Emergency lighting unit/exit sign combination

Information

  • Patent Grant
  • 6499866
  • Patent Number
    6,499,866
  • Date Filed
    Tuesday, October 31, 2000
    24 years ago
  • Date Issued
    Tuesday, December 31, 2002
    22 years ago
Abstract
An emergency lighting fixture combining the functions of an illuminated sign such as an exit sign and an emergency lighting unit integrated into one housing onto which one or more emergency lights can be mounted at predetermined locations of the housing, the combined emergency lighting structure providing both exit location information and ambient emergency lighting in a single cooperatively operating device. The present device replaces bulky prior combinations of discrete exit signs and emergency lighting units which have been assembled together essentially as individual devices without integration into a single housing or without substantial integration of operational features, the housing of the present device being only slightly larger than standard exit signage. The present fixture is preferably formed from light weight materials such as polycarbonate/ABS or sheet metal configured to mount in tension internal weight such as weight due to enlarged battery mass and the like as well as externally mounted emergency lights. Manufacture of the present fixture is improved by the ability to mold major portions of the fixture from suitable polymeric materials, thereby allowing formation of substantial portions of the fixture located internally of the housing integrally with the housing to substantially reduce the number of parts necessary to be assembled together in an assembly situation. Assembly, installation and maintenance of a molded fixture according to the invention is further improved by the ability to snap-fit together all structural elements of the fixture both internally and externally of the housing.
Description




DESCRIPTION OF THE PRIOR ART




1. Field of the Invention




The invention relates generally to emergency lighting fixtures including illuminated signs and emergency lighting units and particularly relates to combinations of illuminated exit signs and the like with emergency lighting units to form fixtures having multiple emergency lighting functions in a single device.




2. Background of the Invention




Emergency lighting capability is mandated by building codes throughout most of the world for commercial buildings in particular. The most common type of emergency lighting is the exit sign which is also the most noticed due not only to its ubiquity but also due to the fact that most exit signs are constantly illuminated and are therefore readily seen. Exit signs are typically placed above doorways or in egress paths to indicate in a time of emergency the most efficient manner of exiting a building. Another common form of emergency lighting is generally referred to as an emergency lighting unit and typically operates two spaced lamps which are often referred to as “frog eyes”. Emergency lighting units operate only in the event of emergency and are intended to supply an acceptable degree of ambient illumination under emergency conditions, these conditions usually including loss of normal power. Since emergency conditions requiring the most immediate and effective use of both exit signs and emergency lighting units are normally associated with mains power loss, backup power is necessary for the continued operation of an exit sign and for start-up and continuing operation of an emergency lighting unit. This back-up power is provided by batteries, a typical exit sign having a battery and circuitry capable of switching to DC battery power from AC mains power on loss of AC power to the exit sign. An emergency lighting unit includes a battery and sensing circuitry which initiates operation of the battery on loss of normal building power, the lamps of the emergency lighting unit being then activated to provide emergency lighting. These two forms of emergency lighting, the exit sign and the emergency lighting unit, are placed in a building structure at locations requiring a particular function of each form. Certain situations require the use of both forms of emergency lighting in one location. Rather than USQ separate lighting fixtures in one particular location, common practice has been to use a “combination” exit sign and emergency lighting unit, this type of fixture being commonly referred to as an exit/unit combo. The “combo” has previously taken the form of an emergency lighting unit mounted to an exit sign, the emergency lighting unit most often being mounted along the top of the exit sign. In most instances, the exit sign and the emergency unit operate separately although certain functions can be shared between the exit sign and the unit by providing common circuitry such as would be useful to detect power line failure for switching the exit sign to DC battery power and for initiating operation of the emergency lighting unit. A particular exit/unit combo which has enjoyed substantial market acceptance is the QUANTUM Exit/Unit Combo manufactured by Lithonia Lighting, Inc. of Conyers, Ga., a wholly owned subsidiary of National Service Industries, Inc., of Atlanta, Ga., QUANTUM being a trademark of National Service Industries, Inc. The widespread use of the Lithonia Lighting combo has been brought about at least in part due to the reduced labor costs associated with installation of the Lithonia combo on site, the exit sign and the emergency lighting unit being factory assembled and prewired for shipment to a job site in a configuration allowing rapid and simultaneous final wiring of both the exit sign and the emergency lighting unit. Further, the Lithonia combo manufactured and marketed under the QUANTUM mark is comprised of a substantially all-plastic exit sign and a substantially all-plastic emergency lighting unit, thereby resulting in a combo product which is light in weight relative to previous combo products many of which included metal housings and parts which caused the products to be heavy and therefore more difficult to support especially in end mounted installations. The Lithonia QUANTUM combo could be rapidly and easily mounted at the top, back or ends with adequate support of the assembly being possible even when end mounted. Manufacture and maintenance of the Lithonia combo were facilitated by the virtual all-plastic structure of the Lithonia product which allows at least portions of the product to be positively and readily snap-fitted to each other. While the QUANTUM combo evidenced significant advantages in this art, the combination of two essentially different and distinct forms of emergency lighting into a single product with both the exit sign and the emergency lighting unit retaining its own housing inter alia such as would be employed in their separate use has caused combo products to continue being somewhat bulky in size and to be less attractive than most other forms of emergency lighting have become in recent years as the industry has devoted increased attention to the appearance of emergency lighting products generally.




Accordingly, the art has experienced a long-felt and continuing need for improvement of a combination exit sign and emergency lighting unit or combo product to the end that such products become a true integration of an exit sign and an emergency lighting unit capable of supporting the weights of batteries necessary for providing power to both sides of an exit sign as well as unit lamps including remote unit lamps. In addition to the need to support greater battery weights than previously necessary in exit signs alone, the need exists in a combo to support greater weight than is normally experienced with an exit sign per se so that a combo can be safely and positively mounted in wall or ceiling installations. The art has thus felt the need for the present combo invention which integrates the functions of an exit sign and an emergency lighting unit into a single housing with repositionable lamping elements mounted to exterior portions of the housing. The structure of the present exit/unit combo allows support of battery loads in tension rather than through the usual cantilevered support of loads disposed internally of a sign housing. The structure of the present combo housing provides support of such efficiency as to prevent warping or bowing of the housing over time, thereby providing substantially improved product quality along with substantially improved product appearance. The exit/unit combo of the invention is provided with significant structural features useful not only with the combo but also with exit signs per se and with emergency lighting units per se as well as remote emergency lighting units., The present invention thus provides substantial improvement over the prior art by the provision of an integral and integrated exit/unit combo characterized by ease of assembly, installation and maintenance as well as by extraordinarily acceptable appearance.




SUMMARY OF THE INVENTION




The invention provides an emergency lighting fixture which combines the functions of an illuminated sign, particularly an exit sign, with an emergency lighting unit, the structural combination being integrated into a single housing which internally contains those structural elements necessary to produce the functions of the feature and which carries emergency lamping externally of the housing at multiple locations thereby providing extraordinary flexibility in use. The present combination of an exit sign and an emergency lighting unit or “exit/unit combo” is preferably formed of a polymeric material such as polycarbonate/ABS, thereby allowing molding of a fixture housing with most of the structural elements necessary to produce the functions of the fixture being integrally formed with the housing, these molded structural elements and other structure contained within the housing being located in the housing in a manner whereby the elements combine to produce synergistic effects in addition to the primary functions of the structural elements, the fixture being totally integrated as to structure and function as well as being substantially integral in construction. Formation of the fixture essentially from moldable material further allows integral formation of snap-fitting structural elements which not only provide easy snap fitting of facing plates to the housing to form the primary structural portion of the combo per se but also the integral formation of snap-fitting structure with bulb holders, battery mounting elements and option board storage elements inter alia. Assembly of the fixture is therefore facilitated at least in part due to the reduced number of individual parts occasioned by the integral nature of the housing inter alia.




The housing of the present exit/unit combo fixture is configured to support battery weights inter alia which are typically greater than those battery weights encountered in conventional exit signs due to the need to operate exit lighting, unit lighting and even remote unit lighting with a single battery disposed within the housing. In order to accommodate greater battery weight and the weight of the fixture itself, the battery is centered with the housing disposed at a lower portion thereof, battery location couples with a central, vertical structural beam known as a “ladder” allows support of the battery inter alia in tension rather than in a cantilevered arrangement as has been previously employed in exit signs and the like. The structural features such as the ladder integrated with location of major weighting such as the weight of the battery actually allows use of a material such as plastic for formation of the fixture, the self-support provided by the structure itself preventing warping and bowing of the plastic exit/unit combo fixture over time such as would occur with a fixture having the weight of the exit/unit combo fixture if not provided with the integrated structural relationships of the invention. The dimensional stability of the present exit/unit combo fixture occurs due to the structural features of the fixture which maintain substantial portions of the fixture weight in tension.




