This application is a National Phase of PCT Patent Application No. PCT/GB2019/053276 having International filing date of Nov. 19, 2019, which claims the benefit of priority of United Kingdom Patent Application Nos. 1818840.9 filed on Nov. 19, 2018 and 1902952.9 filed on Mar. 5, 2019. The contents of the above applications are all incorporated by reference as if fully set forth herein in their entirety.
This invention relates to a device including a mechanism for mounting the device and a method for mounting such a device.
Recessed ceiling fittings (such as LED fittings) are generally mounted in a ceiling void using some form of torsion spring, a pair of ramped blades or other biasing means.
Some ceiling mounted devices require holding in place with more force than a lightweight lamp. This may be because the devices themselves are heavier. Additional force may also be required to hold a device that vibrates. If the prior art system is adapted to include a constant force spring applying a greater force then it may not be possible for the user to unfurl the spring with their fingers. Attempting to do so could cause an injury.
An object of the present invention is therefore to provide an improved system for mounting a device in a ceiling where more force can be applied to hold the device in place.
The scope of the present invention is defined in the claims. A number of example embodiments are also provided below.
In one example, a device suitable for mounting in a ceiling aperture in a ceiling is provided. The device comprises a body having a front end and defining a longitudinal axis perpendicular to the front end. The device further comprises a flange that extends laterally beyond the body at the front end. The device further comprises one or more elastic members mounted on the body configurable in a restrained position and an engaging position. The device further comprises a respective guide on the body associated with each elastic member. Each guide is configured to receive a restraining member that urges the respective elastic member into the restrained position when the restraining member is inserted into the guide. The respective elastic member is released into the engaging position when the restraining member is removed from the guide. Each elastic member extends laterally beyond the body in the engaging position.
Providing one or more elastic members that are restrained with restraining members allows the device to be inserted easily into a ceiling aperture. This is because the elastic members have a low profile when they are held in the restrained position by the restraining members. Once the device has been inserted into the ceiling aperture, the restraining members can be released and the elastic members will engage with the ceiling to hold the device in the aperture. There is no requirement for the user to manually manipulate the elastic members. The user only needs to remove the one or more restraining members from the guides. The device can therefore be installed easily and safely. Moreover, the device can be removed easily by inserting restraining members back into the guides.
Advantageously, the present invention provides a system that allows a parallel sided body of almost the same dimension as the aperture to be retained in the aperture. The body of the device can be any depth (as long as it fits in the ceiling void). This provides significant advantages over the prior art as much larger devices may be mounted in the ceiling than was possible with prior art systems.
The elastic members may not extend laterally beyond the restraining member in the restrained position. Restraining members and elastic members therefore have a low profile on the body when the elastic members are in the restrained position. The device can therefore be inserted into an aperture in the ceiling that is not much larger than the body of the device.
Each guide may comprise a channel along the body. Each channel may extend from the front end of the body in the longitudinal direction. Each channel may be configured to receive the respective restraining member. Each elastic member may be mounted in the channel of the respective guide. Each elastic member may lie in the respective channel so that it does not extend laterally beyond the body in the restrained position.
Each guide may comprise a pair of channels along the body. Each channel may extend from the front end of the body in the longitudinal direction. The channels in each pair of channels may be located on either side of the respective elastic member. Each channel in each pair of channels may be configured to receive a portion of the respective restraining member.
Each channel may be a retention channel comprising an overhanging portion on one or both sides of the channel. The overhanging portion may be configured to retain the restraining member in the channel when the restraining member is inserted into the channel. For example, the retention channel may be a “T-slot”. The profiled retention channel provides support to the restraining member so that the restraining member is retained against the body whilst applying a force to the elastic member to move the elastic member to (and keep the elastic member in) the restrained position.
Each channel may be formed as an integral part of the body of the device. Alternatively, each channel may be external to the body of the device. If each channel is formed as an integral part of the body, and each elastic member is fastened in a channel, then the mounting system may not protrude laterally from the body of the device at all when the elastic members are in the restrained position. However, this is not essential and the channel may be formed separately (for example as a thin external track) and attached to the outside of the body of the device. Such a system would provide a small increase in the width of the device but would still have a low profile compared to the elastic member in the engaging position. Placing the elastic members in the restrained position would therefore enable the device to be inserted easily into the ceiling aperture.
Each guide may comprise one or more magnetic portions on the body of the device.
Each guide may be configured to receive a restraining member comprising one or more magnets. Each of the magnetic portions may be attracted to a respective magnet when the restraining member is inserted into the guide.
