The present invention relates generally to lighting fixtures.
Lighting fixtures for commercial, industrial, accent and home use often install directly in the ceiling or wall of a room or space of a building. LED lighting fixtures have gained popularity in many applications due to the efficiency of LED lighting, and the flexibility in lighting fixture design. An LED lighting fixture typically include a fixture frame that supports LED lights, electrical circuits that provide power to the LED lights, and a lens through which light from the fixture can illuminate a space.
It is desirable in some cases to provide lighting fixtures that conform to the shape of the wall and/or ceiling to which they are attached. Lighting fixtures arranged for curved walls are particularly challenging because the radius of curvature of the wall can vary significantly, as opposed to straight walls and/or wall corners.
Accordingly, there is a need for a lighting fixture that can readily be adapted for use in curved walls of varying radii.
The embodiments disclosed herein address the above-referenced need, as well as others, by flexible lighting fixture having a segmented mounting bracket. The flexible bracket and other features allow the fixture to be readily be curved (e.g. bent) in any number of curved shapes.
A first embodiment is light fixture assembly that includes a bracket, a flexible substrate, and a flexible lens. The bracket has a plurality of connected segments. Each segment has a back wall operably connected to a back wall of an adjacent segment such as to allow relative rotatable movement therebetween. Each segment has a top wall fixedly attached to the back wall, and a bottom wall fixedly attached to the back wall. The flexible substrate has a plurality of lamps affixed thereto. The flexible substrate is attached to the back walls of the plurality of connected segments. The flexible lens is configured to be mounted to the top walls and the bottom walls of at least some of the segments, such that light from the plurality of lamps radiates through the lens.
The above-described features and advantages, as well as others, will become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings.
The illuminated contoured cove 10 in this embodiment includes a cove 12 and the fixture assembly 100. The cove 12 is a concave space formed by a portion of an upper wall 14, a backing wall 16, and a cove base 18. As shown in
In this example, the cove 12 is part of an architectural feature that includes a pillar 15 around which the cove 12 extends. However, it will be appreciated that coves may be used in a variety of settings, and that cove 12 is given only by way of example. For example, the upper wall 14 and/or the cove base 18 may form all or part of the ceiling of a room or other interior or exterior space. In other embodiments, the cove 12 may constitute an inset from a wall, not shown, or other architectural structure that is below and/or near the ceiling. The fixture assembly 100 is compatible with coves 12 disposed in any commercially known cove structure having an upper wall, base and backing wall.
In general, the fixture assembly 100 includes a configurable bracket 102, a flexible substrate 104 having a plurality of lamps affixed thereto, and a flexible lens 106. Further detail regarding the structure of the fixture assembly 100 is provided below with additional reference to
With reference to
Further detail regarding the bracket 102 is provided in connection with
Referring again to the present embodiment, as shown in
The back wall 114 of the segment 110b is coupled to the back wall of the adjacent segment 110c by at least one flexible hinge, and in this case flexible hinges 130a, 130b. The flexible hinge 130a is connected at the tops of the back walls 114 of the segments 110b, 110c, and the flexible hinge 130b is connected at the bottoms of the back walls 114 of the segments 110b, 110c. The flexible hinges 130a, 130b define a vertical axis, parallel to the axis a of
All of the segments 110a, 110b, 110c . . . 110n are connected to each other by similar flexible hinges, such that all are capable of relative pivotal or rotational movement about vertical axes parallel to the vertical axes a shown in
The flexible hinges 130a, 130b in this embodiment are integral to the back walls 114 of the segments 110b, 110c. Specifically, as discussed above, the segments 110a, 110b, 110c . . . 110n in this embodiment are formed from a single sheet of metal. The segments 110a, 110b, 110c . . . 110n are formed by punching out the metal between adjacent segments. To form the flexible hinges 130a, 130b, a small portion of the metal near the tops of the back walls 114 between adjacent segments 110b and 110c is not punched, or in other words is left in place. This creates an interior void 132 between the back walls 114 of the segments 110b, 110c, and between the flexible hinges 130a, 130b. The flexible hinges 130a, 130b and void 132 are configured to retain a strong connection between the segments 110b, 110c, but also create reduced stiffness about the axis a. The reduced stiffness allows at least some relative rotational movement between the segments 110b, 110c about the axis a when suitable pressure is applied. It will be appreciated that the back wall 114 of the segment 110b is preferably coupled to the segment 110a in the same manner, thereby providing a similar axis of rotation (parallel to the axis a) between the segments 110a, 110b.