The exit/unit combo fixture of the invention provides “unit” emergency lighting by the disposition of one or more emergency lamps mountable at different locations on the periphery of the fixture housing to accommodate differing lighting situations. The lamps are mounted by lamp holders fitted with swiveling concentric spherical structural elements which allow movement of the lamps with a degree of freedom not previously possible, the structure of the concentric spherical elements additionally yielding a compact profile which is not only attractive in appearance but functional due to the volumetric efficiency thus provided. The lamp holders of the invention are formed with torsion snap elements which fit into slots formed in peripheral edges of the housing, the slots receiving the snap elements of the lamp holders to positively mount the lamp holders in desired locations on the fixture. The particular snap element/slot arrangement of the invention allows rapid and ready mounting and dismounting of the lamp holders to and from the fixture housing with positive locking of the lamp holders to the housing once assembled. The lamp holders of the invention can be removed from the present fixture and mounted to remote slave mounting stations driven by the fixture with the snap elements of the lamp holder fitting into arranged slots of the slave station. Further, the lamp holder can be mounted to a station separate from the fixture with battery or other operation, the lamp holder being mounted to the station through use of the snap elements of the lamp holder in cooperation with slots formed in the station.




Various other features of the invention include structure for minimizing the “shadow” of the battery appearing through face plates of the exit/unit combo fixture; registration structure for mounting of a diffusion panel in a face plate of the fixtures; routing of wiring in association with the ladder support and in front of the battery with the use of slack in the wiring and structure for compartmentalization of electrical components within the interior of the fixture housing including snap-mounting of a capacitor inter alia. Many of the inventive features disclosed herein are useful in fixtures other than exit/unit combo fixtures and are disclosed for use in that variety of fixtures for which these features find utility. Use of these features is thus not limited to use in an exit/unit combo fixture.




Accordingly, it is an object of the invention to provide an integral exit/unit combo fixture having the capabilities of an exit sign and of an emergency lighting unit integrated into a fixture formed with a single housing for containing a substantial portion of the structures and for mounting emergency unit lamps on the housing externally thereof and at repositionally distinct locations of the housing.




It is another object of the invention to provide an integral exit/unit combo fixture substantially moldable of a polymeric material to allow formation of substantial structural portions of the fixture with a fixture housing, the housing and associated face plates being rapidly fitted together with snap features, components of the fixture internally of the housing being snap-fitted to the housing for rapid assembly thereof, structure holding emergency lighting lamping further being rapidly snap-fitted to the housing at predetermined locations on the exterior of the housing.




It is a further object of the invention to provide an integral exit/unit combo fixture substantially moldable of a polymeric material with structural support features providing dimensional stability to the fixture thereby minimizing warping and bowing of the fixture over time in spite of substantial weight occasioned by the use of heavy batteries as well as the weight of the fixture itself, the fixture including internal support elements which mount battery weight as well as the weight of the fixture per se substantially in tension.




It is a still further object of the invention to provide an integral exit/unit combo fixture having unit lighting provided by lamps mounted on exterior portions of the fixture by lamp holders mounted to the fixture by tension snap elements, each lamp being mounted by a swiveling double concentric structure which allows an extraordinary range of movement of the lamp and which allows formation of the unit lighting structure with a compact profile, the fixture requiring a reduced volume and vertical height for mounting of the fixture, the fixture being also mountable with the back of the fixture directly against a flat surface such as a wall.




Further objects and advantages of the invention will become more readily apparent in light of the following detailed description of the preferred embodiments.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a perspective view of a first embodiment of the invention;





FIG. 2

is a side elevational view of the embodiment of the invention shown in

FIG. 1

;





FIG. 3

is a perspective view of a second embodiment of the invention;





FIG. 4

is a side elevational view of the embodiment of

FIG. 3

;





FIG. 5

is a front elevational view of a third embodiment of the invention;





FIG. 6

is a front elevational view of a fourth embodiment of the invention;





FIG. 7

is a front elevational view of a fifth embodiment of the invention;





FIG. 8

is a plan view of the embodiment of

FIG. 3

;





FIG. 9

is a view of the housing of the invention;





FIGS.10A and 10B

are view of the back plate of the invention intended for wall mounting of the fixtures;





FIG. 11A

is a front elevational view of the frame of the invention;





FIG. 11B

is an elevational view taken from the rear of the frame of the invention;





FIG. 12

is a front elevational view of the invention partially in schematic illustrating an incandescent embodiment of the invention;





FIG. 13

is a front elevational view partially in schematic illustrating an LED/incandescent embodiment of the invention;





FIG. 14

is a perspective view of the invention illustrating remote location of a slave fixture according to the invention;





FIG. 15

is a perspective view of a fixture having a portion of the combination fixture forming a part thereof;





FIG. 16

is a perspective view illustrating the structure of

FIG. 15

in an assembled relationship;





FIGS. 17A-E

are elevational view of the frame of the invention;





FIG. 18

is a view of the ladder structure;





FIGS. 19A and 19B

are detailed views of the battery compartment having a relatively small lead-acid battery mounted therein;





FIGS. 20A and 20B

are detailed view of the battery compartment having a relatively larger lead-acid battery mounted therein;





FIGS. 21A and 21B

are elevational views of a DC lamp mounting arrangement;





FIGS. 22A and 22B

are detailed views of the electrical compartment of the housing.





FIG. 23

is a detailed view of an option storage compartment formed in the housing;





FIG. 24

is an assembly view of components comprising the repositionable emergency lighting unit lamp assembly;





FIGS. 25A-25C

are views of the apparatus of

FIG. 24

;





FIGS. 26A-26C

are views of the apparatus of

FIG. 24

;





FIGS. 27A-27F

are views illustrating operation of the torsion snaps of the invention;





FIG. 28

is a simplified diagram of the circuitry of the invention; and,





FIG. 29

is a view of a front plate and diffusion panel arrangement of the invention.











DESCRIPTION OF THE PREFERRED EMBODIMENTS




Referring now to the drawings, and particularly to

FIGS. 1 and 2

, a combination exit sign/emergency unit fixture is seen at


10


to be comprised of a housing


12


and two emergency lighting unit lamp assemblies


13


. The fixture


10


will generally be referred to herein as the combo fixture


10


or merely as the fixture


10


. The housing


12


is essentially formed from frame


14


and face plate


16


as well as back plate


18


. In certain embodiments of the invention, the back plate


18


can be essentially identical to the face plate


16


, such a combo fixture


10


within constituting a double-faced fixture having indicia


20


on both faces thereof such as can occur in top and end mounted installations. In a direct wall-mounted installation, the back plate


18


is necessary in order for the combo fixture


10


to be mounted directly to a wall as will be described hereinafter.




The combo fixture


10


is typically provided with one or more directional indicators


22


which are often referred to as “chevrons”, the indicators


22


preferably comprising snap-fitting chevron structures which can be rapidly and positively mounted into openings


23


formed on the face plate


16


without the requirement for gaining access into the interior of the housing


12


. While various chevron structures can be utilized, a particularly suitable structure is disclosed in United States patent application Ser. No. 08/327,487, filed Oct. 21, 1994, now U.S. Pat. No. 5,611,163 by Stephen T. Smith with the title “Direction Indicator Covers for Emergency Lighting System”, the patent application being assigned to the assignee of the present patent application, the disclosure of Ser. No. 08/327,487, now U.S. Pat. No. 5,611,163 being incorporated hereinto by reference. Depending upon the exigencies of a particular installation, at least one of the indicators


22


is mated into the corresponding opening


23


to prevent light generated interiorly of the housing


12


from passing through the opening


23


. In certain installations wherein the combo fixture


10


may be placed directly over a doorway or the like, it is possible that both of the indicators


22


will be placed in the corresponding openings


23


. Certain other installations may require that neither of the directional indicators


22


be mounted in the corresponding openings


23


, such an installation signalling that a path of egress may exist to both sides of the combo fixture


10


.




