BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a perspective view of a recessed type lighting fixture in a servicing position, according to an exemplary embodiment of the invention.
FIG. 2 is a perspective view of a recessed type lighting fixture in a closed/operating position, according to an exemplary embodiment of the invention.
FIG. 3 is an elevation view taken along the line III-III of FIG. 1, shown without a junction box.
FIG. 4 is an elevation view of a light support casting, shown without twist-lock stops, according to an exemplary embodiment of the invention.
FIG. 5 is a top view of the light support of FIG. 4.
FIG. 6 is a side view of the lighting fixture of FIG. 2 with a reflective insert installed.
FIG. 7 is a side view of the lighting fixture of FIG. 2, shown with a junction box and with two DC bayonet type lamps.
FIG. 8 is a bottom perspective view of the lighting fixture of FIG. 2, shown with an optional handle secured to the top of the main reflector housing.
FIG. 9 is a bottom perspective view of the lighting fixture of FIG. 1 in the servicing position.
FIG. 10 is a flowchart for a method of servicing a recessed lighting fixture, according to an exemplary embodiment of the invention.
FIGS. 11A-11F respectively show, for a reflector housing, a side elevation view, a perspective view, a top view, a view along the line A-A of FIG. 11C, a bottom view, and a view along the line B-B of FIG. 11C, according to an exemplary embodiment of the invention.
FIG. 12 is a cutaway side view of various components installed in and attached to a reflector housing, according to an exemplary embodiment of the invention.
FIGS. 13A-13K show different views and configurations for a socket assembly having improved heat dissipation and universality of configuration, according to exemplary embodiments of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 and 2 respectively show perspective views of a recessed lighting fixture 1 in a servicing/maintenance orientation and in a closed orientation. A flat type mounting plate 10 is formed of sheet metal and has a top surface 11. Bent edge portions 12 are formed along each longitudinal edge of plate 10. An L-shaped bracket holder 13 is attached on each lengthwise end of plate 10 using rivets 14 or other suitable fastener. Bracket holders 13 each have a vertical groove 15 formed in a center portion thereof. A mounting bracket 16 is slidably attached to each bracket holder 13 with a fastener 17, such as a bolt and lockwasher combination. Mounting bracket 16 and bracket holder 13 respectively have projections 18 and indentations 19 that align to assure that mounting bracket 16 remains in alignment with bracket holder 13 as a vertical position of mounting bracket 16 is vertically adjusted and then tightened in place with mounting ear adjustment nut/fastener 17. The just-described apparatus may also be referred-to as an adjustable mounting ear assembly. Mounting brackets 16 are used for securing fixture 1 to a support structure. Lighting fixture 1 is illustrated with a pair of mounting brackets 16 each having holes formed therein on opposed extending walls 76, 77. Such holes allow an installer to secure lighting fixture 1 to a structure, for example, by placing connectors, solid conduit, wire, fastener, etc. therethrough, and then attaching such conduit, wire, or fastener to the given structure. Any other known apparatus may also be used for mounting lighting fixture 1 to a ceiling or other structure.
Mounting plate 10 is formed to have a hole 20 formed in a central location. Longitudinal Z-channel members 31 are mounted on top surface 11, in the illustrated example, essentially in parallel with sides 21 of hole 20, using fasteners 32 to secure Z-channel members 31 on opposite sides of hole 20. Each Z-channel member 31 has an upper longitudinal portion 33 that is offset at a distance above top surface 11, creating an offset space due to the Z shape. A cast light support member 34 has laterally-extending flanges 35 on each of its sides, flanges 35 having a thickness less than the offset of the upper longitudinal portions 33 of Z-channel members 31. As a result, cast light support member 34 is able to slide back and forth between the respective open and closed positions of FIGS. 1 and 2, with the flanges 35 being guided along the offset spaces of opposed and essentially parallel Z-channels 31. As shown in FIGS. 1 and 2, one of the two Z-channels 31 may extend a shorter distance compared with the other. Structure other than or in addition to flanges may alternatively be used for guiding light support 34 along longitudinal guides, such as roller wheels, bearings, etc.
Light support member 34 is preferably formed by casting a metal such as aluminum or other suitable metal, or alternatively may be formed of an injection molded polymaric (plastic) type material, into a shape having flanges 35 and a box-like structure adapted for attaching a reflector housing 36. Reflector housing 36 is also preferably formed by casting a suitable metal such as aluminum, or alternatively by forming of an injection molded polymaric (plastic) material, into a form having a domed shape and having additional metal volume, such as ribs 37, for increasing heat sinking and dissipation. Light support member 34 has a hole of a same general shape as the dome of reflector housing 36, so that light from reflector housing 36 passes therethrough. The mating surfaces between light support member 34 and reflector housing 36 are preferably flush with one another, thereby transferring heat therebetween for optimal heat dissipation.
