SSL CAN LIGHT FIXTURE WITH BUILT-IN JUNCTION BOX

Abstract

A can light assembly includes a junction box, the junction box defining a top junction box end and a bottom junction box end; a light engine mounted to the bottom junction box end, the light engine includes a reflector, the reflector defining a top reflector end and a bottom reflector end, the reflector defining a reflector bore extending through the reflector from the top reflector end to the bottom reflector end, the reflector bore defining a top reflector aperture at the top reflector end and a bottom reflector aperture at the bottom reflector end; a lens covering the bottom reflector aperture; and a light PCB, the light PCB includes an SSL source, the light PCB covering the top reflector aperture; and a trim housing, the trim housing bore defining a top trim housing aperture at the top trim housing end, the light engine extending through the top trim housing aperture.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/327,221, filed on Apr. 25, 2016, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

This disclosure relates to light fixtures. More specifically, this disclosure relates to solid-state lighting downlight light fixtures.

BACKGROUND

Incandescent light bulbs operate at very low luminous efficiency compared to solid-state lighting (“SSL”), such as light-emitting diode (“LED”), organic light-emitting diode (“OLED”), polymer light-emitting diode (“PLED”), or other semiconductor sources of illumination. Incandescent light bulbs also have very short lifespans compared to many SSL sources. Because of the benefit of increased power efficiency and bans on traditional incandescent lighting by government bodies in some areas, it can be desirable to provide a can light assembly with an SSL source for installation in new facilities or for renovation of existing facilities. Additionally, most household, commercial, and industrial are powered with alternating current (“AC”) power. SSL sources commonly operate off of direct current (“DC”) power. It is desirable to produce a new can light fixture comprising SSL sources which can be powered by common AC power sources.

SUMMARY

It is to be understood that this summary is not an extensive overview of the disclosure. This summary is exemplary and not restrictive, and it is intended to neither identify key or critical elements of the disclosure nor delineate the scope thereof. The sole purpose of this summary is to explain and exemplify certain concepts of the disclosure as an introduction to the following complete and extensive detailed description.

Disclosed is a can light assembly comprising a junction box, the junction box defining a top junction box end and a bottom junction box end; a light engine, the light engine mounted to the bottom junction box end, the light engine comprising a reflector, the reflector defining a top reflector end and a bottom reflector end, the reflector defining a reflector bore extending through the reflector from the top reflector end to the bottom reflector end, the reflector bore defining a top reflector aperture at the top reflector end and a bottom reflector aperture at the bottom reflector end; a lens, the lens covering the bottom reflector aperture; and a light PCB, the light PCB comprising an SSL source, the light PCB covering the top reflector aperture, the SSL source aligned with the top reflector aperture, the SSL source configured to emit light through the lens; and a trim housing, a top trim housing end of the trim housing positioned adjacent to the bottom junction box end, the trim housing defining a trim housing bore extending through the trim housing, the trim housing bore defining a top trim housing aperture at the top trim housing end, the light engine extending through the top trim housing aperture.

Also disclosed is a junction box comprising a junction box housing; a lid hingedly attached to the junction box housing, the junction box housing and the lid defining a junction box compartment within the junction box, the lid selectively positionable about and between an open position and a closed position; a partition wall disposed within the junction box compartment, the partition wall dividing the junction box compartment into a driver sub-compartment and a wiring sub-compartment, the partition wall comprising a wiring connector extending through the partition wall; and a driver PCB disposed within the driver sub-compartment, the driver PCB in electrical communication with the wiring connector.

Also disclosed is a method for manufacturing a can light assembly, the method comprising attaching a lid of a junction box to a junction box housing of the junction box, the junction box defining a top junction box end and a bottom junction box end, the lid and the junction box housing defining a junction box compartment within the junction box; mounting a driver PCB within the junction box compartment; attaching a trim housing to the bottom junction box end, the trim housing defining a top trim housing aperture positioned adjacent to the bottom junction box end; positioning the light engine within the top trim housing aperture; and connecting the light engine in electrical communication with the driver PCB.

Various implementations described in the present disclosure may include additional systems, methods, features, and advantages, which may not necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims. The features and advantages of such implementations may be realized and obtained by means of the systems, methods, features particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. The drawings are not necessarily drawn to scale. Corresponding features and components throughout the figures may be designated by matching reference characters for the sake of consistency and clarity.

FIG. 1 is a perspective view of a can light assembly in accordance with one aspect of the current disclosure with a lid of the can light assembly in a closed position.

FIG. 2 is a cross section of the can light assembly of FIG. 1 taken along line 2-2 shown in FIG. 1.

FIG. 3 is a side view of a light engine of the can light assembly of FIG. 1.

FIG. 4 is cross-section of the light engine of FIG. 3 taken along line 4-4 shown in FIG. 3.

FIG. 5 is a top perspective view of the light engine of FIG. 3.

FIG. 6 is a cross-section of the can light assembly of FIG. 1 taken along line 6-6 shown in FIG. 1.

FIG. 7 is a perspective view of the can light assembly of FIG. 1 with the lid in an open position.

FIG. 8 is a detail view of a partition wall of the can light assembly of FIG. 1 taken from Detail 8 shown in FIG. 7.

FIG. 9 is an exploded view of another aspect of the can light assembly in accordance with another aspect of the current disclosure.

FIG. 10 is a side view of another aspect of a light engine of the can light assembly of FIG. 9.

FIG. 11 is a cross-section of the light engine of FIG. 10 taken along line 11-11 shown in FIG. 10.

FIG. 12 is a top perspective view of the light engine of FIG. 10.

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and the previous and following description. It is to be understood that this disclosure is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, and, as such, can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

The following description is provided as an enabling teaching of the present devices, systems, and/or methods in its best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the present devices, systems, and/or methods described herein, while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “an element” can include two or more such elements unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

For purposes of the current disclosure, a material property or dimension measuring about X or substantially X on a particular measurement scale measures within a range between X plus an industry-standard upper tolerance for the specified measurement and X minus an industry-standard lower tolerance for the specified measurement. Because tolerances can vary between different materials, processes and between different models, the tolerance for a particular measurement of a particular component can fall within a range of tolerances.