As will be described in more detail hereinafter, and with additional reference to

FIG. 9

, a pair of incandescent lamps


24


are disposed within the interior of the housing


12


and operate on AC line voltage to illuminate the combo fixture


10


during normal, non-emergency situations during which the location of emergency egress paths is to be recognized by those persons using the environmental spaces within which the fixture


10


is mounted. A pair of emergency lamps


26


such as are seen in

FIG. 9

are located internally of the housing


12


and powered only during loss of AC line voltage by means of a battery


30


(as seen in

FIG. 9

inter alia), appropriate circuitry (not shown in

FIGS. 1 and 2

) causing DC voltage from the battery


30


to operate the emergency lamps


26


during a power failure such as would occur during emergency situations. The non-emergency lamps


24


thus illuminate the indicia


20


in normal situations with the emergency lamps


26


illuminating the indicia


20


during emergency situations. While the combo fixture


10


intends the indicia


20


to take the form of the word “EXIT” formed in the face plate


16


, it is to be understood that other indicia could be formed in the face plate


16


such as is conventional in the art. The use of non-emergency lamps such as the lamps


24


and driven by alternating current from building mains as well as the use of emergency lamps such as the lamps


26


operated on DC battery current in the event of power loss and/or emergency conditions is known in the art and need not be described in greater detail herein. As will be described hereinafter relative to

FIG. 13

, it is to be seen that a light emitting diode array


28


can be utilized in non-emergency situations as replacement for the lamps


24


.




Continuing to refer to

FIGS. 1 and 2

as well as to

FIGS. 3 through 5

and


8


, a canopy


32


is employed to mount the combo fixture


10


to a J-box (not shown) so that the fixture


10


is positively mounted either to the ceiling or to a wall of an environmental space within which the fixture


10


operates. As is seen in

FIGS. 17B

, C and D, openings


34


are provided in the frame


14


at least centrally of an upper edge of-the housing


12


. Openings


34


can similarly be provided on side edges of the housing


12


for end mounting of the fixture


10


such as can occur with the structure of

FIGS. 6 and 7

, that is, when one of the ends of the fixture


10


is available for end mounting. It is preferred that the combo fixture


10


be mounted either from the top or from the back as will be described in detail hereinafter and as is particularly shown relative to a top mount in

FIGS. 1 and 2

inter alia. While various canopy structures can be utilized including a number of canopies which are conventional in the art, it is preferred to use the canopy described in co-pending United States patent application Ser. No. 08/343,775, filed Nov. 22, 1994, now U.S. Pat. No. 5,526,251 by Gary S. Andre, Andrew E. Masters and Stephen P. Smith. and entitled “Emergency Lighting Connections”, Ser. No. 08/343,775 now U.S. Pat. No. 5,526,251 being assigned to the assignee of the present application. While the canopy


32


and corresponding structure such as the openings


34


in the frame


14


inter alia which are present in the combo fixture


10


can be identical to that corresponding structure disclosed in co-pending patent application Ser. No. 08/327,487, now U.S. Pat. No. 5,611,163 it is to be understood that the canopy of the co-pending application for patent is only one of a number of canopy structures usable to fasten the combo fixture


10


to a J-box (not shown). In essence, mounting of the canopy


32


or any other canopy to such a J-box (not shown) is conventional in the art and further discussion of same is not believed necessary to an understanding of the present disclosure.




While the structural features of the combo fixture


10


which have been generally referred to hereinabove will be described in greater detail hereinafter, it is necessary at this point to describe certain general concepts which underlie the defined structure as seen in the drawings. Prior art combination exit sign/emergency lighting unit fixtures have usually been formed at least partially of metal especially in situations where the weight of the entire fixture is supported essentially by a housing such as the housing


12


which contains within the interior thereof essentially all structure except for the unit lamp assemblies such as the assemblies


13


. In such prior situations, batteries of substantial size have been necessary in order to provide power for the exit sign function as well as for the emergency unit function. Due to the substantial weight of the batteries and of the fixtures themselves, it has not been previously possible to support the weight of a combo fixture


10


when the fixture


10


has been effectively formed of “plastics” that is, polymeric materials, since a structurally all-plastic unit, until the present invention, would warp and bow over time even when formed of the strongest polymeric materials. If formed of plastic materials of lesser strength, a combination fixture usually deforms and is likely to break rather than merely deform. Therefore, the present invention provides a dimensionally stable combo unit


10


which does not warp or bow over time even though effectively formed completely of “plastic”, the combo fixture


10


being the first and only combo fixture formed of plastic wherein all batteries and other structural features are effectively contained and/or supported by a single housing such as the housing


12


. While the combo fixture


10


could be formed of a material such as sheet metal, it is to be understood that a number of the advantages of the invention would be lost if the combo fixture


10


is so formed. In particular, the combo fixture


10


can be assembled from a relatively small number of individual parts especially since the frame


14


as will be more fully described hereinafter can be molded from a plastic material to produce a single part having a very large number of structural features integrally formed therewith. All structural features of the combo fixture


10


are formed of plastic and are molded. Certain parts such as the lamps


24


and


26


and the battery


30


, for example, are not formed of plastic but are items which must be otherwise formed. However, these parts are not structural and have no function in support of the overall weight coupled with maintenance of the integrity of the combo fixture


10


per se. The function of the housing


12


as a single containing unit is further improved by the ability to snap-fit together virtually every combination of parts comprising the combo fixture


10


. Formation of the combo fixture


10


substantially from plastic materials facilitates not only the essentially integral nature of the fixture


10


with fewer parts but also facilitates the snap-fitting together of the relatively few parts comprising the fixture


10


. The essentially all-plastic single housing


12


is constructed as will be described hereinafter such that fixture weight can be supported without resort to metal structural features such as would be occasioned by battery weight inter alia in a combination exit sign/emergency unit fixture.




The structural strength of the present combo fixture


10


is provided even though the housing


12


is only slightly larger than the housings of most conventional exit signs.




A further general feature of the combo fixture


10


is occasioned by the cooperative relationship between the emergency lighting unit lamp assemblies


13


and the frame


14


of the housing


12


. The assemblies


13


can be positioned on each end of the housing


12


as is seen in

FIGS. 1 and 2

. However, the assemblies


13


can be otherwise mounted to the housing


12


such as is seen in

FIGS. 5 and 7

by the simple provision of a pattern of slots (not shown in these figures) so that the assemblies


13


can be mounted to one side and to the top as seen in

FIG. 5

or with two assemblies on top as seen in FIG.


7


. Although not shown in the drawings, slots can be formed in lower surfaces of the housing


12


so that one or more of the assemblies


13


could be mounted along the lower edge of the housing


12


. As is seen in

FIG. 6

, a dual unit lamp assembly


36


is mounted along the top edge of the housing


12


utilizing the same slot pattern as would be used with the structure shown in FIG.


7


. The structure preferred for mounting of the assemblies


13


and the assembly


36


will be described in detail hereinafter. Appreciation of the structure of the assemblies


13


and of the assembly


36


is necessary in order to understand the importance of the fact that said assemblies


13


and


36


can be repositioned on the housing


12


or removed entirely to constitute slave and/or remote units for producing lighting at locations distant from the combo fixture


10


.




Reference to

FIGS. 3

,


4


and


8


in particular illustrates a further capability of the invention, double-sided dual unit lamp assemblies


38


being substituted for the assemblies


13


so that the unit emergency lighting function can be provided relative to both faces of the housing


12


. Due to the low-profile space-saving nature of the structure of the assemblies


13


, it is a simple matter to form the double-sided dual unit lamp assembly


38


without substantial modification, this structure being best understood by subsequent description of the assemblies


13


inter alia.




As is best seen in

FIGS. 14

,


15


and


16


, either of the assemblies


13


and


38


can be removed from the housing


12


and attached to a mounting base


40


and driven as a remote slave unit from power provided by the battery


30


within the housing


12


. optionally, a battery (not shown) within the mounting base


40


(or made a part of the assembly


13


or the assembly


38


) could provide power for a totally separate fixture as shown in

FIGS. 14

,


15


and


16


. The dual unit lamp assembly


36


of

FIG. 6

as previously described could also be removed from the housing


12


of FIG.


6


and provided with a mounting base (not shown) of a greater lengthwise dimension than said base


40


and provided with a slot pattern capable of mounting said assembly


36


for use as a remote slave unit or as a remote, self-contained unit.