Fasteners 41 are attached, such as by using rivets or the like, to top surface 11 on opposite sides of hole 20 adjacent the service access end 22 of hole 20. Fasteners 41 in the illustrated example each include a bracket having a shape that coincides with the shape of Z-channel members 31, with the addition of a vertical section threaded to receive a threaded nut such as a thumbnut. The threaded nut, when loosened, on either side of hole 20 is positioned to fit into a corresponding slot 38 formed on the respective corner of light support 34. After light support 34 has been pushed into the closed position shown in FIG. 2, the nuts of fasteners 41 are tightened by a service person from the inside of light support 34 via hole 20, thereby locking light support 34 and the attached reflector assembly to frame 10. Similarly, when service access is desired, light support 34 may be loosened to be slid to the service access position shown in FIG. 1, by loosening the nuts of fasteners 41 from the underside of fixture 1 via hole 20. Such allows field maintenance to be performed without disassembling the fixture.
A junction box 51 is secured to top surface 11 with rivets or the like being attached via holes in mounting tabs 55 of junction box 51. A rear plate 52 covers one side of junction box 51 and is attached thereto by engagement of tabs and slots (not shown) at one end and by an affixed clip 54 at the other end. A front plate 53 covers the other longitudinal side of junction box 51 and is similarly attached, except that clip 54 is not affixed to front plate 53 but merely acts in a moveable leaf spring arrangement so that clip 54 may be moved to release front plate 53 to be removable from junction box 51. Such a release of clip 54 may be performed by a service person via hole 22, and components of junction box 51 may then be serviced. Such components (not shown) may include, but are not limited to, wires, conduit fittings, connectors such as twist-on wire connectors, ballasts, switches, dimmers, communications equipment, relays, sensors, etc. As shown, a thermal protector 57 protects fixture 1 from overheating, such as in an event where an incorrect lamp is installed or, for example, per NEC Article 410-66, in an event where insulation is inadvertently installed above or around fixture 1. Thermal protector 57, for example, may trigger a relay or similar switch for shutting off power when an over-temperature condition is sensed, and may then reset itself after a cooling off period. Although shown in FIGS. 1 and 2 installed near hole 22, junction box 51 may alternatively be installed in an end mounting location 24.
FIG. 3 is an elevation view taken along the line III-III of FIG. 1, except that hole 20 is shown as a dashed line rather than being shown as a distal end of hole 20. The spaces 30 between top surface 11 and Z-channels 31 have a vertical height greater than a height of flanges 35 of light support 34, so flanges 35 are able to slide freely within spaces 30. Although the illustrated embodiments utilize Z-channels, any other guide structure or slide rail(s) may be used for allowing light support 34 to slide along frame 10. FIG. 4 is a side elevation view of light support 34, showing an example of a slot 38 for receiving the threaded shaft of fastener 41. When light support 34 is slid laterally along longitudinal spaces 30, such threaded shafts of opposed fasteners 41 enter slots 38 of corresponding opposite sides of light support 34, and such threaded shafts become seated into respective securing ends 39. With the threaded shafts seated, light support 34 is at its operating position, and the service person then fastens the nuts onto the threaded shafts of fasteners 41 to hold light support 34 in place. Other alternative fasteners 41 (not shown) may include, but are not limited to, leaf springs adapted to engage notches in light support 34, clips, connectors, quick-release devices, and the like.
FIG. 5 is a top view of light support 34. In the present example, flanges 35 are formed on all four sides of light support 34, with a cutout portion 44 formed on a flange 35 of one side. In one embodiment, cutout 44 allows light support 34 to slide until an abutment surface 45 thereof abuts bracket holder 13. Light support 34 has curved guide projections 42, 43 formed to assist installation of reflector housing 36 onto light support 34. In a preferred embodiment, guide projections 42, 43 are curved portions that have a same curvature as that of the mounting surface of reflector housing 36 and that are disposed to allow reflector housing 36 to be precisely situated between guide projections 42, 43 and then fastened to light support 34 at the desired location by use of one or more fastening members (not shown). Additional alignment structure may be provided for securing reflector housing 36 at a predetermined position. Further description of reflector assemblies and their mounting are discussed further below.