As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

The word “or” as used herein means any one member of a particular list and also includes any combination of members of that list. Further, one should note that conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain aspects include, while other aspects do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular aspects or that one or more particular aspects necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular aspect.

Disclosed are components that can be used to perform the disclosed methods and systems. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutation of these may not be explicitly disclosed, each is specifically contemplated and described herein, for all methods and systems. This applies to all aspects of this application including, but not limited to, steps in disclosed methods. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the disclosed methods.

According to some aspects, a can light assembly is disclosed, along with associated methods, systems, devices, and various apparatus. The can light assembly comprises a junction box, a light engine, a trim housing, and a trim piece. It would be understood by one of skill in the art that the can light assembly is described in but a few exemplary embodiments among many. No particular terminology or description should be considered limiting on the disclosure or the scope of any claims issuing therefrom.

FIG. 1 is a perspective view of a can light assembly 100 in accordance with one aspect of the present disclosure with a lid 120 of the can light assembly in a closed position. The can light assembly 100 can comprise a junction box 110, a trim housing 160, and a trim piece 170. In the present aspect, the trim housing 160 and the trim piece 170 can sized to fit within a 4″ nominal opening in a ceiling, a tile, or other overheard structure (not shown). The trim piece 170 can be received by the trim housing 160, and the trim housing 160 can be attached to the junction box 110.

The junction box 110 can define a top junction box end 136 and a bottom junction box end 134. The junction box 110 can comprise the lid 120 and a junction box housing 130. The lid 120 can define the top junction box end 136, and the junction box housing 130 can define the bottom junction box end 134. In the present aspect, the lid 120 can be hingedly attached to the junction box housing 130. The junction box housing 130 can define a plurality of fins 132 disposed at the bottom junction box end 134 of the junction box 110, proximate to the trim housing 160, and the junction box housing 130 can act as a heat sink. In the present aspect, the fins 132 can extend downwards from the bottom junction box end 134 and overlap with the trim housing 160. The fins 132 can be configured to dissipate heat from the can light assembly 100, and in the present aspect, the junction box housing 130 can comprise a metal such as aluminum, brass, steel, or any other suitable metal. The fins 132 can be distributed around a circumference of the junction box housing 130.

In some aspects, the trim housing 160 can comprise a thermally conductive material, and either the trim housing 160 or both the trim housing 160 and the junction box housing 130 can act as heat sinks. In such aspects the trim housing 160 can comprise a metal or a thermally conductive plastic such as polyamide, acrylonitrile butadiene styrene (“ABS”), or carbon-filled polycarbonate (“PC”), for example and without limitation. In some aspects, the trim housing 160 can comprise over-molded metal wherein a metal sub-frame is coated with a plastic, such as polyethylene, polypropylene, silicon, thermoplastic rubber, thermoplastic elastomers, or any other suitable material. The metal sub-frame can comprise a metal such as aluminum, steel, copper, or any other suitable metal which can be formed by spinning, die casting, deep drawing stamping, casting, machining, forging, or any other suitable method of manufacturing. A portion of the metal sub-frame may be left exposed (i.e., not over-molded) in order to dissipate heat from internal components. In aspects in which the trim housing 160 acts as the heat sink, the junction box housing 130 can comprise a plastic, such as polybutylene terephthalate (“PBT”), ABS, PC, polyamide, or any other suitable material.

In the present aspect, the trim piece 170 can comprise a thermosetting material such as 2 mm to 3 mm thick ABS or 1 mm to 3 mm thick PC, and the trim piece 170 can be rated HB fire retardation classification under the UL 94 standard entitled “Standard for Safety of Flammability of Plastic Materials for Parts in Devices and Appliances,” Mar. 28, 2013 edition. In some aspects, the trim piece 170 can comprise a thermally conductive material, and either the trim housing 170 can conduct and dissipate heat. In such aspects the trim piece 170 can comprise a metal or a thermally conductive plastic such as polyamide, ABS, or carbon-filled PC, for example and without limitation. In some aspects, the trim piece 170 can comprise over-molded metal wherein a metal sub-frame is coated with a plastic, such as polyethylene, polypropylene, silicon, thermoplastic rubber, thermoplastic elastomers, or any other suitable material. The metal sub-frame can comprise a metal such as aluminum, steel, copper, or any other suitable metal which can be formed by spinning, die casting, deep drawing stamping, casting, machining, forging, or any other suitable method of manufacturing. A portion of the metal sub-frame may be left exposed (i.e., not over-molded) in order to dissipate heat from internal components.

In some aspects, the can light assembly 100 can further comprise a sleeve or housing (not shown) which fits around the junction box 110. The sleeve can be sized larger than the junction box 110, and the sleeve can be configured to maintain an air gap around the junction box 110 when the can light assembly 100 is installed within the opening of the ceiling, tile, or overhead structure. The air gap can facilitate cooling of the junction box 110 when surrounded by insulation.

The lid 120 can define a top lid end 123 and a bottom lid end 125. The lid 120 can comprise a lid body 121 and a top plate 112. The top plate 112 can comprise steel, such as low carbon steel or stainless steel; however in other aspects, the top plate 112 can comprise other suitable metal or plastic materials. The top plate 112 can be disposed at the top lid end 123. The top plate 112 can define a pair of conduit knockouts 114a,b which can be removed in order to attach metallic or non-metallic flexible conduit or other protected wiring structures to the can light assembly 100. In the present aspect, the knockouts 114a,b can be sized to receive ½″ or ¾″ conduits, as per the Underwriters Laboratories (“UL”) 50 standard entitled “Enclosures for Electrical Equipment, Non-Environmental Considerations”, Oct. 16, 2015 edition, as published and maintained by Underwriters Laboratories LLC, headquartered in 333 Pfingsten Road, Northbrook, Ill. 60062, United States of America.