The top wall 116 extends away from a first end of the back wall 114 in a first direction, which in this embodiment perpendicularly. The top wall 116 is fixedly attached to the back wall 114. The top wall 116 in this embodiment is also an elongate plate, and may be formed from the same piece of metal as the back wall 114. The top wall 116 of the segment 110b further includes at least one through-hole 122 that may be used for mounting the bracket 102 to a wall, such as the upper wall 14 of the cove 12, as shown in
The bottom wall 118 has a main portion 118a that extends away from the second end of the back wall 114 in generally the same first direction. The bottom wall 118 is fixedly attached to the back wall 114. The bottom wall 118 in this embodiment also includes a bent portion 118b that extends from the end of the main portion 118a in a second direction generally perpendicular to the first direction. The second direction may extend in the same general direction as the back wall 114. In general, the main portion 118a may suitably be an elongate plate and the bent portion 118b may be formed from the same material as the main portion 118a, with both portions 118a, 118b formed from the same piece of metal as the back wall 114. The main portion 118a of the bottom wall 118 of the segment 110b further includes at least one through-hole 124 that may be used for mounting the bracket 102 to a wall, such as the lower wall 18 of the cove 12, as shown in
A first subset of the segments 110a, 110b, 110c . . . 110n may have the same structure as the segment 102b. In this embodiment, another subset of the segments 110a, 110b, 110c . . . 110n may have the same general structure, but with different configurations of the top wall 116′ and the bottom wall 118′. By way of example, each of the segments 110a, 110c has a back wall 114 identical to that of the segment 102b, but has a different top wall 116′ that has a different configuration than the top wall 116. Likewise, the segment 112c may have a different bottom wall 118′ than the bottom wall 118.
The alternative configuration of the top wall 116′ is identical to the top wall 116 but includes a bridge lance 126 instead of the through-hole 122. The bridge lance 126 is a downward bridge structure that allows for connection of a clip, a will be discussed further below. Likewise, the alternative configuration of the bottom wall 118′ is identical to the bottom wall 118 but includes another bridge lance 128 instead of the at least one through-hole 124. The bridge lance 128 is likewise a bridge structure that allows for connection of a clip, a will be discussed further below. The bridge lances 126, 128 may be formed from partially punched out metal strips that extend vertically from the surfaces of the surfaces of, but remain connected at either end to, the top wall 116′ and the bottom wall 118′, respectively.
In this embodiment, every other segment 110b, 110d and so forth has the first configuration of the top wall 116 and bottom wall 118, and every other segment 110a, 110c etc. have the second configuration of the top wall 116′ and bottom wall 118′. However, it will be appreciated that in other embodiments, the configurations need not alternate, or need not even be split into multiple configurations. It will be appreciated that to the extent bridge lances 126, 128 and through-holes 122, 124 are used, they may be arranged on the tops and bottom walls of the segments 110a, 110b, 110c and so forth in any configuration, or even on the same segments.
In general, the adjacent segments 110a, 110b, 110c form a flexible C-shaped frame or channel in which lighting elements may be disposed, as will be discussed further below.
Referring again to
It will be appreciated that in some embodiments the flexible substrate 104 can be affixed instead to the top walls 116, 116′ to provide a different angle of light emission.
The fixture 100 further includes a flexible linear optic 142 which is configured to extend over the LED lamps 140 of the flexible substrate 104, and reflect and/or refract light generated by the LED lamps 140 to concentrate the light in a select direction. Such flexible linear optics may suitably be formed of PMMA, and have a geometry configured to enhance the concentration of the generated light to a desired feature of the cove 12 or other architectural element. In this embodiment, the flexible linear optic 142 is affixed against or adjacent to the LED lamps 140 by a plurality of clips 144. The clips 144 and the linear optic 142 also support the flexible substrate 104 against the back wall. Each of the plurality of clips 144 has two feet 144a, 144b that are coupled to the back walls 114 of at least some of the segments 110a, 110b, 110c . . . 110n. Each of the plurality of clips 144 has a bridge section 144c that extends over the flexible linear optic 142, lamps 140 and substrate 104 between the feet 144a and 144b.