FIG. 15

illustrates the pattern of slots


42


useful for mounting of the assemblies


13


and


38


to the mounting base


40


in a manner such as will be described in detail hereinafter.




Due to the complexity of the structural details of the combo fixture


10


and further in view of the independent nature of at least certain of the sub-systems comprising the fixture


10


, the remaining disclosure is organized by sub-headings which will allow for more ready access to information concerning the various structural features and sub-systems of said fixture


10


.




Housing Frame Construction




As previously described, the housing


12


essentially comprises a container formed by the frame


14


, the face plate


16


and the back plate


18


. In those installations wherein both faces of the housing are visible and are intended to provide egress information, the back plate


18


is replaced by a plate which would be essentially identical to the face plate


16


. The back plate


18


is used to enclose the housing


12


in those situations wherein the visible indicia


20


is only required on the “front” of the housing


12


and is provided by the face plate


16


. The back plate


18


is particularly used in situations wherein the combo fixture


10


is installed directly against a J-box (not shown) mounted flushly in a vertical wall (not shown), the back plate


18


being then mounted directly to such a J-box (not shown) through use of conventional connections with the back plate


18


connecting to the frame


14


as will be described hereinafter.




Referring now to

FIGS. 17A through 17E

, inter alia, the face plate


16


and the back plate


18


each connect to the frame


14


by means of four snap-fitting connections


44


which comprise two spaced slots


46


formed along top and bottom edges of each of the plates


16


,


18


, each plate


16


,


18


thus having a total of four slots


46


intended to facilitate connection of the plates


16


,


18


to the frame


14


. The frame


14


is provided with a total of eight rounting tabs


48


with two each of said tabs


48


being disposed along each side of both of the top and bottom edges of the frame


14


, the tabs


48


being positioned to be received one each within each of the slots


46


formed in the plate


16


,


18


so that the plate


16


,


18


can be readily and rapidly assembled to the frame


14


to enclose the housing


12


as is best seen in

FIGS. 17D and 17E

.




Essentially all of the features of the combo fixture


10


, with the exception of the lamp assemblies


13


or similar structure, are contained within the housing


12


and are supported by the frame


14


. The lamp assemblies


13


are in essence also carried by the housing


12


but on exterior portions thereof. The weight of the combo fixture


10


due both to that structure located interiorly and exteriorly of said housing


12


is effectively supported in tension rather than by cantilever as is conventional in the prior art. The housing


12


and particularly the frame


14


is thus engineered in a manner particularly intended to support the weight of the fixture


10


in tension, thereby allowing the formation of the fixture


10


and particularly of the frame


14


essentially entirely of a “plastic” material such as polycarbonate/ABS. This ability to form the fixture


10


and particularly the frame


14


from plastic material then further allows the frame


14


to be molded integrally to thereby reduce the number of parts which must be formed and then assembled to produce the combo fixture


10


. The construction and structure of the frame


14


as a single molded piece still further allows the carriage of heavy parts such as the battery


30


inter alia internally of the housing


12


and within the single housing


12


. Formation of the combo fixture


10


and especially the integral frame


14


from a plastic material further facilitates the snap-together construction of the combo fixture


10


, virtually all parts of the fixture


10


being snap-fitted together thereby yielding a total structure which can be readily and rapidly assembled.




The advantages thus enumerated which accrue from the structure of the frame


14


inter alia can be best appreciated by consideration of the frame


14


shown in

FIGS. 17A

inter alia.

FIG. 17A

illustrates the one-piece frame


14


without mounting of other portions of the fixture


10


thereto.

FIGS. 17B through 17E

illustrate the frame


14


with the plates


16


,


18


mounted thereto as illustration of the enclosed housing


12


. Prior to a discussion of the interior structure of the frame


14


, those features best seen exteriorly. of the fixture


10


will be described.




The frame


14


is seen to be provided on each end with a pattern of four slots


50


which are of a size and which are spaced apart in a rectangular form in the manner of the slots


42


discussed above relative to the mounting of one of the lamp assemblies


13


to the mounting base


40


to form a remote fixture. The top of the frame


14


is provided with two of the patterns of four slots


50


. The slots


50


are formed in the frame


14


; however, portions of the periphery of the plates


16


,


18


face the slots


50


on assembly of said plates


16


,


18


to the frame


14


and to render less conspicuous the slots


50


into which torsion snaps


52


are inserted to mount the lamp assemblies


13


(as well as the lamp assembly


36


to the top of the housing


12


) to the housing


12


. While not shown in

FIG. 17E

, a pattern of the slots


50


could be formed along the bottom of the housing


12


if mounting of one or more of the lamp assemblies


13


to the bottom of the housing


12


is desired. Mounting of one or more of the lamp assemblies


13


to the bottom of the housing


12


would be advantageous in situations where flexibility of operation is desirable within the space within which the combo fixture


10


is utilized. The frame


14


is also seen in

FIG. 17E

to be provided with fixed louver vent openings


54


to facilitate ventilation of the housing


12


. A flapper switch


56


is provided in the bottom of frame


14


in association with test circuitry (not shown in

FIG. 17E

) to allow testing of the electrical systems of the combo fixture


10


as will be described in detail hereinafter.




The canopy


13


referred to hereinabove can be used to mount the combo fixture


10


as will be described hereinafter and as is described in co-pending U.S. patent application Ser. No. 08/343,775, filed Nov. 22, 1994 as aforesaid, the disclosure of this application for patent being incorporated hereinto by reference.




Considering now the construction of the frame


14


, reference is particularly made to

FIG. 17A

wherein upper and lower walls


58


and


60


are integrally formed with side walls


62


and


64


, said walls defining the periphery of the frame


14


and thus of the housing


12


. An upper interior wall


66


extends parallel to the upper wall


58


and terminates at respective ends in corner plates


68


and


70


, the plates


68


and


70


each having side-mounted upper and lower angled elements


72


and


74


which have open-ended slots


76


which are capable of receiving wiring (not shown in

FIG. 17A

) for holding said wiring in place within the interior of the housing


12


. The plates


68


and


70


respectively define spaces


78


,


80


within which wiring, wire nuts, plugs and the like (not shown) can be disposed. The plates


68


,


70


along with the angled elements


72


and


74


provide strengthening of the frame


14


even in the absence of the interior wall


66


. Coupling of the interior wall


66


with the plates


68


,


70


and angled elements


72


,


74


, respectively, and further with interior side walls


82


and


84


provides a high degree of stiffness and rigidity to the frame


14


. The side walls


82


and


84


connect at respective ends to a lateral platform


86


comprised of horizontally disposed side tables


88


and


90


which connect to a central mounting angle


92


which is surmounted by central support webs


94


and


96


which further connect to side webs


96


and


98


respectively through upper vertical walls


100


and


102


. The side webs


96


and


98


respectively connect to end webs


104


and


106


through triangular normally related supports


108


and


110


, the end webs


104


and


106


respectively connecting to lowermost ends of the side walls


82


and


84


, thereby providing a continual interior structural web which is centrally bisected by a vertical ladder


112


formed of spaced vertical stiles


114


having horizontal rungs


116


regularly disposed along the stiles


114


. Openings between the rungs can be utilized for management of wiring within the interior of the housing


12


and particularly relative to options available with the combo fixture


10


. At the lower end of the ladder


112


, the support webs


94


bend 90° to form ladder connection walls


118


which join to respective ends of the stiles


114


. A bottom ladder plate


120


completes connection of the stiles


114


, the plate


120


, the lower ends of the stiles


114


, the walls


118


, and the support webs


94


by connecting to and being integrally formed with top portions of the angle


92


. The top end of the ladder


112


joins integrally with the upper interior wall


66


and the upper wall


58


, thereby providing a tensioned support structure internally of the housing


12


which acts to support the weight of the combo fixture


10


substantially in tension rather than cantilevered as in prior exit signs and sign-like fixtures. The weight of the battery


30


located within battery compartment


122


is particularly seen to be mounted in tension by the ladder


112


inter alia due also in part to the placement of the battery


30


(and any other battery) centrally of the interior of the housing


12


and along the lower portion thereof.