The top plate 112 can define a pair of breakaway pull tabs 116a,b which can be removed to provide access for an electrical conductor, such as a cable or a wire. In some aspects, the cable can be a Romex cable, such as a 4 core Romex cable comprising four 12 American Wire Gauge (“AWG”) wires. The top plate 112 can be secured to the lid body 121 by a plurality of locking tabs 118a,b,c (locking tab 118b shown in FIG. 2, locking tab 118c shown in FIG. 6). In other aspects, the top plate 112 can be attached to the lid body 121 by another mechanism, such as with one or more fasteners.

In the present aspect, the lid 120 can be secured in the closed position by a lid fastener 122. The lid 120 can define a fastener channel 124 configured to provide access for tightening and removal of the lid fastener 122. In the present aspect, the lid fastener 122 can be a screw; however, in other aspects, the lid fastener 122 can be a bolt, a nut, a stud, or any other suitable fastener. In the present aspect, the bottom lid end 125 can be defined by the lid body 121. A portion of the bottom lid end 125 can be sloped as further described below with respect to FIG. 6.

The trim housing 160 can be attached to the bottom junction box end 134 of the junction box 110. The trim housing 160 can comprise three bull clips 164, as represented by bull clips 164a,b. In other aspects, the trim housing 160 can comprise greater or fewer than three bull clips 164. The bull clips 164 can be configured to secure the can light assembly 100 within the opening in a ceiling, a tile, or other overheard structure (not shown). The bull clips 164 can be evenly distributed about a circumference of the can light assembly 100. The bull clips 164 are shown in a withdrawn configuration in which the bull clips 164 lie flat alongside the trim housing 160.

The bull clips 164 can each be respectively mounted on a screw 166, as represented by the screws 166a,b. Rotating the screws 166 in a clockwise direction (when viewed from the screw head) can rotate the respective bull clip 164 until the bull clip 164 contacts a ridge 162, as represented by ridges 162a,b, in an extended configuration. The ridges 162 can prevents further rotation of the adjacent bull clip 164. In the extended configuration, the bull clips 164 can contact the respective ridges 162, and the bull clips 164 can extend substantially radially outward from the trim housing 160.

Further rotating the screws 166 in the clockwise direction can draw the respective bull clips 164 towards a trim housing lip 168 disposed at a bottom trim housing end 169 of the trim housing 160. Drawing the bull clips 164 towards the trim housing lip 168 can pinch the ceiling, the tile, or the overheard structure between the bull clips 164 and the trim housing lip 168 to secure the can light assembly 100 within the opening (not shown). The bull clips 164 are exemplary of one mounting mechanism, and should not be viewed as limiting. In other aspects, the can light assembly 100 can comprise other well-known mounting mechanisms such as insulation brackets for grid ceilings, torsion springs, braces, hanger bars, brackets, plates, clips, and pans configured to secure the can light assembly 100 within the opening of the ceiling, the tile, or the overhead structure.

FIG. 2 is a cross-section of the can light assembly 100 of FIG. 1 taken along line 2-2 shown in FIG. 1. The junction box 110 can define a junction box compartment 210 disposed within the junction box 110. In the closed position, the lid 120 can enclose and seal the junction box compartment 210. The lid body 121 can define a first sealing lip 206 which can cooperate with a second sealing lip 202 defined by the junction box housing 130 to securely align and seal the lid 120 with the junction box housing 130.

The locking tabs 118a,b,c (locking tab 118c shown in FIG. 6) of the top plate 112 can be received within locking pockets 218a,b,c (locking pocket 218c shown in FIG. 6) defined by the lid body 121. The locking tabs 118a,b,c can each respectively define a locking opening 222a,b,c (locking opening 222c shown in FIG. 6) which can be configured to receive a locking shoulder 220a,b,c (locking shoulder 220c shown in FIG. 6) defined by the lid body 121. Engagement between the respective locking shoulders 220a,b,c and the locking openings 222a,b,c of the respective locking tabs 118a,b,c can prevent withdrawal of the locking tabs 118a,b,c from the respective locking pockets 218a,b,c, thereby securing the top plate 112 to the lid body 121.

The lid body 121 can define a pair of stress-relieving inlets 214a,b. The stress-relieving inlets 214a,b can be covered by the breakaway pull tabs 116a,b, respectively, of the top plate 112. The breakaway pull tabs 116a,b can be scored to easily break off from the top plate 112 when folded upwards and away from the lid body 121. The lid body 121 of the lid 120 can comprise a pair of flexible friction levers 216a,b biased to occlude the stress-relieving inlets 214a,b, respectively. In the present aspect, the flexible friction levers 216a,b can partially occlude the stress-relieving inlets 214a,b; however in other aspects, the flexible friction levers 216a,b can fully occlude the stress-relieving inlets 214a,b.

Each flexible friction lever 216a,b can be flexibly attached to the lid body 121. When the conductor (not shown), such as the cable or the wire, is inserted through a one of the stress-relieving inlets 214a,b and into the junction box compartment 210, the respective flexible friction lever 216a,b can deflect inwards towards the junction box compartment 210, and the flexible friction lever 216a,b can exert a residual pinching force on the conductor. The residual pinching force acting on the conductor can resist outwards withdrawal of the conductor from the respective stress-relieving inlet 214a,b and the junction box compartment 210.

Resisting withdrawal of the conductor can protect electrical connections within the junction box compartment 210. For example, a grounding clamp 232 can be disposed within the junction box compartment 210, and the conductor can be attached to the grounding clamp 232 to provide a grounding connection for the can light assembly 100. By resisting withdrawal of the conductor through the stress-relieving inlet 214a,b, the flexible friction levers 216a,b can resist the conductor pulling away from the grounding clamp 232 and severing the grounding connection. The grounding clamp 232 can be secured to a grounding post 234 by a fastener 230. The grounding post 234 can be defined by the junction box housing 130.

The can light assembly 100 can further comprise a light engine 212 configured to emit light. In the present aspect, the light engine 212 can be configured to emit visible light; however in other aspects, the light engine 212 can emit light in a different spectrum, such as infrared light. In the present aspect, the light engine 212 can be mounted to a floor 236 of the junction box housing 130 by a pair of fasteners 205a,b. In the present aspect, the fasteners 205a,b can be screws; however, in other embodiments, the fasteners 205a,b can be bolts, nuts, studs, rivets, or any other suitable fastener. The floor 236 of the junction box housing 130 can define the bottom junction box end 134.