The flexible lens 106 in this embodiment may also be a PMMA structure that passes light and covers the interior of the fixture 100. The flexible lens 106 in this embodiment has a flexible lens plate 106a that includes an asymmetric throw ribbing pattern for directing light in a predetermined, select direction. The flexible lens plate 106a extends lengthwise approximately the length of the bracket 102. The flexible lens 106 further includes an upper connection rib 106b and a lower connection rib 106c, both of which may be integrally formed with the lens plate 106a. The upper connection rib 106b is disposed on the rear of, and near the top of, the lens plate 106a, and extends substantially the entire length of the lens 106. The lower connection rib 106c is disposed on the rear of, and near the bottom of, the lens plate 106a, and extends substantially the entire length of the lens 106.
The upper connection rib 106b is configured to be received by a first snap clip 148a of each of a plurality of double clips 148, and the lower connection rib 106c is configured to be received by a first snap clap 150a of each of another plurality of double clips 150. The second snap clip 148b of each of the double clips 148 is configured to receive and engage a corresponding one of the bridge lances 126 on the bracket 102, and the second snap clip 150b of each of the double clips 150 is configured to receive and engage a corresponding one of the bridge lances 128 of the bracket 102. As a result, the lens 106 is operably coupled to bracket 102.
The fixture 100 in this embodiment further includes an additional flexible diffusion lens or film 152, which may be frosted to soften the light. The flexible diffusion film 152 is operably coupled to or against the lens 106. To this end, the lens 106 in this embodiment further includes an upper channel 106d and a lower channel 106e. The upper channel 106d has a downward facing opening, and extends below and along the upper connection tab 106b. Conversely, the lower channel 106e has an upward facing opening, and extends above and along the lower connection tab 106c. The upper and lower channels 106d, 106e are configured to receive the edges of the flexible diffusion film 152 to secure retain the film 152 against the lens 106.
The fixture 100 in this embodiment further includes a flexible spackle plate 154 that extends the length of the fixture 100, and has a vertical width to extend over the bent portion 118b of the bottom plates 118, 118′ of the segments 110a, 110b, 110c . . . 110n of the bracket 102. The spackle plate 154 includes a front face plate 154a, a top plate 154b, and bottom hook 154c. The front face plate 154a is configured to extend downward on or against an exposed edge of the cove base 18 if necessary, in order to provide a base for spackling to finish the installation. The top plate 154b is configured extend part way along the bottom walls 118, 118′, and may be secured in position by a feature that interacts with a corresponding mating feature on the clips 150. The bottom hook 154c extends from the bottom face plate 154a to receive and engage the bottom edge of the bent portion 118b of the bottom walls 118, 118′.
In at least one embodiment, the design of the light fixture 100 allows not only for various curved shapes, but also facilitates producing versions of the light fixture 100 at select lengths. In particular, to generate the light fixture 100 at a select length, the user obtains a bracket 102 having a quantity of segments 110a, 110b, 110c . . . 110n corresponding to the desired length. To this end, the user can cut or otherwise separate the select number of segments 110a, 110b etc. from a blank formed of longer set of segments, not shown, but which would constitute a longer version of the segments 110a, 110b, 110c . . . 110n shown in
In operation, the light fixture 100 is initially in a non-contoured state, such as shown in
Another embodiment of lighting fixture 200 that may also be manually contoured and easily adjusted to multiple lengths is shown in
In general, the fixture assembly 200 includes a bracket 202 and a plurality of lamp modules 205a, 205b, 205cc. Each of the lamp modules 205a, 205b, 205c includes a module frame 222 at least one substrate 204 having a plurality of lamps affixed thereto, and a lens 206. As will be discussed below, the fixture assembly 200 is configured to flex along its length to fit contoured coves such as the cove 12′ of
With reference to
Referring to the segment 210a, the front wall 214 may be in the form of an elongate malleable plate, such as an aluminum plate, that extends vertically lengthwise up from a first end of the bottom wall 218. The end wall 216 may have a similar form, and extends vertically up from a second end of the bottom wall 218 is also an elongate plate. As discussed above, it will be appreciated that the use of the directional terms “vertical”, “top”, “bottom”, etc. refers to directions with respect to the mounting of lighting assembly 100 as shown in
The front wall 214 of the segment 210 is coupled to the front wall 214 of the adjacent segment 210b by at least one flexible hinge 230a, 230b, which may suitably be the same in form and function as the flexible hinges 130a, 130b. The flexible hinge 230a is connected at the tops of the back walls 214 of the segments 210a, 210b, and the flexible hinge 230b is connected at the bottoms of the back walls 214 of the segments 210a, 210b. The flexible hinges 230a, 230b define a vertical axis b of relative rotation or pivotal movement between the segment 210a and the segment 210b. The flexible hinges 230a, 230b may suitably have the same flex properties as those described above in connection with the hinges 130a, 130.
