SSL CAN LIGHT FIXTURE WITH BUILT-IN JUNCTION BOX
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.
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.