The trim housing 160 can define a top trim housing end 269 disposed opposite from the bottom trim housing end 169. The trim housing 160 can define a trim housing bore 260 extending through the trim housing 160 from the top trim housing end 269 to the bottom trim housing end 169. The trim housing bore 260 can define a trim housing bore axis 200. A top trim housing aperture 268 of the trim housing bore 260 can be defined at the top trim housing end 269, and a bottom trim housing aperture 267 of the trim housing bore 260 can be defined at the bottom trim housing end 169. The trim housing 160 can define a rounded shoulder 211 proximate to the top trim housing end 269. In the present aspect, the fins 132 can be shaped complimentary to a contour of the rounded shoulder 211.

The light engine 212 can be positioned within the top trim housing aperture 268 defined by the trim housing 160. The light engine 212 can define a reflector shoulder 208 which can overlap a portion of the trim housing 160 proximate to the top trim housing aperture 268. With the light engine 212 mounted to the bottom junction box end 134, the top trim housing aperture 268 can be captured between the reflector shoulder 208 and the bottom junction box end 134. The reflector shoulder 208 can secure the trim housing 160 to the bottom junction box end 134 of the junction box 110.

The junction box housing 130 can also define an outer circumferential groove 203 at the bottom junction box end 134. In particular, the outer circumferential groove 203 can be defined at an outer edge of the floor 236. The trim housing 160 can define an outer circumferential collar 207 shaped and sized complimentary to the outer circumferential groove 203. The outer circumferential collar 207 can extend upwards from the top trim housing end 269. Engaging the outer circumferential collar 207 with the outer circumferential groove 203 can align the trim housing 160 relative to the junction box 110.

The trim piece 170 can define a top trim end 285 disposed opposite from the bottom trim end 179. The trim piece 170 can define a trim bore 280 extending through the trim piece 170 from the top trim end 285 to the bottom trim end 179. The trim bore 280 can be coaxial to the trim housing bore axis 200. A top trim aperture 284 of the trim bore 280 can be defined at the top trim end 285, and a bottom trim aperture 271 of the trim bore 280 can be defined at the bottom trim end 179.

The trim housing bore 260 can receive the trim piece 170, and in the present aspect, the trim bore 280 can be concentric with the trim housing bore 260. In other aspects, the trim bore 280 can be pivotable relative to the trim housing bore 260. The light engine 212 can extend through the top trim housing aperture 268 and the top trim aperture 284. In particular, the light engine 212 can comprise a lens 204, and the lens 204 can be centered within the top trim aperture 284. The trim bore 280 can define a reflection surface 282. The reflection surface 282 can be configured to direct light emitted from the light engine 212 through the lens 204. In the present aspect, the reflection surface 282 can be parabolic; however, in other aspects, the reflection surface 282 can define a frustoconical, a spherical segment, or any other suitable shape. In some aspects, the reflection surface 282 can define a plurality of concentric baffles (not shown) to diffuse and “soften” light emitted from the light engine 212.

The trim housing bore 260 can define a substantially circular cross sectional shape, and the trim housing 160 can define a pair of recesses 265a,b extending radially outward from the trim housing bore 260. Each recess 265a,b can extend axially from the bottom trim housing end 169 to the rounded shoulder 211. A plurality of ridges 266, each extending in a circumferential direction, can be defined within each recess 265a,b.

In the present aspect, the trim piece 170 can comprise a pair of friction clips 240a,b. For example and without limitation, the friction clips 240a,b can comprise polyamide or polyoxymethylene (“POM”) and can be 1.5 mm thick. In other aspects, the friction clips 240a,b can comprise ferrite material such as stainless steel or spring steel, for example and without limitation. The friction clips 240a,b can each engage a socket 242a,b of the trim piece 170 to secure the friction clips 240a,b to the trim piece 170. Each socket 242a,b can be positioned radially outward from the top trim aperture 284, and in the present aspect, each socket 242a,b can extend upwards from the top trim end 285. The sockets 242a,b can be partially defined by a trim collar 217 which extends upwards from the top trim end 285. The light engine 212 can closely fit within the trim collar 217. In other aspects, the sockets 242a,b can be positioned between the top trim end 285 and the bottom trim end 179. The friction clips 240a,b can be flexible, and the friction clips 240a,b can extend radially outward from the trim piece 170 and axially downwards towards the bottom trim end 179.

The friction clip 240a can comprise a first locking tab 246a and a second locking tab 244a, and the friction clip 240b can comprise a first locking tab 246b and a second locking tab 244b. The second locking tabs 244a,b can act as a secondary friction mechanism. The first locking tabs 246a,b and the second locking tabs 244a,b can engage the plurality of ridges 266 of the recesses 265a,b to secure the trim piece within the trim housing bore 260. Interference between the trim housing 160 and each friction clip 240a,b can deflect the friction clips 240a,b downwards. Due to the deflection, each friction clip 240a,b can exert a residual force radially outwards which biases the locking tabs 244a,b,246a,b to engage the ridges 266, thereby securing the trim piece 170 to the trim housing 160. With the trim piece 170 secured to the trim housing 160, a trim lip 270 of the trim piece 170 can overlap the trim housing lip 168.

FIG. 3 is a side view of the light engine 212 of FIG. 2. The light engine 212 can comply with the UL 8750 standard entitled “Standard for Light Emitting Diode (LED) Equipment for Use in Lighting Products”, Sep. 15, 2015 edition. The light engine 212 can comprise a reflector 310. The reflector 310 can comprise a material such as 1 mm to 3 mm thick PC or 2 mm to 3 mm ABS, for example and without limitation, and can be rated V0 fire retardation classification under UL 94. The lens 204 can be positioned at a bottom reflector end 320 of the reflector 310. The lens 204 can comprise 1 mm to 3 mm thick PC and be rated V0 fire retardation classification under UL 94. The reflector 310 can comprise two side clips 306a,b and a center clip 308 configured to retain a light printed circuit board (“PCB”) 410 (shown in FIG. 4). The side clips 306a,b and the center clip 308 can extend upwards from a top reflector end 322 of the reflector 310. A pair of fastener receptacles 305a,b can extend upwards from the top reflector end 322 of the reflector 310, and the fastener receptacles 305a,b can be configured to receive the fasteners 205a,b (shown in FIG. 2) to mount the light engine 212 to the bottom junction box end 134 (shown in FIG. 2). The reflector shoulder 208 can extend radially outward from an outer circumferential surface 312 of the reflector 310. The reflector shoulder 208 can define a trough 340 which can be configured to control rotational indexing of the light engine 212 about the trim housing bore axis 200 relative to the junction box housing 130 (shown in FIG. 2).