Interior canopy mounting housing


124


are respectively disposed centrally between the upper wall


58


and the interior wall


66


and between the side walls


62


,


64


and the interior side walls


82


,


84


. wiring guide clips


126


are disposed on either side of the uppermost mounting housing


124


to facilitate a desired location of wiring (not shown in

FIG. 17A

) along upper portions of the housing


12


. Substantially conventional mounting elements


128


each releasably hold lamp bases


130


and associated non-emergency AC bulbs


132


, the mounting elements


128


also being integrally formed with the frame


14


. Mounting bases


134


capable of holding lampsockets


136


and associated DC emergency bulbs


138


are integrally formed on respective portions of the support webs


94


, the location of the bulbs


138


acting to produce light at locations above the battery compartment


122


so that light can be directed about the upper portions of the battery


30


(or other battery) to reduce the shadowing effect of the battery


30


within the indicia


20


as will be described in greater detail hereinafter.




An electronics compartment


140


is located below the side table


88


and laterally of the battery compartment


122


while an options compartment


142


is located below the side table


90


and to the other side of the battery compartment


122


. The respective compartments


140


and


142


are separated from the battery compartment


122


by means of respective vertical walls


144


and


146


. The various structures integrally formed with the frame


14


and contained within the compartments


122


,


140


and


142


will be described in detail hereinafter. Clips


148


disposed on opposite sides of the interior of the housing


12


extend respectively from the corner plates


68


,


70


and are adapted to hold respective LED arrays


28


(see

FIG. 13

) within the interior of the housing


12


. The structures described above and which can be seen in

FIG. 17A

are integrally formed with the frame


14


by molding of a plastic material. In essence, the entire structure seen in

FIG. 17A

is a single unitary structure comprising the frame


14


and molded with said frame


14


are openings provided as a means for reducing the amount of plastic necessary for molding thereof.




Tension Support and Weight Management Arrangements




As described above, the ladder


112


is provided as an integral portion of the frame


14


to provide support in tension for the entirety of the combo fixture


10


and particularly for the battery


30


held within the battery compartment


122


(or for any other battery held within the battery compartment


122


). The ladder


112


is advantageously located within the interior of the housing


12


to provide tension support for the weight of the fixture


10


as well as for battery weight. It should be understood, however, that the ladder


112


could take other forms, such as a solid vertical member whether or not connected permanently to the angle


92


at the lower end thereof or to the interior wall


66


and the wall


58


. The ladder


112


is formed of the stiles


114


and of the rungs


116


in order to provide openings


115


between the rungs through which wiring can be strung for management of the location of wiring within the interior of the housing


12


. The openings


115


are also provided for reduction of material and for facilitating light movement within the interior of the housing


12


. When the fixture


10


is back mounted, the openings


115


also serve to provide access for routing wiring (not shown) within the interior of the housing


12


as will be better appreciated hereinafter. The battery


30


is located centrally of the lower portion of the housing


12


so as to advantageously allow the ladder


112


to act in tension to support the weight of the battery


30


. While the battery


30


is intended to be a conventional rechargeable lead-acid battery, it is possible to utilize lead-acid batteries of greater capacity with weights up to approximately 4 pounds when a greater amount of power is necessary for providing for a greater period of time and for that additional power necessary to operate slave units remote from the fixture


10


such as has been described above. It is also possible to utilize nickel-cadmium batteries of smaller size, the smaller Ni—Cd battery (not shown) being mounted within the interior of the battery compartment


122


, the details of mounting of the Ni—Cd battery within the compartment


122


not being described herein. As aforesaid, the ladder


112


is provided with horizontal elongated tab elements


154


and


156


, the elements


154


and


156


being preferably used for management of wiring (not shown) associated with the fire alarm interface


150


. The ladder


112


is further provided with peg elements


152


disposed one each on either side of the ladder


112


and extending from each of the stiles


114


near the uppermost end of the ladder


112


, the peg elements


152


acting to receive snap elements


158


and


160


located on the interior wall of the back plate


18


as will be described hereinafter, the snap elements


158


and


160


cooperating respectively with the peg elements


152


to facilitate mounting of the frame


14


to the back plate


18


when the back plate


18


is mounted directly to a J-box (not shown) mounted flushly in a wall surface.




Battery Mounting Arrangements




As aforesaid, the battery compartment


122


is configured to house the battery


30


as well as a larger battery


162


. It is to be understood, however, that only one of the batteries


30


and


162


would be utilized at any one given time. As can be seen in

FIGS. 17A

inter alia, the battery compartment


122


is formed centrally of the lower portion of the combo fixture


10


and is provided with snap fingers


164


on inner surfaces of the walls


144


and


146


, the snap fingers


164


extending from said wall surfaces at a lesser height forwardly of the compartment


122


and terminating at a greater height interiorly of the compartment


122


such that the battery


30


can slide over the snap fingers


164


and into a position of essentially against a back wall


166


of the battery compartment


122


. It is to be seen that the battery compartment


122


is provided with a top wall


168


having tabs


170


extending downwardly therefrom at the outermost end of said top wall


168


so that the larger battery


162


can be slipped into place under the tabs


170


and into a position abutting the back wall


166


and held by the tabs


170


in order to hold the larger battery


162


in place. Accordingly, the battery compartment


122


is provided with structure capable of holding batteries of at least two different sizes within said compartment


122


by snap-fitting arrangements.




When placed within the battery compartment


122


as is necessary for operation, the batteries


30


and


162


are of a sufficient height as to extend into the lower part of the indicia formed in the face plate


16


. Due to this extension of the battery


30


and the battery


162


into the legend, it is possible that a shadowing effect is caused such that lower portions of the indicia are darker than upper portions of the indicia. The location of the lamps


24


within the interior of the housing


12


during normal operation and the location of the lamps


26


within the interior of the housing


12


during emergency operation provides light within the interior of the housing


12


which is reflected within said housing interior. This light is controlled in part by means of a reflective cover


172


attached to the top of the battery


30


(or the battery


162


) with the lower edge of the reflective cover


172


extending downwardly to at least the level of the side tables


88


and


90


such that light is reflected outwardly of the lower portions of the indicia


20


on the face plate


16


to locally increase the amount of light passing through said indicia


20


at lower portions thereof. Provision of the reflective cover


172


thus acts to reduce the effect of the otherwise dark form of the battery


30


or the battery


162


so that the shadowing effect does not detract from the appearance and function of the indicia


20


. Optionally, at least the upper portion of the batteries


30


,


162


could be painted with a white paint or coated with a reflective material in order to provide a function similar to the function of the reflective cover


172


. The reflective cover


172


can also be utilized as a pull tab for removal of the battery


30


,


162


from the battery compartment


122


. The ability to allow the upper portion of the battery


30


,


162


to extend into the “legend” or indicia


20


, allows the height of the housing


12


to be reduced so that the combo fixture


10


is more compact and exhibits a relatively lower profile.




It is to be seen that wiring extends from the electronics compartment


140


to the options compartment


142


as is seen in

FIG. 9

, this wiring


174


is caused to be slack in front of the battery compartment


122


so that insertion of one of the batteries


30


,


162


into the battery compartment


122


does not engage the wiring


174


and pull said wiring into the battery compartment


122


.




Emergency DC Lamp Mounting




Referring now to

FIGS. 21A and 21B

, as well as to

FIGS. 17A

inter alia, one of the mounting bases


134


intended for mounting one of the DC bulbs


138


is now described, a description of one of the DC emergency lamps


26


sufficing for a description of both. The bulb


138


is snapped into the lamp socket


136


to be structurally held thereby and to electrically connect with the lamp socket


136


to power provided in an emergency situation by the battery


30


,


162


inter alia. The lamp socket


136


is formed of a rectangular collar


176


open at one end to receive the bulb


138


, electrical contacts (not shown) being located within the interior of the collar


176


. The collar


176


terminates at the end opposite the bulb


138


in a reduced lower base portion, the lamp socket


136


snap-fitting into one of the mounting bases


134


. The lamp base


134


is formed of two basic upper elements


180


each having walls


182


which are perpendicular to each other, rear walls


182


extending toward each other but not contacting at the rear of the base


134


. Snap tabs


184


extend from the facing walls


182


toward each other at the upper end of the base


134


, the heights of the walls


182


being essentially equal to the height of the collar


176


. A pair of lateral snaps


186


extend from the rear of the base


134


below the walls


182


and receive the lower base portion


178


therebetween when the lamp socket


136


is snap-fitted into the mounting base


134


. The collar


176


of the lamp socket


136


is partially enclosed by the walls


182


with the sanp tabs


184


abutting against upper edges of the collar


176


to prevent dislodgement of said socket


136


in an upward direction. The discontinuity provided by the lack of contact between the rear walls


182


thereby allows upper portions of the mounting base


134


to expand on insertion of the lamp socket


136


thereinto. Snap mounting of the lamp socket


136


to the mounting base


134


therefore occurs. The lateral snaps


186


prevent dislodgement of the lamp socket


136


forwardly of the mounting base


134


, the snaps


186


fitting against the reduced lower base portion


178


so that the lamp socket


136


is positively retained within the mounting base


134


.




