Patent Application
20200393097
The present invention is directed to a cast concrete durable light fixture design that will reduce the parts and materials required and facilitate a simpler installation of a drive over in-grade or in-ground lighting fixture. The cast concrete design enables curves and shapes to be manufactured as easily as straight or linear configurations. Casting fixtures as precast interlocking sections from concrete, polymer concrete mixtures or other non-corrosive structural materials, which will withstand heavy drive over traffic, solves the environmental problems associated with present metal body in-ground lighting system applications in a cost-effective configuration.
The present invention optimizes the advantages of light emitting diode (LED) lights for in-ground lighting architectural products. LED versions can provide colored or color changing effects. The miniature size of LEDs enables the creation of narrow linear images. The long life of the LEDs are particularly suitable for the in-ground applications due to their long useful lifetime as compared to other types of lights, and the LED's require limited maintenance. Recent developments of long flexible LED strips with miniaturized electronics using standard line voltages, which can be run continuously in lengths as long as 300 feet, enable new fixture designs to be created which are free-form as well as straight linear lines. In addition, because of the LED low energy requirements, they can be used economically due to their energy efficiency.
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The cast concrete bodies 10, 30 and 70 are preferably formed from concrete, polymer concrete mixtures or other non-corrosive castable or moldable structural materials including for example plastics and high strength thermoplastic or resin materials capable of bearing substantial loads. The pre-cast lighting fixture is a self-supporting structure capable of being placed in the ground without additional structural materials or the need to pour concrete in place. Pre-cast lighting fixture sections of various lengths can be interconnected to form infinitely continuous lines of light in roadways, entrances or pathways, without the need for complicated forms or shuttering to be built to set the lights in place. The pre-cast lighting fixture may alternatively be used to house other electronic components for intelligent roadways and pathways, for example housing cellular, wi-fi or other wireless communication technologies enabling vehicular communication and automation.
The pre-cast light fixture define a channel running the full length of the body, with white or light colored reflective sides, which may be angled or shaped to reflect light in a specific pattern. The pre-cast light fixture is designed to contain sealed waterproof LED array or interconnecting arrays or continuous sealed LED strips which may be secured in place by adhesive materials or channels made from plastic or non corrosive metal or other materials, or a secondary channel cast in to the base of the main channel. Each side of the channel preferably has the shoulders or ledges formed to support a flush fitting lens. The lens may be made of plastic or glass or formed from light transmissive materials including natural stone.
Preferably, the lens should be capable of supporting the weight of automobile and truck traffic for in-pavement locations, thus at least capable of supporting 150 kPa to 700 kPa. However, for architectural lighting uses the lens may not need to be capable of supporting vehicular traffic. The lens may be trapezoidal with its narrowest width at the upper position to leave an even space which will allow a sealant or grout material to be applied to secure and seal the lens in position. The main channel within the cast concrete body may have open ends to allow continuous LED lighting arrays or strips to run from section to section of the pre-cast units to create continuous lines of light, or they may have closed ends to seal the fixture as an individual unit. Interlocking connectors and recesses at opposite ends of the fixtures enable fixtures to align and lock together to form continuous linked lines or shapes.
Abutting ends of interconnecting pre-cast sections are glued with a flexible waterproof adhesive/sealant which allows linear expansion and contraction during climatic changes. The linear lighting arrays are secured within the channel, which is enclosed by structural weight bearing plastic or glass lenses, each being longer than a single pre-cast section so that it bridges the joint of each section. The lenses will be supported by load bearing shoulders or ledges which are formed in the pre-cast structure, and are designed to be sealed in place with a waterproof adhesive glue or grout.
Assembly and installation of the cast concrete body sections is achieved by setting the first section on a level bed of sand or other level surface; applying a thin film of adhesive sealant to the end face of the cast concrete body section containing the female interconnector recesses and then placing a second cast concrete body section having the male interconnectors in to place to form a continuous channel. Multiple sections are interconnected until the complete linear or curvilinear light is in place. Open ends are sealed with endcaps, or where circles or similar forms are created the last section is set in place as a keystone after removing the interlocking male interconnectors. Waterproof LED or other illuminating lamps are installed in the channel by appropriate support structures such as formed supports or recesses in the channel, or other secondary supports of non corrosive materials. Liquid tight connectors enable power to be supplied to the lights through round holes cast or drilled into the cast concrete body sections or at the ends of connected runs, and cable routing components enable continuous power connector cords or wire to be run throughout the lighting channel to allow power connections.
Alternatively, the lens 24 of the assembly may be formed as a structural architectural glass having embedded LEDs within the glass. The embedded LEDs are provided with electrical power circuitry within the glass which allows for the design of an illuminating lens capable of color change and being digitally addressed and controlled to display or project messages or images. These types of glass assemblies are currently available and readily adapted to be included as the lens or under a clear lens in the in-ground lighting assembly of the present invention.
Various alternative styles are envisaged where the design details allow for different conditions and finished appearance. The invention has been described in detail above in connection with the figures, however it should be understood that the system may include other components and enable other functions. Those skilled in the art will appreciate that the foregoing disclosure is meant to be exemplary and specification and the figures are provided to explain the present invention, without intending to limit the potential modes of carrying out the present invention. The scope of the invention is defined only by the appended claims and equivalents thereto.
In-ground or below grade lighting systems provide a number of desirable benefits and enhancements to building designs and architectural features. In-ground linear lighting can be used to create unobtrusive, directional or decorative illumination in pedestrian or vehicular traffic areas, which will not obstruct traffic. Placing the lighting features in-ground has an added benefit of making the lighting vandal resistant. In-ground lighting can be used to delineate pathways and access points or to direct illumination on architectural structures and facades. However, in-ground lighting systems are exposed to a number of environmental factors, including water, salt water, corrosive materials and chemicals, requiring special design considerations. Examples of in-ground lighting systems are disclosed in U.S. Pat. Nos. 7,478,916; 9,638,381; 9,784,440 and 10,082,260. In-ground light fixtures intended to be used in roadways, driveways and entrances, which may be called “drive over” lighting fixtures, further require a durable and structurally sound assembly. In-ground drive over resistant lighting fixtures have a shell or body made from metal, often stainless steel or aluminum, where the shell or body is fixed in the ground to be back-filled and surrounded by concrete or pavers. After setting the concrete or pavers around the body, a secondary waterproof sealed lighting fixture is then installed in the body. The strong supporting metal body together with the lighting fixture is then capable of supporting considerable weight of drive over traffic without being distorted or crushed. Stainless steel is usually the preferred material body as it resists corrosive elements which may be present in many soil conditions, or where salt water or chemicals could cause materials such as aluminum to have a galvanic reaction, resulting in corrosion and weakening of the fixture. The high cost of the metal components and the lighting fixture plus additional costs associated with complicated installation cause the application of existing drive over lighting fixtures to be prohibitively expensive to install for many locations. Existing available inground lighting fixtures are also limited to single cans or in some cases straight line assemblies, as the cost and complexity of manufacturing and installing curved or custom fixtures is more expensive and complex making them impractical. An in-ground lighting structure having a simple yet variable design which could be installed more easily with less associated expense, and which would also resist corrosion, would be beneficial to the industry and could become a preferred option for in-ground lighting systems.