FIG. 4 is a cross-section of the light engine 212 of FIG. 2 taken along line 4-4 shown in FIG. 3. The light PCB 410 can define a top surface 411 and a bottom surface 412 disposed opposite from the top surface 411. The center clip 308 and the side clips 306a,b (306a shown in FIG. 3) can engage the top surface 411 to secure the light PCB 410 to the reflector 310. A plurality of SSL sources 425 can be disposed on the bottom surface 412 of the light PCB 410. In the present aspect, each SSL source 425 can be encapsulated by fire retardant material. In the present aspect, the SSL sources 425 can be LEDs; however, in other aspects, the SSL sources 425 can be OLEDs, PLEDs, or any arrangement or combination of LEDs, OLEDs, and PLEDs.

The reflector 310 can define a reflector bore 401 extending through the reflector 310 from the top reflector end 322 to the bottom reflector end 320. A top reflector aperture 408 of the reflector bore 401 can be defined at the top reflector end 322, and a bottom reflector aperture 409 of the reflector bore 401 can be defined at the bottom reflector end 320.

With the light PCB 410 secured to the reflector 310, the SSL sources 425 can be aligned and positioned within the top reflector aperture 408. The reflector bore 401 can define a reflector surface 414 configured to reflect and direct light emitted by the SSL sources 425 outward through the lens 204. In the present aspect, the reflector surface 414 can define a parabolic shape; however, in other aspects, the reflector surface 414 can define a frustoconical, spherical segment, or any other suitable shape.

The reflector 310 can define an inner circumferential groove 442 at the bottom reflector end 320. The inner circumferential groove 442 can be defined radially inward from the bottom reflector aperture 409. The lens 204 can define a lens collar 440 which can be sized and shaped to provide a friction fit with the inner circumferential groove 442. The inner circumferential groove 442 can receive the lens collar 440 to secure the lens 204 to the bottom reflector end 320 of the reflector 310. With the lens 204 secured to the reflector 310, the lens can cover the bottom reflector aperture 409.

The light PCB 410, the reflector 310, and the lens 204 can together define a light engine compartment 402 within the light engine 212, and the SSL sources 425 can be enclosed and dielectrically isolated within the light engine compartment 402. In the present aspect, the light PCB 410 can be a metal-core printed circuit board (“MCPCB”). The reflector 310 can comprise PC defining a reflective finish. The lens 204 can comprise PC defining a clear or opaque finish. The reflector 310 and the lens 204 can be rated as V0 fire retardation classification under UL 94. Because the SSL sources 425 are enclosed and dielectrically isolated within the light engine compartment 402, the trim housing 160 and the trim piece 170 can be rated at lower fire retardation classifications and can comprise less expensive materials. In the present aspect, the trim housing 160 can be rated as 5VA under the UL 94 standard, and the trim piece 170 can be rated as HB under the UL 94 standard. In the present aspect, the trim piece 170 and the trim housing 160 can each comprise ABS. In other aspects, the reflector 310, the lens 204, the trim piece 170, and the trim housing 160 can each comprise other suitable materials and can be rated at a higher or lower fire retardation classification.

For the UL 1598 standard entitled “Luminaires”, Sep. 17, 2008 edition, the lid 120 can comprise a thermoplastic polymer with a fire retardation classification of 5VA under the UL 94 standard. For example and without limitation, the lid 120 can comprise 2.5 mm to 3 mm thick PC, 2.5 mm to 3 mm thick ABS, 2 mm to 3 mm thick PC and ABS hybrid plastic material, or 2 mm to 3 mm thick PC and PBT hybrid plastic material.

The light PCB 410 can further comprise a light connector 415. In the present aspect, the light connector 415 can be a through-board connector which extends through the light PCB 410 from the top surface 411 to the bottom surface 412. The light connector 415 can be electrically connected to the plurality of SSL sources 425 to supply power to the SSL sources 425. In other aspects, the light connector 415 can be a surface-mount connector.

FIG. 5 is a top perspective view of the light engine 212 of FIG. 2. In the present aspect, a protective film 550 can be attached to the lens 204 (shown in FIG. 4), and the protective film 550 can protect the lens 204 during manufacturing, shipping, handling, and installation of the can light assembly 100 (shown in FIG. 1). The light connector 415 can be a female connector in the present aspect. In other aspects, the light connector 415 can be a male connector. The light connector 415 can define a pair of receptacles 515a,b each configured to receive a pin 645a,b (shown in FIG. 6) of a driver PCB 630 (shown in FIG. 6).

FIG. 6 is a cross-section of the can light assembly 100 of FIG. 1 taken along line 6-6 shown in FIG. 1. The can light assembly 100 can further comprise a partition wall 612 disposed within the junction box compartment 210. The partition wall 612 can divide the junction box compartment 210 into a driver sub-compartment 610 and a wiring sub-compartment 611. The driver PCB 630 can be disposed within the driver sub-compartment 610. The trim housing 160 can comprise a pair of side tabs 660a,b (side tab 660b shown in FIG. 9) and a center tab 661 which can extend upwards from the top trim housing end 269. The pair of side tabs 660a,b and the center tab 661 can extend through the bottom junction box end 134 and into the junction box compartment 210. The pair of side tabs 660a,b and the center tab 661 can be configured to secure the trim housing 160 to the bottom junction box end 134. The side tabs 660a,b can extend into the driver sub-compartment 610, and the center tab 661 can extend into the wiring sub-compartment 611. The trough 340 of the reflector shoulder 208 can provide clearance for the center tab 661, and engagement between the center tab 661 and the trough 340 can rotationally index the light engine 212 relative to the bottom junction box end 134.