The mounting of the DC emergency lamps


26


can thus be accomplished both rapidly and easily and within a minimum of parts not integrally formed with the frame


14


.




Housing Details




As seen particularly in

FIG. 23

, the options compartment


142


is further defined by back wall


188


which has a plurality of openings


190


formed therein to reduce the quantity of plastic material necessary for formation of the frame


14


and to facilitate ventilation of the housing


12


. A variable printed circuit board capturing assembly is seen to be disposed centrally of the compartment


142


at


192


to comprise spaced apart upper and lower plates


194


and


196


with each plate having an inwardly extending lip


198


formed along respective outer edges of the plates


194


,


196


. The plates


194


,


196


are attached along inner edges thereof to the back wall


168


and have the capability of springing together when separated from each other by pressure. A printed circuit board bearing an option such as a fire alarm interface option can be mounted between the plates


194


,


196


and held by the spring function existing between said plates


194


,


196


. The lips


198


further act to hold the printed circuit option board between the plates


194


,


196


. The printed circuit board is thus mounted in a manner to prevent damage thereto.




Pairs of horizontal surfaces


200


and


202


mount respectively at lower portions of the compartment


142


and at upper portions thereof to form small interior spaces within the compartment


142


for placement of other options such as buzzers and the like. A pair of vertical stem walls


204


mounted in spaced relation to each other and under the lower plate


196


also act to form a space capable of storing an option board or a shrink-wrap option or the like.




Referring now to

FIG. 22

, inter alia, the electronics compartment


140


is seen to be provided with a space for snap-mounting of a capacitor


206


therewithin, upper and lower housing walls


208


and


210


extending interiorly of the compartment


140


to form a housing space for the capacitor


206


. A flexible snap element


212


mounted to back wall


214


and formed in a slot between side walls


216


and


218


which are also mounted to the back wall


214


. The snap element


212


is provided with fingers


220


which abut the capacitor


206


and in combination with fixed snap tabs


222


formed on interior wall surfaces of the frame


14


act to positively hold the capacitor


206


within the compartment


140


. A charger board


224


is snap-fitted within the compartment


140


by tabs


226


, the board


224


having an LED indicator


228


extending therefrom through an aperture


230


formed in the frame


14


, the aperture


230


being best seen in FIG.


17


E. The flapper switch


56


seen in

FIG. 17A

is seen in

FIG. 22

to engage a test circuit seen as a block diagram in FIG.


28


. The electronics compartment


140


is covered by means of a shaped cover


234


formed preferably of a fiberboard material known as fish paper. The cover


234


form fits over the opening in the compartment


140


to prevent accidental intrusion into the compartment


140


.




Diffusion Panel Mounting Arrangement




Referring now to

FIG. 29

, the face plate


16


is seen with diffusion panel


236


in an assembly view illustrating the manner by which the panel


236


is mounted to inner walls of the face plate


16


. As is seen in

FIG. 1

inter alia, portions of the diffusion panel


236


are seen through the indicia


20


formed in the face plate


16


. The diffusion panel


236


is formed as a filter or from colored material so that a desired color such as red or green is seen through the indicia


20


. The diffusion panel


236


is held to the face plate


16


by means of spaced pairs of snaps


238


located on opposite sides of the indicia


20


, the pairs of snaps


238


being spaced apart a distance equal to the width of the panel


236


at the locations of the snaps


238


. The panel


236


is formed with a tab


258


located on lower edge


244


, the tab


258


allowing the panel to only fit within rectangular recess


240


in one orientation such that the appropriate face of the panel


236


faces outwardly and is disposed immediately behind the indicia


20


. The panel


236


also has an upper edge


242


with angled side edges


246


and


248


which terminate in opposing flat edges


250


and


252


, the flat edges


250


and


252


respectively fitting between raised tabs


254


and


256


. The tabs


254


and


256


prevent lateral motion of the panel. The tab


258


abuts the upper edge of the recess


240


to prevent mallocation of the panel. Further, the tab


258


will not fit under one of the snaps


238


when the panel


236


is inappropriately inverted.




The face plate


16


is also provided at its upper edge with a structural wall


260


which joins to corner elements


262


and


264


each having angled elements


266


and


268


respectively formed thereon, this structure cooperating with opposed structure on the frame


14


as described above to further strengthen the housing


12


.




Back Panel Mounting Arrangement




Referring to

FIGS. 10A and 10B

, the back panel


18


is seen to be formed with knock outs


270


,


272


and


274


as well as with a center channel knock out


276


. The knock out


276


is removed when the back panel


18


is to be used to directly mount the combo fixture


10


to a wall (not shown). A J-box (not shown) in a wall is fitted with a bracket (not shown) as is conventional and the appropriate knock out


270


,


272


or


274


corresponding to the size of the J-box is knocked out by removing the plastic flashing within ovals


278


associated with a particular ring of the knock outs. The back plate


18


is then mounted to the J-box and bracket (not shown). The frame


14


is then mounted to the back plate


18


with peg elements


152


being received within apertures


155


formed in the snap elements


158


and


160


extending from the inner face of the back plate


18


. Housing


12


is thus snap-fitted to the back plate


18


to mount substantial portions of the weight of the combo fixture


10


in tension. Angled ramps


161


and


163


provide lead-ins to engage the peg elements


152


in the apertures


155


.




The back plate


18


is formed at upper corners thereof with structural corner plates


280


and


282


each having angled elements


284


and


286


respectively formed thereon, the structure cooperating with opposed structure of the frame


14


as described above to further strengthen the housing


12


.




Unit Lamp Mounting Arrangement




Referring now to

FIGS. 24 and 25

, one of the emergency lighting unit lamp assemblies


13


is seen to comprise a lamp holder


284


having an opening


286


formed in at least one major face thereof, an arcuate swivel plate


288


having the general shape of a spherical segment and being receivable within the opening


286


and snap-fitted thereinto for swiveling motion in said opening


286


, a lamp housing


290


which snap-fits onto the swivel plate


288


for movement relative to said plate


288


, a parabolic reflector


292


and a lens


294


. A bulb


296


preferably comprising a T5 wedge base incandescent lamp manufactured by the General Electric Corporation is mounted to the lamp housing


290


and is activated on failure of AC line voltage and driven by DC power supplied by the battery


30


, the battery


162


or a Ni—Cd battery as aforesaid. The structure of one of the assemblies


13


sufficies for description of any other one of the assemblies


13


since the assemblies are essentially identical.




The lamp holder


284


comprises a stationary platform mounted to the frame


14


by insertion of the four torsion snaps


52


into any one of the patterns of four of the slots


50


. The lamp holder


284


is thus quickly mountable to the frame


14


and readily removed from the frame. The lamp holder


284


preferably takes the form of front and rear angled surfaces which outwardly terminate at


298


. Triangular lateral surfaces of the lamp holder


284


complete the shape of the lamp holder


284


. It is to be understood that the lamp holder


284


can be otherwise shaped as long as at least one major surface is available for formation of the opening


286


therein. It is also to be understood that an opening such as the opening


286


could be formed in the other major surface of the lamp holder


284


so that additional lamping could be carried by the lamp holder


284


as seen generally in

FIGS. 3 and 4

inter alia. Four of the torsion snaps


52


are formed on base edges of the lamp holder


284


and are positioned thereon to mate with the slots


50


as aforesaid.