FIG. 6 is a cutaway side view of a fixture 1 having a primary lamp 61 mounted in a socket assembly 62. Lamp 61 may be any suitable type that fits into a given size reflector housing 36 including, but not limited to compact fluorescent, HID, quartz, incandescent, etc. Socket assembly 62 is attached to an upper compartment 63 of reflector housing 36. A removable cover 47 is attached to the topmost part of reflector housing 36 with screws or the like. A conduit 71 is attached to reflector housing 36 with a strain relief panel 48 and is used for feeding electrical wires to compartment 63. Cover 47 and strain relief 48 may be combined into a single structure. A light passage housing 82 is attached on the bottom surface 81 of plate 10, such as by using rivets or the like. In a preferred embodiment, light passage housing 82 is rectangular and has flanges extending to be coplanar with one another, with holes in the flanges for the riveting to bottom surface 81. As shown, flange 83 of light passage housing 82 is installed by being inserted into notch 85 formed in bottom surface 81 to assist proper alignment prior to the riveting. In the illustrated example, a second socket assembly 64 is provided for a secondary light, such as an emergency light having its own separate electrical feed, as shown in FIG. 7.
FIG. 7 is a cutaway side view of a fixture 1 having a removable insert 91 that includes leaf springs 92, 93 which maintain a snug fit for insert 91 when it is installed into light passage housing 82. Leaf springs 92, 93 abut reflective walls 98 and apply increasing holding force against walls 98 as insert 91 is pushed upward by an installer. Insert 91, when installed with light support 34 in the operating position, extends through hole 20 and up into light support 34. A top portion of insert 91 has a lens holder platform 94 at the bottom of a lens placement and retaining portion 95. A lens (not shown) is held on platform 94 by tabs or the like formed in retaining portion 95. Insert 91 preferably has reflective surfaces 96 on the interior portion thereof, and insert 91 may be formed entirely of a single reflective material. Junction box 51 is shown mounted at side position 24.
FIGS. 8 and 9 respectively show perspective views of lighting fixture 1 in a closed and operational state, and in an open servicing state. FIG. 10 is a flowchart of an exemplary method of performing servicing on an installed lighting fixture 1. First, at step 111, the service person shuts off the circuit breaker feeding electrical power to fixture 1. At step 112, reflective insert 91 is removed by grasping the rims thereof and pulling down so that the sides of insert 91 become disengaged with leaf springs 92, 93 holding insert 91 in place. After setting reflective insert 91 aside, the service person reaches up through light passage housing 82 and loosens the thumbnuts of fasteners 41 at step 113 so that light support 34 is no longer fastened to fasteners 41. At step 114, the service person slides light support 34 in a lateral direction away from fasteners 41, such as by pushing against flange 35, until light support 34 is at a servicing position. At step 115, servicing of lighting fixture 1 is performed via housing 82.
FIGS. 11A-11F respectively show, for reflector housing 36, a side elevation view, a perspective view, a top view, a view along the line A-A of FIG. 11C, a bottom view, and a view along the line B-B of FIG. 1C. Quartz restrike mounts 121 are provided as an integral part of the casting for par lamp fixtures. Bosses 122 are also cast integrally for twist-lock type engagement with a locking stop boss assembly, as described in co-pending application Ser. No. ______, entitled “Top Relamping System,” incorporated herein in its entirety. A top wiring compartment 123 allows for wiring connections and extra wire, and is provided with a strain relief section 48 for securing conduit 71 thereto, for example including a conduit cover and locking screw boss(es), or an integral power feed conduit lock 49. At the bottom of compartment 123 is an access hole 27 having a universal clearance pattern allowing different type sockets to be mounted in a first socket assembly space 28 and accommodate wiring thereto. For example, G-12 wiring and mounting of DC bayonet and mini-candelabra sockets may be accommodated completely within space 28. A mounting surface 29 within space 28 has threaded screw attachment holes for securing such a socket assembly within space 28. The bottom walls of space 28 form an additional socket assembly mounting surface 125 that is laterally extended to include threaded mounting holes 126, and such may be used for mounting a cast type socket assembly 62 where a heat conducting portion thereof is within space 28, and where a socket and surrounding portion extends into internal reflector space 127. Socket assembly 62 is further described below. A second socket mount assembly 64 is integrally cast in reflector housing 36, providing a direct mount conduit connection and knock-out wire access, and being adapted for receiving a quartz restrike DC bayonet type socket therein. The bottom perimeter surface of reflector housing 36 has an integral series of annularly arranged steps 120 for varying the vertical level of mounting of a reflector therewithin. Each step 120 has a corresponding screw hole for securing a mounting tab of a reflector thereto. Such allows an installer, service person, or customer to implement or change the light distribution by varying vertical reflector position. For ease of manufacturing assembly and field adjustment of the reflector assembly, step level markings 129 are provided to assure correct optical distributions by referencing the placement with a letter.