All of the segments 210a, 210b, 210c . . . 210n are connected to each other by similar flexible hinges. As a result, all of the segments 210a, 210b, 210c . . . 210n are capable of relative pivotal or rotational movement about vertical axes parallel to the vertical axes b shown in
As with the bracket 102, the segments 210a, 210b, 210c . . . 210n and hinges 230a, 230b in this embodiment are formed from a single sheet of metal. The segments 210a, 210b, 210c . . . 210n all have substantially the same structure, but may have different through hole patterns or other surface features.
In this embodiment, the lamp modules 205a, 205b, 205c are disposed serially (or end-to-end) along and within the U-shaped channel formed by the adjacent segments 210a, 210b, 210c of the bracket 202. In this embodiment, each lamp module 205a, 205b, 205c is generally in the form of rectangular box, and includes a front wall 220a, a rear wall 222c, and a bottom section 220c, 222b.
Referring the lamp module 205a by way of example, in this embodiment, each lamp module 205a, 205b, 205c includes a first frame 220 and a second frame 222. The first frame 220 includes the front wall 220a, an angled surface 220b, and a portion 220c of the bottom section 220c, 222b. The second frame 222 includes the rear wall 222c, and the other portion 222b of the bottom section 220c, 222b. The bottom portions 220c, 222b, run parallel to each other to collectively form the bottom of the lamp module 205a.
The angled surface 220b extends upward and diagonally rearward from the bottom potion 220c. The angled surface 220b forms a mount for the substrate 204. As with the flexible substrate 104, the substrate 204 includes a plurality of LED lamps 240 affixed thereto. The substrate 204 can extend the length of the module 205 and is affixed to the angled surface 220b of the first frame 220. The substrate 204 and lamps 240 may suitably be a flexible LED module available from Luxtech LLC of Philadelphia, Pa. However, in this embodiment, it is not necessary for the substrate 204 to be flexible, since the lamp modules 205a, 205b, 205c do not themselves bend by a significant amount.
Each module 205b, 205c has a structure similar to that of the lamp module 205a. Each module 205a, 205b, 205c is mounted within the bracket 202 such that the individual segments 210a, 210b, 210c . . . 210n can rotate or bend partially about axes parallel to the axes b without damaging the corresponding lamp module 205a, 205b, 205c.
Each lens 206 in this embodiment may be a PMMA structure similar to the lens 106, which passes light. In general, each lens 206 covers a corresponding lamp module 205a, 205b, 205c. To this end, each lens 206 extends lengthwise approximately the length and width of the corresponding lamp module 205a, 205b, 205c. It will be appreciated, however, that the lens 206 in this embodiment need not have the flexibility of the lens 106.
In use, the bracket 202 may be manually contoured about the axes of rotations of the back walls 214 of the segments 210a, 210b, 210c . . . 210n. The lamp modules 205a, 205b, 205c do not necessarily bend, but instead retain their shape within the contoured set of segments 210a, 210b, 210c . . . 210n in which they are located. As a result of contouring the bracket 202 to have curves the lamp modules 205a, 205b, 205c can be at skewed angles with respect to each other.
The embodiment of
It will be appreciated that the above describe embodiments are merely exemplary, and that those of ordinary skill in the art may readily devise their own implementations and modifications that incorporate the principles of the present invention and fall within the spirit and scope thereof.