The swivel plate


288


is provided with pairs of lands


300


placed about the periphery of said plate


288


, three pairs of the lands


300


being adequate for support of the plate


288


within the opening


286


of the lamp holder


284


. The lands


300


prevent the plate


288


from falling into the interior of the holder


284


and facilitate swiveling motion of the plate


288


within the opening


286


. Cut-outs


302


are formed between two pair of the lands


300


. Each of the cut-outs


302


has a U-shaped snap


304


located within the cut-out


302


, the snaps


304


facilitating the snap-fitting of the plate


288


into the opening


286


of the lamp holder


284


, movement of the plate


288


within the opening


286


being also thus facilitated. The third pair of the lands


300


is spaced equidistantly from the two pair of lands


300


having the cut-outs


302


formed therein, a T-shaped cut-out


306


being formed between the lands


300


of this third pair of lands. A prong


308


is formed immediately behind the cut-out


306


, the prong


308


acting to hold the plate


288


within the opening


286


and to provide a stop function in concert with detent


309


located interiorly of the lamp holder


384


. A guide track assembly


310


is formed centrally of the spherical swivel plate


288


and comprises a base


312


having spaced pairs of spaced track tangs


314


which surmount one each of a slot


316


in a pattern of the slots


316


, the slot pattern being rectangular in conformation. An oval slot


318


is formed in the plate


288


centrally thereof and within the assembly


310


, one each of a pair of apertures


320


being formed in the plate


288


on opposite sides of the oval slot


318


and between vertically related slots


316


of the pairs of slots


316


. At least certain of the openings thus formed in the swivel plate


288


facilitate passage of wiring (not shown) from a bulb socket


297


into the interior of the lamp holder


284


.




The lamp housing


290


is formed as a spherical segment which is concentric with the spherical shape of the swivel plate


288


, the spherically shaped rear walls of the lamp housing


290


being received into the concentrically formed spherical concavity of the swivel plate


288


to cause the assembled unit to exhibit a low profile. Flats


322


are formed parallel to each other at spaced edges of the lamp housing


290


with a perpendicularly disposed flat


324


being also formed at the edge of the lamp housing


290


. An arcuate slot


326


formed centrally of the lamp housing


290


and extending from the flat


324


to the edge of the lamp housing


290


opposite the flat


324


. An arcuate bridge


328


extends immediately below the slot


326


and is formed with a snap detent


330


therein immediately interiorly of the flat


324


, the detent


330


having a spring capability such that the detent


330


snaps back to its original position after being biased inwardly of the housing


290


on fitting of the swivel plate


288


to the lamp housing


290


. The bridge


328


is further formed with a bulb base mount


332


near the end thereof opposite the detent


330


. The mount


332


is formed of spaced track elements


334


with a depressable tongue


336


being disposed between the track elements


334


. The bulb


296


is mounted by a socket base


338


having a plate


340


extending from the base


338


to fit under the track elements


334


and being held therebetween by the tongue


336


which is depressed downwardly on insertion of the plate


340


between the track elements


334


and which rebounds to bias against the plate


340


to maintain the base mount


332


and thus the bulb


296


in place. Track following edges


342


of the lamp housing


290


which define the slot


326


are received under the tangs


314


of the guide track assembly


310


on the swivel plate


288


to allow the lamp housing


290


to move in an are relative to the swivel plate


288


essentially along a detent of that circle-like geometric shape defined by the periphery of the swivel plate


288


. When the lamp housing


290


is fully received by the guide track assembly


310


, the detent


330


, which detent


330


is depressed as the lamp housing


290


is received by said guide track assembly


310


, is released and springs back to engage a wall


344


of the assembly


310


to prevent disengagement of the lamp housing


290


from the swivel plate


288


without first depressing the detent


330


.




A reflector


292


is received within the lamp housing


290


, the reflector


292


comprising a plastic structure which is coated with a reflective layer


346


. The reflector


292


is formed as a parabola of rotation which fits within the lamp housing


290


and is received within the housing


290


. An opening


348


formed in the reflector


292


allows the bulb base mount


332


of the lamp housing


290


to extend therethrough to be exposed for its intended purpose. The periphery of the reflector


292


is shaped to fit the shape of the lamp housing with a flange


350


having a cut-out


352


being formed at the periphery of the reflector


292


adjacent the opening


348


, the cut-out


352


receiving an end of the bridge


328


of the lamp housing


290


. Portions of the flange


350


are received under a peripheral segment


354


formed on the lamp housing


290


, the segment


354


being connected to that end of the bridge


328


received by the cut-out


352


.




The lens


294


snap-fits onto the lamp housing


290


, the periphery of the lens being shaped to fit the shape of the lamp housing. A flange


356


having a cut-out


358


is formed on one edge of the lens


294


, the cut-out


358


receiving an end of the bridge


328


of the lamp housing


290


. Portions of the flange


356


are received under the peripheral segment


354


of the lamp housing


290


to facilitate holding of the lens


294


to the lamp housing


290


. A snap


360


formed in the lens


294


opposite the flange


356


snaps the lens


294


onto the lamp holder


290


in cooperation with a cut-out


362


formed in the reflector


292


and snap fingers


364


formed on the lamp holder


290


and received into the cut-out


362


. The lens


294


can be “frosted” if desired to provide a more diffuse light.




The lamp assembly


13


is seen to mount to the frame


14


of the housing


12


by means of the torsion snap


52


fitting into the slots


50


. Each of the torsion snaps


52


are essentially plow-shaped with a rounded shank


366


extending directly from the lamp holder


284


, distal end


368


of the snap


52


tapering to a point and being outwardly angled medially of the shank


366


. The torsion snaps


52


on insertion into the slots


50


actually act to pull the lamp holder


284


to the housing


12


. When the snaps


52


are inserted into the slots


50


, the snaps


52


are bent straight in order to fit into said slots


50


. While the snaps


52


are formed of a plastic material, the snaps


52


are resistant to creeping. Even if the snaps


52


creep, the degree of creep will not be sufficient to cause the snaps


52


to creep to clearance, that is, the snaps


52


will not deform over time to allow the snaps


52


to straighten sufficiently to fall from the slots


50


.




The concentrically spherical arrangement of the swivel plate


288


and the lamp housing


290


allow an optimized degree of freedom while allowing a low profile of the assembly


13


. The assembly


13


is therefore compact volumetrically while being adjustable in position over a wide angular range. The degree of angular freedom is constrained by stop structure as described above which prevents wire breakage.




Electrical Systems




Referring now to

FIGS. 12 and 28

, the circuitry employed in the incandescent embodiment of the invention is shown. The circuit is disclosed in co-pending U.S. patent application Ser. No. 08/519,804, filed Aug. 28, 1995, by James C. Johnson, and entitled Emergency Lighting Battery Charging Circuit, the pending application for patent being assigned to the assignee of the present application for patent. The disclosure of Ser. No. 08/519,804 now U.S. Pat. No. 5,646,502, is incorporated hereinto by reference.

FIG. 28

comprises a wiring diagram which particularly shows the use of a single pole battery connector


370


used with a lead-acid battery such as the battery


30


. When the Ni—Cd battery is used as seen in

FIG. 28

, a polarized battery connector


372


is utilized.

FIG. 13

illustrates mounting of the LED arrays


28


on opposite sides of the housing


12


. The arrays


28


provide non-emergency lighting of the indicia


20


on AC mains power. When the arrays


28


are used, the AC lamps


24


are eliminated.




Particular embodiments of the invention have been described above in relation to illustrations of a preferred combo fixture


10


as provided in the drawings. However, it is to be understood that the invention can be embodied other than as is described and shown herein. The invention can particularly be used in the construction of emergency lighting fixtures other than combination exit sign/emergency unit fixtures. Accordingly, the scope of the invention is defined by the recitations of the appended claims.



