DMF, Inc.

A gateway controls a portion of lighting fixtures within a lighting system in response to a first digital signal and comprises a power input port to receive AC power, a power line filter to filter electrical noise from the received AC power, a power output port to output the filtered AC power to the portion of lighting fixtures, an input signal port to receive the first digital signal, an output signal port to pass the received first digital signal to a second gateway, a local controller, a first transceiver coupled to the input signal port to receive the first digital signal, and a second transceiver coupled to the power output port to couple the second digital signal to the power output port.

A recessed lighting system includes a substantially heat conducting unified casting having a front face and a rear heat conducting portion and having dimensions to fit inside a standard-sized junction box. The system further includes a light source module, housed within the heat conducting unified casting, to emit light, wherein the light source module is positioned closer to the rear heat conducting portion than the front face of the substantially heat conducting unified casting. A driver, housed within the heat conducting unified casting and insulated from the heat conducting unified casting, provides power the light source module. A lens, coupled to the heat conducting unified casting, direct lights produced by the light source module out into an area surrounding the recessed lighting system. The substantially heat conducting unified casting significantly dissipates heat generated by the light source module during operation of the light source module.

A lighting module includes a heat sink with a sidewall and a partition defining two cavities, a LED light source disposed in one cavity to emit light, a driver module disposed in the other cavity with driver circuitry to provide electrical power to the light source, and an optical assembly to provide a desired emission profile. The optical assembly is field-changeable and includes a cover lens with snap-fit connectors to facilitate removal and replacement. The optical assembly further includes either a reflector coupled to the cover lens or an optical lens coupled to the heat sink via an optic holder. In some examples, the driver circuitry facilitates dimming of the light source. The heat sink also dissipates heat generated by the light source and the driver circuitry to maintain desired operating temperatures and thereby facilitate increased light output.

Apparatus and methods for operating low-voltage lighting systems are described. Wiring hubs can reduce installation wiring complexity. A smart power supply can provide more than 100 watts of power on Class 2 low-voltage wiring to compliant loads and limit power delivery to 100 watts for non-compliant loads.

A housing assembly for a recessed lighting system includes a housing with integrally formed cable routing features, mounting features, and alignment features. The integration of multiple features into the housing is enabled by forming the housing from a polymer using an injection molding process instead of sheet metal. For a new construction installation, the housing includes integrally formed bar hanger holders to support and guide bar hangers for installation onto two or more support structures, nail-in features for installation onto a single support structure, and one or more alignment features to position the housing against the single support structure when the nail-in features are used for installation. For a remodel installation, the housing includes a flange to abut a bottom surface of a ceiling and one or more spring clips mounted to the housing to abut a top surface of the ceiling.

A modular linear lighting system includes a mounting track securely coupled to an installation surface of a ceiling or a wall, a run of one or more light bars of various lengths to emit light, an input connector to receive electrical power and, in some instances, control signals to adjust the light output, one or more middle connectors to electrically couple a pair of light bars in a daisy-chain configuration, and an end connector to mechanically couple the last light bar in the run to the mounting track. The light bars and the connectors may be mechanically and electrically coupled to each other in a tool-free manner. In some implementations, the input connector may include an integrated LED controller to provide additional customization of the light output, such as adjusting the color (e.g., the correlated color temperature) of the light output.

A junction box having a cavity to contain electrical wires that provide a connection to a building mains voltage from an electrical system of a building is coupled to a plurality of telescoping hanger bars to hold the junction box in a wall or ceiling in the building. Each telescoping hanger bar is extendible and/or retractable to vary a length of the hanger bar. A position of the junction box is adjustable along the length of each telescoping hanger bar. In one example, the apparatus does not include a can, separate from the junction box, to contain a lighting device of a recessed lighting assembly.

A mud-in plate assembly is configured to convert a previously installed recessed lighting fixture having a first trade size into a trimless recessed lighting fixture having a second trade size smaller than the first trade size. The mud-in plate assembly includes a mud-in plate having a flange and a sidewall. The flange is sufficiently large to cover a first opening formed in a ceiling, which corresponds to an opening of a housing in the previously installed recessed lighting fixture. The sidewall defines a second opening smaller than the first opening. The sidewall is configured to support a lighting module designed for the second trade size. The mud-in plate assembly is implemented as part of a retrofit recessed lighting installation that utilizes components from the previously installed recessed lighting fixture, such as a housing, wiring, or a junction box, and does not require removal of drywall.

Apparatus and methods for controlling correlated color temperature (CCT) and lighting intensity in lighting fixtures are described. The CCT and intensity may be controlled independently over conventional AC wiring using a conventional dimmer. A lighting controller that resembles a conventional dimmer and that can be installed in place of a dimmer may be used instead of a conventional dimmer to access more control functionalities, still using conventional AC wiring. Wireless communication with the lighting fixture and/or lighting controller are possible.

A lighting module includes a heat sink having a sidewall and a partition that defines a first cavity and a second cavity; a driver enclosure disposed in the first cavity and electrically insulated from the heat sink; a driver disposed in the driver enclosure to provide electrical power; a light source disposed in the second cavity and receiving the electrical power; an optical element positioned over the light source; and a retaining ring/optic cover closing the second cavity. A trim is mechanically and electrically coupled to the heat sink of the lighting module and connected to an electrical ground via the heat sink. The lighting module fits into a space having a width less than 2.4 inches. The heat sink includes at least one curved keyed feature reducing the volume of the heat sink and providing sufficient clearance for the heat sink to fit within an enclosed space.