The device may be configured so that in use, when the body of the device is inserted in the ceiling aperture and each restraining member is removed from the respective guide, each elastic member engages a rear side of the ceiling and exerts a force against the ceiling in the longitudinal direction. The flange may extend laterally beyond the ceiling aperture to engage a front side of the ceiling and exert a force against the ceiling in a direction opposite the direction of the force exerted by the elastic members to brace the device against the ceiling.
The device may comprise two or more elastic members and respective guides. Where the device comprises two or more guides, the elastic members may be arranged symmetrically (or evenly) around the device. Alternatively, the elastic members may be distributed in a non-symmetric manner to correspond with any potential off-centre mass in the retained body. This provides balanced support of the device so that the device is held securely in the ceiling aperture. The device may comprise three or four elastic members and these may be distributed in multiple orientations per side.
Each elastic member may be a constant force spring (CF spring). For example, the elastic member may be an extension type constant force spring. CF springs can beneficially provide a constant force, regardless of the displacement of the spring. The force used to hold the device is place is therefore determined only by the characteristics of the spring. The thickness of the ceiling does not affect the force applied by the spring.
Moreover, constant force springs can be unrolled into a restrained position in which they have a low profile. This enables the device to be inserted into an aperture only slightly larger than the body to be retained. When the constant force springs are released, they roll up under their own bias. This means that the springs will stand proud of the device on which they are mounted. Thus the constant force springs engage with the upper surface of the ceiling when in use.
The device may be a lighting device including a lighting element. The device may be an audio device including a loudspeaker. Audio devices vibrate when in use and therefore more force may be required to mount such devices in the ceiling. In particular, it is desirable to retain the body of the device static relative to the panel in which it is mounted, despite movement or vibration caused by vibrating or moving elements in the device. Typically, forces 2 to 3 times the weight of the device or greater are desirable. Ideally the force is as high as is practical in order to provide a rigid clamping force to resist vibration and/or resonance.
Advantageously, by mounting the device using an elastic member, vibrations can be dampened. This can help to reduce loosening of physical static fixtures on the device. For example, screws in a speaker can sometimes be loosened by vibration of the speaker. By dampening the vibration of the device, the elastic members can help to prevent components in the device coming loose.
The device may further comprise a respective screw, rivet, pin or fastener used to fasten (i.e. retain or fix) the elastic member to the body. In some examples, the elastic member is fastened in the channel. The screw (or rivet etc.) may be located at or towards the front end of the body. Mounting the elastic member close to the front of the device may allow the restraining member to be inserted into the guide easily. Moreover, there may be a “ramp up” force on the CF spring, whereby the initial unfurling requires slightly less force (i.e. at small displacements of the spring). By attaching the spring very close to the flange it enables the spring to have reached effectively full force at the thinnest conventional ceiling thickness. For example, the spring may be operating in a constant force mode at a displacement of approximately 10 mm.
In another example, a kit of parts is provided. The kit of parts comprises a device as described in one of the above examples and one or more restraining members. Each restraining member may be inserted into a respective channel to urge the elastic member mounted in that channel into the restrained position.
In another example, a kit of parts is provided. The kit of parts comprises a mount for mounting a device in a ceiling aperture in a ceiling. The mount comprises a flange, one or more guides on the flange, and a respective elastic member associated with each guide. Each elastic member is configurable in a restrained position and an engaging position. The kit of parts further comprises a respective restraining member for each guide. Each guide is configured to receive the respective restraining member to urge the respective elastic member into the restrained position when the restraining member is inserted into the guide. The respective elastic member is released into the engaging position when the restraining member is removed from the guide. Each guide and respective restraining member comprise complementary engaging means that permit relative movement in an axis normal to the flange (perpendicular to the flange), restrict relative movement in other axes and restrict relative rotation, when the restraining member is inserted into the guide.
The kit of parts may further comprise a device, wherein the mount and the device comprise complementary fastening means. For example, the device may be fastened to the flange of the mount using screws.
Providing one or more elastic members that are restrained with restraining members allows the mount to be inserted easily into a ceiling aperture. This is because the elastic members have a low profile when they are held in the restrained position by the restraining members. Once the mount has been inserted into the ceiling aperture, the restraining members can be released and the elastic members will engage with the ceiling to hold the mount in the aperture. There is no requirement for the user to manually manipulate the elastic members. The user only needs to remove the one or more restraining members from the guides. The mount can therefore be installed easily and safely. Moreover, the mount can be removed easily by inserting restraining members back into the guides.