The driver PCB 630 can be configured to convert incoming AC power input into DC power output to be supplied to the light PCB 410 of the light engine 212. In some aspects, the light driver circuit can comprise digital logic circuitry to control voltage, amperage, frequency, wave form shape, and/or the like of the DC power output. In some aspects, the light driver circuit can further comprise a communication module so that the light driver circuit can be remotely controlled, such as by a Wi-Fi signal. For example, the light driver circuit can be remotely instructed to turn the can light assembly 100 on or off, to increase or decrease the light output of the can light assembly 100, or to change a color of light emitted from the can light assembly 100. In another aspect, the driver PCB 630 can be configured to boost or multiply the output voltage value to be supplied to the light PCB 410 to be greater than the input voltage value of the AC power input. Operating the SSL sources 425 of the light PCB 410 at higher voltages, such as 200-240V, can improve the operating efficiency of the SSL sources 425 and reduce generation of waste heat.

The partition wall 612 and the junction box housing 130 can dielectrically isolate the driver PCB 630 within the driver sub-compartment 610. In the present aspect, the partition wall 612 can comprise a material such as PBT, ABS, PC, polyamide, a metal, or any other suitable material. In the present aspect, the junction box housing 130 can comprise aluminum, for example and without limitation, aluminum die cast 12 alloy (“ADC12”) as specified under Japanese Industrial Standard H 5302:2006, entitled “Aluminum Alloy Die Castings,” Jan. 1, 2006 edition, as published and maintained by the Japanese Standards Association, headquartered at Mita MT Bldg., 3-13-12 Mita, Minato-ku, Tokyo, 108-0073, Japan. The junction box housing 130 can be formed through a method such as die casting, deep drawing, or spinning. In other aspects, the junction box housing 130 can comprise a different aluminum alloy or a different material such as copper, steel, polyamide, ABS, PBT, PC, or any other suitable material.

In the present aspect, the driver PCB 630 can be a glass epoxy PCB or MCPCB. The driver PCB 630 can comprise a plurality of wire connectors 615a,b,c,d (wire connectors 615a,c,d, shown in FIG. 7). The wire connectors 615a,b,c,d can extend through the partition wall 612 from the driver sub-compartment 610 to the wiring sub-compartment 611. In the present aspect, the driver PCB 630 can receive a through-board pin, as represented by the through-board pin 616b of wire connector 615b, to connect each wire connector 615a,b,c,d in electrical communication with the driver PCB 630. In other aspects, the wire connectors 615a,b,c,d can be surface-mounted wire connectors. Each wire connector 615a,b,c,d can be configured to receive a wire of an AC power supply conductor, thereby connecting the AC power input to the driver PCB 630.

In some aspects, the wire connectors 615a,b,c,d can be push wire connectors, such as a WAGO Push Wire® connector, as manufactured by WAGO Corporation, headquartered at N120 W19129 Fresistadt Rd., Germantown, WI 53022, a division of WAGO Kontakttechnik, GmbH of Minden Germany. In other aspects, the drive PCB 630 may not comprise the wire connectors 615a,b,c,d. In such aspects, a plurality of PCB wires (not shown) can extend through the partition wall in place of the wire connectors 615a,b,c,d. The PCB wires can be configured to connect to the wires of the AC power supply conductor by forming wire-to-wire connections within the junction box housing 130, such as with a wire nut.

The driver PCB 630 can further comprise a driver connector 640. In the present aspect, the driver connector 640 can be a through-board connector; however, in other aspects, the driver connector 640 can be a surface-mount connector. The driver connector 640 can comprise the pair of pins 645a,b (pin 645b shown in FIG. 9) configured to engage the light connector 415. Each of the pins 645 can be received by a different one of the receptacles 515a,b (shown in FIG. 5) of the light connector 415 to connect the driver PCB 630 in electrical communication with the light PCB 410 and to supply the DC power output from the driver PCB 630 to the light PCB 410 of the light engine 212. Each of the pins 645 can extend through the bottom junction box end 134 of the junction box housing 130.

In other aspects, the light connector 415 can define more than two receptacles 515, and the driver connector 640 can comprise more than two pines 645 in order to individually control separate circuits of the light PCB 410. For example and without limitations, a first group of SSL sources 425 can be on a first circuit and a second group of SSL sources 425 can be on a second circuit. In some aspects, the first group of SSL sources 425 can differ in color from the second group of SSL sources 425, and the first circuit and second circuit can be controlled separately to control a color of light emitted from the light engine 212.

The partition wall 612 can also define a hinge pin notch 603 configured to receive a hinge pin 602 of the lid 120. The hinge pin 602 can be captured between the hinge pin notch 603 of the partition wall 612 and the junction box housing 130 to hingedly attach the lid 120 to the junction box housing 130. The hinge pin 602 can rotated within the hinge pin notch 603 in order to open and close the lid 120. The junction box housing 130 can define a junction box opening 619 to the junction box compartment 210. The junction box opening 619 can define a sloped portion 620 and a squared portion 621. The sloped portion 620 of the junction box opening 619 can extend downwards from the squared portion 621 towards the bottom junction box end 134. The lid body 121 of the lid 120 can be shaped complimentary to the sloped portion 620 and the squared portion 621 of the junction box opening 619. The sloped portion 620 of the junction box opening 619 can facilitate access to the wiring sub-compartment 611 which can be desirable for attaching wires to the grounding clamp 232 or the wire connectors 615a,b,c,d.

The junction box compartment 210 can be sized according to Table 6.16.1 of UL 1598. For double entry of three way 12AWG wire, the junction box compartment 210 can define a volume of 6 in³ or greater. In such aspects, the junction box 110 can define a height of 124 mm. To accommodate an additional input of three core 12AWG wire, the junction box compartment 210 can define the volume of 9 in³ or greater and a junction box height of 135.5 mm.