Claims
  • 1. A combination exit sign and emergency lighting unit having at least one emergency lighting unit assembly mountable to an exit sign portion of the combination, at least the exit sign portion of the combination being formed of a polymeric material and having wall portions formed of a relatively low thickness relative to wall portions of a conventional exit sign and emergency lighting unit formed of a polymeric material in order to cause the combination to be of a low weight, the exit sign portion having sufficient structural integrity to provide a necessary rigidity even though formed of a relatively thin polymeric material subject to deformation and the like when subjected to loading such as is occasioned by the weight of the combination exit sign and emergency lighting unit.
  • 2. The combination of claim 1 and further comprising means carried by at least the exit sign portion for imparting structural integrity to the combination to enable said combination to be formed of sufficiently thin material capable of providing a necessary rigidity to the combination to cause said combination to be suitable for use.
  • 3. The combination of claim 1 and further comprising a structural web formed integrally with inner walls of at least the exit sign portion.
  • 4. The combination of claim 1 and further comprising a structural web formed integrally with inner walls of at least the exit sign portion.
  • 5. The combination of claim 1 wherein the exit sign portion bears the weight of the combination to support the combination.
  • 6. The combination of claim 1 wherein the exit sign portion comprises a housing for the combination, the combination being housed by the single housing.
  • 7. The combination of claim 1 and further comprising means for removably mounting the emergency lighting unit assembly to the exit sign portion of the combination.
  • 8. The combination of claim 7 wherein the mounting means comprises means for swiveling the assembly relative to the combination.
  • 9. The combination of claim 1 wherein batteries for providing power to the combination in the event of failure of mains power to the combination are disposed within a housing formed at least partially by the wall portions of the exit sign portion of the combination, the weight of the batteries comprising a portion of the weight of the combination which is supported by the combination exit sign and emergency lighting unit.
  • 10. A combination exit sign and emergency lighting unit having circuitry components comprising at least one battery, interior lamping producing exit sign function, and circuitry elements forming at least one circuit with at least the one battery and the interior lamping, the combination having a housing formed of a polymeric and relatively low gauge material in order to cause the combination to be of a low weight yet having sufficient structural integrity to support the circuitry components, and at least one emergency lighting unit assembly mounted to the housing exteriorly thereof for providing emergency unit illumination.
  • 11. The combination of claim 10 wherein the housing bears the weight of the combination to support the combination.
  • 12. The combination of claim 10 and further comprising means for removably mounting the emergency lighting unit assembly to the housing.
  • 13. The combination of claim 12 wherein the mounting means comprises means for mounting the assembly for swiveling motion relative to the combination.
  • 14. The combination of claim 10 wherein the housing comprises support means for carrying at least major portions of the circuitry components, the support means being formed of a plastic material.
  • 15. The combination of claim 10 and further comprising support means mounted by the housing for carrying at least major portions of the circuitry components, the housing and the support means being formed of a plastic material.
  • 16. The combination of claim 15 wherein the support means is integrally formed with the housing.
  • 17. The combination of claim 10 and further comprising a structural web formed integrally with inner walls of the housing.
  • 18. The combination of claim 10 wherein the housing comprises an exit sign portion of the combination, the circuitry components being disposed within the confines of the exit sign portion of the combination.
  • 19. A combination exit sign and emergency lighting fixture comprising:a housing comprising at least three mounting locations adapted for mounting an emergency lighting assembly to the housing, wherein each mounting location comprises a plurality of openings adapted to receive and engage a plurality of corresponding projections on the emergency lighting assembly; at least one emergency lighting assembly mounted to the housing at one of the mounting locations; and an exit sign on at least one side of the housing, wherein the remaining components of the combination are contained inside the housing and the housing bears the weight of the combination to support the combination.
  • 20. The combination exit sign and emergency lighting fixture of claim 19, wherein the housing and assembly comprise plastic.
  • 21. The combination exit sign and emergency lighting fixture of claim 19, wherein projections on the emergency lighting assembly comprise torsion snap elements angled to positively engage the opening into which the projection is received and engaged when the emergency lighting assembly is mounted onto the housing.
  • 22. A combination exit sign and emergency lighting unit fixture having circuitry components comprising at least one battery, at least one interior lamp, and circuitry elements forming at least one circuit with the at least one battery and interior lamp, the combination comprising:a housing comprising plastic and at least three mounting locations adapted for mounting an emergency lighting assembly to the housing, wherein the housing supports at least some of the circuitry components; and at least one emergency lighting assembly mountable in at least one of the mounting locations.
  • 23. The combination exit sign and emergency lighting unit fixture of claim 22, wherein the emergency lighting assembly is snap-fitted into the at least one mounting location.
  • 24. The combination exit sign and emergency lighting unit fixture of claim 22, wherein the at least one of the mounting locations comprises a plurality of openings adapted to receive and engage a plurality of corresponding projections on the emergency lighting assembly.
  • 25. The combination exit sign and emergency lighting unit fixture of claim 24, wherein the projections comprise torsion snap elements angled to positively engage the respective openings formed in the housing into which the projections are received and engaged when the assembly is mounted onto the housing.
  • 26. The combination of claim 10 wherein the circuitry components are disposed within the confines of the housing.
  • 27. The combination of claim 10 wherein the mounting means comprises means for mounting the assembly for swiveling motion relative to the combination.
  • 28. A combination exit sign and emergency lighting unit having circuitry components comprising at least one battery, interior lamping producing exit sign function and circuitry elements forming at least one circuit with at least the one battery and the interior lamping, the combination having a housing formed of a polymeric and relatively low gauge material in order to cause the combination to be of a low weight yet having sufficient structural integrity to support the circuitry components, and further comprising support means mounted by the housing for carrying at least major portions of the circuitry components, the housing and the support means being formed of a plastic material, the support means being integrally formed with the housing.
  • 29. A combination exit sign and emergency lighting unit having circuitry components comprising at least one battery, interior lamping producing exit sign function, and circuitry elements forming at least one circuit with at least the one battery and the interior lamping, the combination having a housing formed of a polymeric and relatively low gauge material in order to cause the combination to be of a low weight yet having sufficient structural integrity to support the circuitry components, and further comprising a structural web formed integrally with inner walls of the housing.
  • 30. A combination exit sign and emergency lighting unit having circuitry components comprising at least one battery, interior lamping producing exit sign function, circuitry elements forming at least one circuit with at least the one battery and the interior lamping, the combination having a housing formed of a polymeric and relatively low gauge material in order to cause the combination to be of a low weight yet having sufficient structural integrity to support the circuitry components, and at least one emergency lighting unit assembly mounted to the housing for providing emergency unit illumination.
  • 31. A combination exit sign and emergency lighting fixture, comprising:a plastic housing comprising: a frame having an inside, an outside, a front and a back; a removable face plate having indicia mounted to the front of the frame; a removable back plate mounted to the back of the frame; and at least three mounting locations; at least one light emitting component inside the frame for illuminating the indicia; at least one emergency lighting assembly mounted on the outside of the frame at one of the at least three mounting locations; and at least one battery and associated circuitry mounted inside and supported by the frame for supplying power to the light emitting component and the emergency lighting assembly during a power failure.
CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of application Ser. No 09/132,814, filed Aug. 12, 1998, now U.S. Pat. No. 6,142,648 which is a continuation of application Ser. No. 08/561,956, filed Nov. 22, 1998, now U.S. Pat. No. 5,797,673, issued Aug. 25, 1998, by the same inventors and assigned to the same assignee, said prior applications being incorporated hereinto by reference.

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3478455 Fremont Nov 1969 A
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4071749 Balogh Jan 1978 A
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4255756 Johnson et al. Mar 1981 A
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Photograph No. 21 depicting the Emergi-Lite EXPK Series Product—admitted prior art.
Photograph No. 22 depicting the Emergi-Lite EXPK Series Product—admitted prior art.
Photograph No. 23 depicting the Emergi-Lite EXPK Series Product—admitted prior art.
Photograph No. 24 depicting the Emergi-Lite EXPK Series Product—admitted prior art.
Photograph No. 25 depicting the Emergi-Lite EXPK Series Product—admitted prior art.
Photograph No. 26 depicting the Emergi-Lite EXPK Series Product—admitted prior art.
Photograph No. 27 depicting the Emergi-Lite EXPK Series Product—admitted prior art.
Photograph No. 28 depicting the Emergi-Lite EXPK Series Product—admitted prior art.
Dual-Lite EXquIsiTe RG Series product brochure—1988.
Elan Lighting Product Series ED Combination Emergency Light/Exit Sign product brochure—1987.
Photograph No. 31 depicting the Elan EEDA unit—admitted prior art.
Photograph No. 32 depicting the Elan EEDA unit—admitted prior art.
Photograph No. 33 depicting the Elan EEDA unit—admitted prior art.
Photograph No. 34 depicting the Elan EEDA unit—admitted prior art.
Photograph No. 35 depicting the Elan EEDA unit—admitted prior art.
Photograph No. 36 depicting the Elan EEDA unit—admitted prior art.
Photograph No. 37 depicting the Elan EEDA unit—admitted prior art.
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Continuations (2)
Number Date Country
Parent 09/132814 Aug 1998 US
Child 09/703322 US
Parent 08/561956 Nov 1998 US
Child 09/132814 US