The elastic members may not extend laterally beyond the restraining member in the restrained position. Restraining members and elastic members therefore have a low profile on when the elastic members are in the restrained position, as compared to when the elastic members are in the unrestrained position. The mount can therefore be inserted into an aperture in the ceiling having appropriate dimension. Once the restraining members are removed, the mount is held in place by the elastic members and may not be removed from the aperture.
The mount may be configured so that in use, when the mount is inserted in the ceiling aperture and each restraining member is removed from the respective guide, the respective elastic member engages a rear side of the ceiling and exerts a force against the ceiling in a direction normal to the flange. The flange may extend laterally beyond the ceiling aperture to engage a front side of the ceiling and exert a force against the ceiling in a direction opposite the direction of the force exerted by the elastic members to brace the mount against the ceiling.
The mount may comprise two or more elastic members and respective guides. Where the mount comprises two or more guides, the elastic members may be arranged symmetrically (or evenly) around the mount. Alternatively, the elastic members may be distributed in a non-symmetric manner to correspond with any potential off-centre mass in a device to be retained by the mount. This provides balanced support of the device so that the device is held securely in the ceiling aperture. The mount may comprise three or four elastic members and these may be distributed in multiple orientations per side.
Each elastic member may be a constant force spring (CF spring). For example, the elastic member may be an extension type constant force spring. CF springs can beneficially provide a constant force, regardless of the displacement of the spring. The force used to hold the device is place is therefore determined only by the characteristics of the spring. The thickness of the ceiling does not affect the force applied by the spring.
Moreover, constant force springs can be unrolled into a restrained position in which they have a low profile. When the constant force springs are released, they roll up under their own bias. This means that the springs will present a wider profile in the unrestrained position compared to the restrained position. Thus the constant force springs engage with the upper surface of the ceiling when the restraining members are removed from their respective guides.
The mount may be used for mounting a device in a ceiling aperture in a ceiling. The device may be a lighting device including a lighting element. The device may be an audio device including a loudspeaker. Audio devices vibrate when in use and therefore more force may be required to mount such devices in the ceiling. In particular, it is desirable to retain a body of the device static relative to the panel in which it is mounted, despite movement or vibration caused by vibrating or moving elements in the device. Typically, forces 2 to 3 times the weight of the device or greater are desirable. Ideally the force is as high as is practical in order to provide a rigid clamping force to resist vibration and/or resonance.
Advantageously, by mounting the device using one or more elastic members, vibrations can be dampened. This can help to reduce loosening of physical static fixtures on the device. For example, screws in a speaker can sometimes be loosened by vibration of the speaker. By dampening the vibration of the device, the elastic members can help to prevent components in the device coming loose.
In another example, a method of mounting a device in an aperture is provided (for example, a ceiling aperture in a ceiling). The method comprises inserting a body of the device into the aperture, wherein the body of the device has a front end and defines a longitudinal axis perpendicular to the front end, wherein the device comprises a flange that extends laterally beyond the body at the front end. The method further comprises removing a restraining member from one or more channels along the body, wherein each of the channels extends from the front end of the body in the longitudinal direction, wherein the restraining member urges an elastic member mounted in the channel into a restrained position when the restraining member is in the channel, wherein removal of the restraining member from the channel releases the elastic member into an engaging position, wherein the respective elastic member extends laterally beyond the channel in the engaging position.
The present invention may be put into practice in a number of ways, and some specific examples will now be described with reference to the following drawings.
As described above, prior art devices are mounted in the ceiling by manually unfurling the constant force springs and posting the partially unrolled springs through a hole in the ceiling. This is also illustrated in
In order to mount a device in a ceiling where the device includes a speaker, the unit must be held in place with a force approximately equal to 2 to 3 times the weight of the device. This at least partly due to vibration generated by the drive unit of the speaker.
A constant force spring capable of providing sufficient force for such a device will be difficult for a user to unfurl in the manner described above in relation to the prior art. Injury may occur if a user attempts to partially unfurl the springs and post the coils through the ceiling aperture in this way.
In the case of the prior art system, the risk of injury is even more pronounced during removal of the device. The unit can be simply pulled out of the ceiling with the springs unfurling. During the unfurling action, the cylinder part of the CF spring is rotating. Therefore, it has the tendency to move towards and over the edge of the hole. At this point, unless constrained by the user's hand, the cylinder part of the CF spring will move at high speed towards the users other hand that is pulling on the flange. Significant dexterity is required to perform this task. Assistance may be required if the diameter of the body is too large for a single hand to simultaneously restrain both (or all) of the retention CF springs.