FIG. 7 is perspective view of the can light assembly 100 of FIG. 1 with the lid 120 in an open position. The lid 120 can be selectively positionable about and between the closed position and shown in FIG. 1 and the open position of the present aspect. In the open position, the wiring sub-compartment 611 of the junction box compartment 210 can be exposed. With the lid 120 in the open position, a user can connect individual wires from the AC power conductor to the wiring connectors 615a,b,c,d or the grounding clamp 232. The partition wall 612 can further define a pair of cable tie brackets 715a,b. The cable tie bracket 715a can be disposed above the wiring connectors 615a,b, and the cable tie bracket 715b can be disposed above the wiring connectors 615c,d. The cable tie brackets 715a,b can allow individual wires or the conductor to be secured to the partition wall 612 with a cable tie (not shown) to prevent withdrawal of the individual wires from the wiring connectors 615a,b,c,d under tension.

FIG. 8 is a detail view of the partition wall 612 taken from Detail 8 shown in FIG. 7. The wiring connectors 615a,b,c,d can respectively define wire receptacles 815a,b,c,d. Each wire receptacle 815a,b,c,d can be configured to receive a stripped end of an individual wire (not shown). Once the individual wires are received within the wire receptacles 815a,b,c,d, the wiring connectors 615a,b,c,d can connect each individual wire in electrical communication with the driver PCB 630 (shown in FIG. 6). In the present aspect, wire receptacles 815a,c can be configured to each receive a neutral line (not shown) of the AC power conductor (not shown), and wire receptacles 815b,d can be configured to each receive a live line (not shown) from the AC power supply conductor.

The wiring connectors 615a,b can define a first wiring block 806a, and the wiring connectors 615c,d can define a second wiring block 806b. The can light assembly 100 can be individually powered by attaching the live line and the neutral line of the AC power input to either the first wiring block 806a or the second wiring block 806b. In grounded applications, a ground wire (not shown) can be attached to the grounding clamp 232 by the fastener 230. In applications in which multiple can light assemblies 100 are electrically connected in a single wiring scheme, both the first wiring block 806a and the second wiring block 806b can be utilized to wire the can light assemblies 100 together, such as in a daisy chain or a star connection. For example, the live line and the neutral line of the AC power input can be connected to the first wiring block 806a, and an output live line and an output neutral line of an AC power output conductor can be connected between the second wiring block 806b and a first wiring block 806a of a second can light assembly 100.

Each wiring connector 615a,b,c,d can comprise a retention button 816a,b,c,d, respectively. The retention buttons 816a,b,c,d can be biased to occlude the respective wire receptacles 815a,b,c,d, by a spring or other biasing element. Depressing the retention buttons 816a,b,c,d into the respective wiring connectors 615a,b,c,d can open the wire receptacles 815a,b,c,d allowing a one of the individual wires to be inserted into the wire receptacle 815a,b,c,d. Once released, the retention buttons 816a,b,c,d can move outwards to engage and pinch the respective individual wire, thereby securing the wire within the respective wire receptacle 815a,b,c,d.

The wires for the first wiring block 806a can be secured by the first cable tie bracket 715a. The wires for the second wiring block 806b can be secured by the second cable tie bracket 715b. The cable tie brackets 715a,b can cooperate with the stress-relieving inlets 214a,b (shown in FIG. 2) to resist withdrawal of the individual wires from the wire receptacles 815a,b,c,d when the individual wires or the conductor are subjected to tension. Each cable tie bracket 715a,b can define a passageway 814a,b, respectively, which can be sized and shaped to receive a cable tie (not shown). The cable tie can then be wrapped around the wires to secure the wires to the cable tie bracket 715a,b.

The partition wall 612 can further define a wire stripping guide 820 formed into the partition wall 612. The wire stripping guide 820 can be configured to determine a recommended stripping length for the individual wires to be connected to the wiring connectors 615a,b,c,d. For example, in the present aspect, insulation of the individual wires can be stripped back 8 mm as the recommended stripping length. The wire stripping guide 820 can define a height Hi equal in value to the recommended stripping length. An end of the individual wire can be inserted into the wire stripping guide 820, and a stripping tool can be applied to the individual wire above the wire stripping guide 820 to remove the recommended stripping length of insulation from the wire end. The recommended stripping length of 8 mm is not limiting, and the recommended stripping length for the wiring connectors 615a,b,c,d can vary according to the style, size, and design of the wiring connectors 615a,b,c,d.

FIG. 9 is an exploded view of another aspect of the can light assembly 100 comprising the junction box 110 of FIG. 1 and another aspect of the light engine 212, the trim housing 160, and the trim piece 170. In the present aspect, the light engine 212, the trim housing 160, and the trim piece 170 can be sized for use with a 6″ nominal opening. The junction box 110 of FIG. 1 can be compatible with light engines 212, trim housings 160, and trim pieces 170 sized for either 4″ nominal openings or 6″ nominal openings. In the present aspect, the trim piece 170 can comprise three friction clips 240, as represented by friction clips 240a,b. The friction clips 240a,b can be equally spaced around a circumference of the trim piece 170. The trim housing 160 can define three recesses (not shown) spaced complimentary to the arrangement of the friction clips 240a,b. The quantity and distribution of friction clips 240 and recesses should not be viewed as limiting, and the can light assembly 100 can comprise greater or fewer than three friction clips 240. In other aspects, the trim piece 170 can attach within trim housing 160 with another attachment mechanism, such as by engaging a threaded portion of the trim piece 170 with a threaded portion of the trim housing 160.

FIG. 10 is a side view of the light engine 212 of FIG. 9. The light engine 212 of the present aspect can define a plurality of reflector fins 1008 extending radially outward from the outer circumferential surface 312 of the reflector 310. The reflector fins 1008 can function similar to the reflector shoulder 208 of the light engine of FIG. 2, and the reflector fins 1008 can capture the top trim housing aperture 268 (shown in FIG. 2) between the reflector fins 1008 and the bottom junction box end 134 (shown in FIG. 1) to secure the trim housing 160 (shown in FIG. 9) to the junction box 110 (shown in FIG. 9). The reflector fins 1008 can be configured to dissipate waste heat generated by the light engine 212. The reflector 310 can also define a reflector lip 1015 extending radially outward from the reflector 310.

