New construction light pans that securely mount light fixtures and/or light trim modules are generally secured to ceiling joists or rafters located behind and supporting interior surface panels, also known in the industry as sheetrock, gypsum board and drywall. The pans are installed either before the ceiling panel is installed, or while access is still readily available from the back side of the panel. In contrast, when remodeling, a ceiling or wall panel is already in place and access from the back side of the panel is generally no longer available; therefore, all installation steps must be completed from the front side of the ceiling panel, generally through a cutout having a raw unfinished edge through which the remodel light fixture is installed. Additionally, a remodel light fixture usually must be secured to the panel cutout. The cutout in the panel, often lacks enough integrity and strength at the periphery of a cutout to support engagement of typical hardware such as formed spring steel clips used to secure the light fixture to the ceiling panel.
Prior art remodel light fixtures include light fixtures having a can housing with a flange that projects radially from a lower end of the can and hardware to secure the can housing to the ceiling panel. For example, typical hardware includes jackscrew and flag combinations located peripherally around the can at a distance from the flange that allows the ceiling panel to be captured between the flange and flags. To install, the flags are swung inwardly tangential to the surface of the can, the distal end of the can is inserted into the hole through the ceiling panel, then the flange is held flush against the front side of the ceiling panel. Held in this position, the flags are located around the outer circumference of the can at a depth from the flange so that they are just above the back side of the ceiling panel. While the flange is held flush against the ceiling panel, each jackscrew is actuated and the associated flag swings radially outward and the flag is drawn toward the back side of the ceiling panel, capturing and compressing the panel between the flag and the flange. The light trim is then secured to the can housing. In some cases, the light receptacle coupled to the housing must be secured to the trim before the trim is secured to the housing.
Such a prior art remodel light fixture can be cumbersome to hold in place while securing and also requires separate installation of the light housing and trim module. Additionally, the raw, unfinished circumference of the cutout from a front side surface of a ceiling panel is often uneven, imperfect, and not structurally sound, requiring care that the diameter is proper and any crumbled areas or other imperfections do not prevent a flag from catching a solid portion of the back side of the panel or from crumbling a portion of the periphery of the cutout as the flag is swung out and drawn toward the flange.
Another prior art remodel light fixture includes a housing can and spring clips that can be manually actuated from the interior of the can and that extend radially outward from the outer diameter of the can. To install, the can is positioned within the hole in the ceiling panel so that the bottom edge of the can is flush with the front side of the ceiling panel. While the can is held in this position, the spring clips are manually actuated from the interior of the can so that the clips press into the panel thickness between the front and back side surfaces, securing the can in place. Next the light trim is secured to the housing can. In some fixtures, the light receptacle coupled to the housing must be secured to a trim module before the trim module is secured to the housing.
Installation of such remodel light fixtures can be cumbersome, requiring portions of the light assembly be held in place while securing and performing additional assembly of the housing, light receptacle, and trim. Additionally, the raw, unfinished circumference of the cutout from a front side surface of a ceiling panel such as drywall may crumble, give way, or be imperfect in opening size so as to prevent secure engagement by the spring clips that press into it.
It is therefore desirable to provide a remodel light assembly that installs easily, quickly, and securely in panels such as drywall, even when imperfections in the cutouts are present.