Delicate cosmetic or functional components may be contained within the flange/bezel element (typically antennae, microphones, light sensors etc. in a smart speaker). There is a risk of these components being damaged by this uncontrolled high speed retraction of the CF spring. In particular, the risk is more pronounced if the CF springs are attached very close to the flange/bezel (as is required for a device to be mounted in a thin panel).
To address these problems with prior art systems, a device having constant force springs to hold the device in place and blades to manipulate the constant force springs is provided in a specific example. The blades are removed to mount the device in the ceiling. The resulting device therefore provides a very low profile mounting solution that is easy and safe to use.
As shown in
As the blades 202 are pulled (slid) out of their channels 206, the constant force springs 208 are released. They are therefore no longer restrained in an unfurled (restrained) position and will roll up into an engaging position. Removal of the blades deploys the springs to clamp the unit into the ceiling.
As shown in
Once the blades 202 have been completely removed, a cosmetic cover 210 may be placed over the flange 204. This may be achieved using a clip and/or magnetic mechanism, for example. The flange/bezel may itself be cosmetic. This portion and could have a visible slot or and an elastomeric or moving element to conceal the removal slot if desired.
If a user wishes to remove the unit from the ceiling, they can re-insert the blades to get the springs out of the way. The device can then be slid out of the aperture in the same way it was inserted, without risk of injury from unrestrained springs.
The constant force springs 408 are held in place in the channels by a mounting screw 414.
As can be seen from
The examples described and illustrated above include an elastic member mounted within the channel. The channel is in the form of a “T slot” in order to allow retention of the restraining means and also to provide a space in which the elastic member sits when in the restrained position. In this way, the channel is able to guide and support the restraining member. The channel provides support to the restraining member so that it is stiff enough to restrain the elastic member (to overcome the force of the elastic member), whilst being made from a relatively thin material. However, the elastic member does not need to be mounted in a channel.
The examples described above illustrate separate removal tools (restraining members) for each spring. As a further alternative, the elastic members (springs) could be unfurled using a single tool with all of the blades connected together at the front end of the device. For example, where there are two CF springs (one on either side of the device) the removal tool may be “U”-shaped. In this case, channels may not be required to brace the removal tool against the body of the device because the forces required to restrain the springs are approximately equal and opposite. However, the restraining member would need to be thicker to provide rigidity to the restraining member to counteract the bending moment applied by each of the CF springs to each blade of the removal tool.
The examples disclosed in this application advantageously provide a low-profile mounting solution. The physical volume of the device is therefore not significantly increased by applying this mounting system. Where the device is a speaker device, acoustic performance is dependent on the physical volume of the cabinet (body) of the device. Therefore, acoustic performance of speakers mounted using this solution can be maintained, without significantly increasing the size of the hole in the ceiling. This also avoids increasing the size of the cosmetic cover.
When the restraining members are inserted into a respective slot, the support member is held inside the channel of the restraining member. The slot and support members restrict the movement of the restraining member so that the restraining member can be slid in and out of the slot but prevent the restraining member from moving in other directions or rotating when the support member is inside the channel. In this way, the restraining member can be used to urge the elastic member from the engaging position into the restrained position as the restraining member is slid into the slot and the support member is slid into the channel.
In a specific example, the tool (restraining member) provides the guidance channel and edge retention required to unfurl the constant force spring. The tool is in the form of an elongated “C” section channel such that the tool engagement at the edges of the constant force spring provides a retention against which the opposite flat of the “C” can act to unroll the spring. As with the other examples, the tools may be separate/individual per constant force spring or alternatively joined together at the front/proximal end to make a single double or multi-armed tool.
This example can effectively operate in free space, without the need for the device (for example, luminaire or loudspeaker) to have a body or can to carry the guidance channels. The mount can be used to mount any device that is attached to the mount. For example, the device may be fastened to the flange of the mount.
When a restraining member is inserted into a slot, the CF coil spring is held inside the notch of the restraining member. The notch and CF coil spring restrict the movement of the restraining member so that the restraining member can be slid in and out of the slot but is prevented from moving in other directions or rotating when inside the slot. In this way, the restraining member can be used to unroll the CF coil spring as the restraining member is slid into the slot.
In a specific example, the tool (restraining member) provides guidance for the constant force spring using a notch just wider than the CF spring on the tool's the top edge.