FIG. 11 is a cross section of the light engine 212 of FIG. 9 taken along line 11-11 shown in FIG. 10. As shown, the reflector lip 1015 can define a reflector lip groove 1115. The reflector lip groove 1115 can be configured to receive the trim collar 217 of the trim piece 170 (shown in FIG. 9). Engagement between the trim collar 217 and the reflector lip groove 1115 can align the lens 204 of the light engine 212 with the trim piece 170. FIG. 12 can be a top perspective view of the light engine 212 of FIG. 9.

It should be emphasized that the above-described embodiments are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.

Claims

1. A can light assembly comprising:

a junction box, the junction box defining a top junction box end and a bottom junction box end;

a light engine, the light engine mounted to the bottom junction box end, the light engine comprising: a reflector, the reflector defining a top reflector end and a bottom reflector end, the reflector defining a reflector bore extending through the reflector from the top reflector end to the bottom reflector end, the reflector bore defining a top reflector aperture at the top reflector end and a bottom reflector aperture at the bottom reflector end; a lens, the lens covering the bottom reflector aperture; and a light PCB, the light PCB comprising an SSL source, the light PCB covering the top reflector aperture, the SSL source aligned with the top reflector aperture, the SSL source configured to emit light through the lens; and

a trim housing, a top trim housing end of the trim housing positioned adjacent to the bottom junction box end, the trim housing defining a trim housing bore extending through the trim housing, the trim housing bore defining a top trim housing aperture at the top trim housing end, the light engine extending through the top trim housing aperture.

2. The can light assembly of claim 1, wherein:

the light PCB, the lens, and the reflector define a light engine cavity; and

the SSL source is dielectrically isolated within the light engine cavity.

3. The can light assembly of claim 1, wherein:

the reflector housing defines a reflector shoulder extending radially outward from the reflector; and

the top trim housing aperture is captured between the reflector shoulder and the bottom junction box end.

4. The can light assembly of claim 3, wherein:

the light engine is secured to the bottom junction box end by at least one fastener; and

the reflector shoulder secures the trim housing to the bottom junction box end.

5. The can light assembly of claim 1, wherein:

a junction box compartment is defined within the junction box;

the trim housing comprises a pair of side tabs extending upwards from the top trim housing end;

the pair of side tabs extend through the bottom junction box end and into the junction box compartment; and

the pair of side tabs are configured to secure the trim housing to the bottom junction box end.

6. The can light assembly of claim 1, wherein:

the junction box further comprises a driver PCB;

the driver PCB comprises a driver connector which extends through the bottom junction box end;

the light PCB comprises a light connector which engages the driver connector; and

the driver connector and the light connector connect the driver PCB in electrical communication with the light PCB.

7. The can light assembly of claim 1, wherein:

the junction box defines an outer circumferential groove at the bottom junction box end;

the trim housing defines an outer circumferential collar extending upwards from the top trim housing end; and

the outer circumferential collar engages the outer circumferential groove and aligns the trim housing with the junction box.

8. A junction box comprising:

a junction box housing;

a lid hingedly attached to the junction box housing, the junction box housing and the lid defining a junction box compartment within the junction box, the lid selectively positionable about and between an open position and a closed position;

a partition wall disposed within the junction box compartment, the partition wall dividing the junction box compartment into a driver sub-compartment and a wiring sub-compartment, the partition wall comprising a wiring connector extending through the partition wall; and

a driver PCB disposed within the driver sub-compartment, the driver PCB in electrical communication with the wiring connector.

9. The junction box of claim 8, wherein:

the partition wall is attached to the junction box housing;

the partition wall defines a hinge pin notch configured to receive a hinge pin of the lid;

the hinge pin is secured between the partition wall and the junction box housing in the hinge pin notch; and

the lid is configured to hingedly rotate about the hinge pin.

10. The junction box of claim 8, wherein:

the lid defines a stress-relieving inlet extending through the lid;

the lid comprises a flexible friction lever biased to occlude the stress-relieving inlet; and

the flexible friction lever is configured to exert a residual pinching force on an electrical conductor when the electrical conductor is inserted through the stress-relieving inlet.

11. The junction box of claim 10, wherein a breakaway pull tab covers the stress-relieving inlet.

12. The junction box of claim 8, wherein:

the driver PCB comprises a driver connector;

the driver connector extends through a floor of the junction box housing;

the driver connector is configured to connect in electrical communication with a light engine; and

the driver PCB is configured to control an SSL source of the light engine.

13. The junction box of claim 12, wherein:

the driver PCB is configured to convert an AC power input to a DC power output;

the AC power input defines an input voltage value;

the DC power output defines an output voltage value; and

the driver PCB is configured to boost the output voltage value to be greater than the input voltage value.

14. The junction box of claim 8, wherein the driver PCB is dielectrically isolated within the driver sub-compartment.

15. A method for manufacturing a can light assembly, the method comprising:

attaching a lid of a junction box to a junction box housing of the junction box, the junction box defining a top junction box end and a bottom junction box end, the lid and the junction box housing defining a junction box compartment within the junction box;

mounting a driver PCB within the junction box compartment;

attaching a trim housing to the bottom junction box end, the trim housing defining a top trim housing aperture positioned adjacent to the bottom junction box end;

positioning a light engine within the top trim housing aperture; and

connecting the light engine in electrical communication with the driver PCB.

16. The method of claim 15, wherein:

the trim housing defines a trim housing bore extending through the trim housing; and

the method further comprises receiving a trim piece within the trim housing bore.

17. The method of claim 15, further comprising inserting a side tab of the trim housing into the junction box compartment to secure the trim housing to the bottom junction box end.

18. The method of claim 15, wherein attaching a trim housing to the bottom junction box end further comprises capturing the top trim housing aperture between the bottom junction box end and a reflector shoulder of the light engine.

19. The method of claim 15, wherein attaching a trim housing to the bottom junction box end further comprises engaging a retention tab of the trim housing with a locking tab opening of the junction box housing.

20. The method of claim 15, further comprising attaching a partition wall to the junction box housing and enclosing the driver PCB within a driver sub-compartment.