FIG. 12 shows a reflector housing 36 with a socket assembly 62 having a same casting as that of housing 36, effecting efficient heat transfer therebetween. A reflector 131 is mounted to housing 36 using screws 132. Reflector 131 has a center hole that allows lamp 61 to pass therethrough, and has a hole in a sidewall portion that allows lamp 65 and socket 60 to pass therethrough. Such allows the lamps to remain static regardless of the distribution effected by reflector 131. Socket 60 is secured into the integrally cast portion secondary socket assembly 64, which has a wire passageway and a conduit mount for feeding electrical power to socket 60. The conduit 71 separately providing power to lamp 61 is locked into place using integrally formed strain relief portion 48 along with a locking screw and cover 47. A handle 140 is attached to housing 36 by two screws 40. Handle 140 has a height that may be used as a reference for placement of lighting fixture 1 in a facility. For example, the top of handle 140 may be placed six inches below a rafter. In other applications, handle 140 may be used for twist locking and unlocking of housing 36 from light support 34, as detailed in co-pending application Ser. No. ______. Cast reflector housing 36 may be configured to allow multiple light sources through use of integral mounting, bracketry, and cast socket mounting inserts. Housing 36 is preferably designed to keep the lamp light center(s) of lamp(s) mounted therein at a constant position at all times. The optical performance and distribution variances are created by mounting reflector 131 to chosen integral mounting steps 120. This allows a user to vary optical performance by simply moving or replacing (e.g., alternate reflective materials or shape) reflector 131. Such changes may be made from below fixture 1 without disassembling fixture 1. Housing 36 is adapted to accept various sockets and lamps. For example, a first casting is designed to be used for T4 quartz, T4/T6 metal halide, and Par 20 lamp sources. A second type casting removes the base socket mount to allow utilization of A19/BT15/Par30/Par38 incandescent, ED17/Par30L/Par38 HID, and PLT compact fluorescent sources. Cast reflector housing 36 also incorporates integral quartz restrike (QEM) socket and conduit mounting and integral power feed conduit locking to allow conduit feeds without any use of additional connectors. When using Par30/Par38 lamp sources, the secondary integral QEM mounting is used.
FIGS. 13A-13K show a lamp socket assembly 62, and some variations thereof, having a heat sinking ability and adapted for receiving a lamp 61. Socket assembly 62 is preferably formed by casting of a same type and material as is used to manufacture light support 34 and reflector housing 36, thereby effecting efficient heat transfer when such structures abut one another. Preferably, lamp socket assembly 62 has a shape and size to mate with reflector housing 36 in a manner that provides consistent lamp positioning and thermal conductivity for socket temperature management. FIGS. 13A-13B are perspective front and rear views, FIGS. 13E, 13G, and 131 are top views, and FIGS. 13C-13D respectively are side and bottom views of socket assembly 62. A top plate 66 of socket assembly 62 is formed with a shape suitable for enclosing a space between upper compartment 63 and the lower open dome portion of reflector housing 36. For example, top plate 66 is secured to threaded receptacles of reflector housing 36 with fasteners (not shown) via mounting holes 67. A base portion 68 extends into upper compartment 63 and provides heat radiating surface area by use of multiple fins 69. A mini-candelabra socket mounting plate 74 is secured to footings 104 with machine screws 75 being fastened into cored holes 73.
Socket mounting casting allows use of several different lamp bases by switching sockets in the casting 62. For example, DC bayonet, mini-candelabra, and others may be utilized, where positioning of integrated socket mounting positions allows for consistent lamp center location regardless of the particular base style used, thereby assuring consistency of optical performance and distribution. FIG. 13E shows a first type DC bayonet socket assembly that allows for anti-twist on a nipple mount socket where the bottom base level assures lamp position. FIG. 13F is a cutaway view along line A-A of FIG. 13E showing relative positioning of a DC bayonet socket 101, which mounts from the top (lamp) side of the casting 62. By comparison, FIG. 13G shows a mini-candelabra type socket assembly that mounts from the bottom side of the casting. FIG. 13H is a cutaway view along line B-B of FIG. 13G, showing an exemplary mini-candelabra socket 102. FIG. 13I shows an elongated double D hole 78 that allows for an anti-rotation mount with a nipple mounted DC bayonet socket. FIGS. 13J and 13K are each cutaway views along line C-C of FIG. 131, where FIG. 13J shows an exemplary socket mount casting for a 250 Watt T4 quartz incandescent lamp, where a DC bayonet socket bottom base level 103 is provided for a top mount DC bayonet socket, and where a mini-candelabra socket footing level 104 is provided for a bottom mount mini-candelabra socket. FIG. 13K shows an exemplary socket mount casting for a 500 Watt T4 quartz incandescent lamp, where internal base 105 and bottom footing 106 are shifted down approximately 0.550 inch to accommodate the larger 500 Watt lamp.
While the principles of the invention have been shown and described in connection with specific embodiments, it is to be understood that such embodiments are by way of example and are not limiting. Consequently, variations and modifications commensurate with the above teachings, and with the skill and knowledge of the relevant art, are within the scope of the present invention. The embodiments described herein are intended to illustrate best modes known of practicing the invention and to enable others skilled in the art to utilize the invention in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.
Patent Application
20080002414