In this variation, the tool tip is effectively held against the unfurled portion of the spring by the cylindrical portion that is still rolled up; the tool must, therefore, be matched in length to the spring such that a “depth stop” always limits the tool insertion to leave about half a “turn” of the spring curled over the top of the tool to retain it in an extended condition. Over insertion of a tool without a depth stop would result in the spring loosing retention on the tool tip and recoiling in an uncontrolled fashion.
The tool is guided/retained by the “roll” until it reaches the end of the spring. At this point, the coil of the spring slips over the end of the tool and is no longer retained. Therefore, the depth of the tool insertion is limited (e.g. by the length of the tool) to a point where the spring is not fully unrolled. This example therefore adds more than a few millimetres to the diameter of whatever the can etc is as you still have a “spring roll” per side.
As with the example of
Many of the features described with respect to the mountable device can equally be applied to the mounting system of
Alternatives and Variations
This system is especially useful where elastic members are required that apply more force than those found in standard lighting fittings (e.g. in mounted speaker devices and combined lighting and speaker devices). However, the system may also be useful to simplify installation of standard lighting fittings (and other devices to be mounted in a ceiling) with elastic members that apply smaller forces. The type and number of elastic members may be selected to apply a suitable force depending on the device to be mounted.
Whilst the above description describes mounting devices in ceiling apertures, the system could also be used to mount devices in apertures in walls or generally any flat panel with a cavity behind. Where the device is mounted in a wall, only one spring may be required to brace the device in position (e.g. at the top of the device). Where the device is mounted in the ceiling, two or more springs may be required to distribute the load more evenly.
Whilst the specific examples described above include constant force springs, other types of elastic members may be used.
The specific examples described above include two blades, channels and springs. However, variations with more blades, channels and springs are possible. Additional springs could be provided to increase the force provided by the mounting system. In some devices, only one spring may be required. It is advantageous to provide more than one spring so that the springs can be mounted symmetrically around the device and thus provide a secure mounting system.
The blades may be manufactured from steel, plastic or other suitably rigid material.
The channel along the body of the device (the outer casing or cabinet of the device) may be extruded into the body of the device. Alternatively, the channel may be formed by an external structure affixed to the body of the device.
Springs are shown mounted in their respective channel using a single screw. However, more than one screw may be used to mount each spring. Other methods of mounting the spring in the channel may be used (e.g. gluing, riveting, welding, clipping or clamping).
Whilst the description generally relates to lighting and loudspeaker devices, the mounting system could be applied to any device. The system is generally applicable to any device to be mounted in a ceiling, wall or other flat panel. For example, the device may include various combinations of lighting, audio and other electronic components. The system is also suitable for mounting alarms, smoke alarms, CO2 detectors, temperature sensors, security cameras and the like.
Number | Date | Country | Kind |
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1818840 | Nov 2018 | GB | national |
1902952 | Mar 2019 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/GB2019/053276 | 11/19/2019 | WO |
Publishing Document | Publishing Date | Country | Kind |
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WO2020/104791 | 5/28/2020 | WO | A |
Number | Name | Date | Kind |
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6016596 | Rodgers | Jan 2000 | A |
8465182 | Davis | Jun 2013 | B1 |
10182279 | Zhou | Jan 2019 | B1 |
Number | Date | Country |
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104165311 | Nov 2014 | CN |
2486498 | Jun 2012 | GB |
57-45712 | Mar 1982 | JP |
WO 2012091660 | Jul 2012 | WO |
WO 2020104791 | May 2020 | WO |
Entry |
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International Search Report and the Written Opinion dated Jan. 8, 2020 From the International Searching Authority Re. Application No. PCT/GB2019/053276. (12 Pages). |
Patents Act 1977: Examination Report Under Section 18(3) dated Sep. 16, 2020 From the Intellectual Property Office of the United Kingdom of Great Britain Re. Application No. GB1902952.9. (2 Pages). |
Patents Act 1977: Search Report Under Section 17(5) dated Aug. 19, 2019 From the Intellectual Property Office of the United Kingdom of Great Britain Re. Application No. GB1902952.9. (3 Pages). |
Notification of Office Action and Search Report dated Sep. 28, 2022 From the National Intellectual Property Administration of the People's Republic of China Re. Application No. 201980088477.0 and Its Tranlsation Into English. (18 Pages). |
Notification of Office Action and Search Report dated Apr. 14, 2023 From the State Intellectual Property Office of the People's Republic of China Re. Application No. 01980088477.0 and Its Translation of Office Action Into English. (19 Pages). |
Number | Date | Country | |
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20220003392 A1 | Jan 2022 | US |