs 30. Each PCB 26, 28 is provided with an electrical connector 64 for connecting to driver 62, directly via wiring or via wiring to another PCB 26, 28.

[0028] As denoted in Figs, la and 5, in order to organize the wires 66 for providing electricity from electrical driver 62 to LEDs 30, luminaire 10 includes a plurality of wire securing assemblies 68 each configured for being fixed to channel base wall 16 for securing wires 66 above light inset 14. Each wire securing assembly 68 includes two flexible arms 68a for receiving wires 66 and clips 68b for removably gripping a longitudinally extending support rail 70 fixed to channel base wall 16. Support rail 70 includes one or more threaded sections 16a integrally formed therein. Arms 68a face each other and each defines a receptacle 72 for receiving a subset of wires 66. Assembly 68 includes a base 68c for contacting support rail 70, and for contacting further rails 74 positioned on both lateral sides of rail 70. Two sets of clips 68b extend upward from opposite longitudinal sides of base 68c, and arms 68a extend downward from opposite lateral sides of base 68c. Each of clips 68b includes two prongs 68d for laterally contacting opposite sides of rail 70. Arms 68a each include a vertical section 69a extending downward from base 68c, a horizontal section 69b extending from the respective vertical section 69a toward the other arm 68a, and inclined section 69c extending upward from horizontal section 69b and horizontally toward the other arm 68a. Inclined sections 69c intersect each other to define an upside-down V-shape, as shown in Fig. la. Wires 66 are inserted into receptacles 72 by forcing wires 66 upward into the V- shape to force inclined sections 69c away from each other to define a gap between sections 69c for the wires 66 to pass through. After wires clear the intersection of sections 69c, the resiliency of arms 68a cause sections 69c to move back toward each other. The gap is eliminated and inclined sections 69c return into contact with each other.

[0029] A method for installing linear luminaire 10 includes fixing linear channel 12 to a support structure and inserting linear light inset 14 into channel 12 in a space 22 between the two channel side walls 18, 20 and connecting the linear light inset 14 to the channel 12 in the space by cover connectors 38, 40 of the linear light insert 14. Prior to the installation of light inset 14 into channel 12, PCBs 26 and/or PCBs 28 are slid in the longitudinal direction into respective gaps 52a, 52b and onto respective support sections 48, 50 of side walls 34, 36 such that PCBs 26 and/or PCBs 28 are connected to cover 24. As noted above, depending on whether or not the desired length of light insert 14 is an integer multiple of the length of PCBs 26, 28, solely PCBs 26 are used, solely PCBs 28 are used, or both at least one PCB 26 and at least one PCB 28 are used with one PCB 26 longitudinally overlapping with one PCB 28. It is noted that in one advantageous embodiment, PCBs 26 are exactly the same as PCBs 28. [0030] After PCBs 26 and/or PCBs 28 are connected to cover 24 to form light inset 14, light inset 14 is inserted into the opening 42 defined at lower ends 18a, 20a of channel side walls 18, 20 with connectors 38, 40 leading the way. Insertion sections 39d of connectors 38, 40 are forced into respective channel connectors 44, 46 such that insertions sections 39d and outwardly extending sections 39a are forced laterally inward toward center plane CCR of cover 24 as outer tips 39e at an intersection of sections 39a, 39d are slid along the respective surfaces 45c and past respective surface 45a. After outer tips 39e pass the respective surfaces 41a, sections 39a move laterally outward to engage the respective surfaces 41a to hold inset 14 in channel 12. Surfaces 41b of inwardly extending sections 39b contact abutment surface 45b to align light inset 14 vertically in channel 12.

[0031] Prior to the installation of light inset 14 into channel, fall down protection fasteners 54 are connected to two or more of PCBs, PCBs 26, 28 by connecting end 60 to the respective PCB 26, 28. Each of cords 56 of fasteners 54 is elastically deformable to increase the distance between the respective ends 58, 60. This allows fasteners 54 to be stretched from the orientation shown in Fig. 5 to the orientation shown in Figs. 4a, 4b. With end 60 connected to the respective PCB 26, 28 and light inset 14 spaced from the opening 42, end 58 is raised upward into space 22 of channel 12 and connected to base wall 16 of channel 12 by screwing end 58 into threaded section 16a of channel base wall 16. In the example shown in Figs. 4a, 4b, fall down protection fasteners 54 are used to secure inset 14 to channel 12, one at each longitudinal end of luminaire 10. Then, light inset 14 is pushed upward into channel 12 and connected to channel 12 via connectors 38, 40.

[0032] The preceding specification refers to specific exemplary embodiments and examples. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative manner rather than a restrictive sense.