The invention relates generally to canopy mounting devices for mounting an illuminated sign or the like to a junction box in a ceiling or wall and, more particularly, to canopy mounting devices having universal mounting plate elements formed integrally with portions of the mounting devices to permit rapid installation of visually appealing sign/canopy combinations.
A mounting device connects an illuminated sign, such as an exit sign, combination emergency lighting/exit sign fixture, and the like, to a junction box so that electrical wiring from the junction box can be pulled through the mounting device and into the interior of the sign for connection of electrical components therein to a source of mains power. Junction boxes are typically recessed within or otherwise mounted to ceilings or walls. Existing mounting devices typically include a canopy that shields the junction box and also provides a pleasing appearance to the finished installation.
One existing canopy mounting device utilizes a camming element that biases a sign housing and a canopy element of the mounting device together in order to provide a secure connection of the sign to a junction box through the canopy mounting device. Another existing canopy mounting device includes resilient spring fingers formed on a canopy element that covers a junction box. The spring fingers are inserted through an opening in a sign housing to snap-fit to the housing. Yet another existing canopy mounting device includes a canopy element having a post received within a slot of a sign housing. The slot has portions of varying width such that the post of the canopy element is inserted into a wide portion of the slot and then moved into a more narrow portion to be locked in place. Another existing canopy mounting device includes a canopy element with a projecting bracket that is received within a slot in a side or top of a sign housing. Screws are then used to connect the sign housing to the canopy element.
Because exit signs and the like are mandated in environmental spaces such as commercial buildings, it is often necessary to install large numbers of such signs at a given job site. Thus, it is important that each sign installation is completed quickly and easily, with a reliable connection of the junction box and the exit sign through the canopy mounting device. In addition to minimizing installation time, effort, and expense, it is also desirable to be able to install exit signs without the need for special or unusual tools. Accordingly, there is a need for canopy mounting devices that may be connected to junction boxes more quickly, easily, and reliably, and preferably without the use of special tools.
The present invention provides canopy mounting devices that cover junction boxes of various configurations and provide a pleasing, finished appearance to a resulting installation.
Canopy mounting devices of this invention provide reliable mounting of exit signs and the like to junction boxes disposed in or on ceilings or walls and may be installed without requiring special tools. Certain embodiments of a canopy mounting device include a universal mounting plate integrally formed with a connector of the mounting device such that direct mounting to junction boxes of different configurations is possible. Screws or other fasteners that connect the junction box to the sign housing through the universal mounting plate element are covered by outer portions of a canopy element of the mounting device in a finished installation such that the screws and fasteners are not visible. Additionally, certain embodiments may include structure capable of accommodating not only appropriate mountings of junction boxes within ceilings or walls but also inappropriate mountings, such as when junction boxes are recessed too deeply within a ceiling or wall or mounted with junction box edges extending outwardly from the ceiling or wall.
In one embodiment, a mounting device for connecting an electrical fixture to a junction box that is mounted to a wall or ceiling surface includes a canopy element that covers the junction box upon connection of the mounting device to the junction box, a connector that connects to the electrical fixture and is disposed between the canopy element and the junction box, and a universal mounting plate integrally formed with the connector that connects to the junction box. The electrical fixture may be an exit sign, and the junction box may be mounted flush with the wall or ceiling surface, completely recessed within the wall or ceiling, or one or more edges of the junction box may extend outside the wall or ceiling surface.
In certain embodiments, a universal mounting plate includes a plurality of apertures patterned to correspond to apertures in a junction box. The mounting device may include at least one fastener that extends through at least one of the plurality of apertures in the universal mounting plate and a corresponding aperture in the junction box. The at least one fastener connects the junction box and the universal mounting plate without engaging or passing through the canopy element. The at least one fastener may be two screws.
In certain embodiments, a connector of the mounting device includes a plurality of circumferential ridges, and a canopy element of the mounting device includes an opening and is positionable relative to the wall or ceiling surface by engagement between a peripheral edge of the opening of the canopy element and any one of the plurality of circumferential ridges of the connector. Alternatively, the connector may include flexible tabs that bias against opposing surfaces of the electrical fixture upon attachment of the electrical fixture to the connector to position the canopy element flush against the wall or ceiling surface.
In certain embodiments, the connector of the mounting device has a plurality of radial ridges disposed about a surface of the connector that mates with the electrical fixture. The plurality of radial ridges engage corresponding ridges disposed on a surface about the periphery of an opening in the electrical fixture to prevent displacement of the electrical fixture relative to the mounting device. In other embodiments, the connector may include a plurality of torsion hooks that extend into an opening in the electrical fixture and engage surfaces of the electrical fixture adjacent the opening.
In certain embodiments, the connector of the mounting device includes at least one hook receivable within an opening in the electrical fixture. The mounting device also includes a locking pin with a camming surface that engages with a surface of the at least one hook of the connector to secure the mounting device to the electrical fixture. The connector may also include at least one redundance member that retains the connector in connection with the electrical fixture during assembly of the electrical fixture and connector. The at least one redundance member may include structure for snap-fitting to surfaces disposed about the opening in the electrical fixture.
In another embodiment, a mounting device for connecting an electrical fixture to a junction box that is mounted to a wall or ceiling surface includes a canopy element that covers the junction box upon connection of the mounting device to the junction box, and a universal mounting plate integrally formed with the connector that connects to the junction box. The canopy element is disposed between the connector and the electrical fixture, and the connector includes flexible tabs that bias against opposing surfaces of the electrical fixture upon attachment of the electrical fixture to the connector to position the canopy element flush against the wall or ceiling surface. The connector may also include at least one hook receivable within an opening in the electrical fixture. The mounting device may also include a locking pin with a camming surface that engages with a surface of the at least one hook of the connector to secure the mounting device to the electrical fixture.
In another embodiment, a mounting device for connecting an electrical fixture to a junction box that is mounted to a wall or ceiling surface includes a canopy element that covers the junction box upon connection of the mounting device to the junction box, a universal mounting plate that connects to the junction box and is disposed between the canopy element and the junction box, and connecting structure integrally formed with the electrical fixture that connects the electrical fixture to the universal mounting plate.
Additional embodiments may include lighting fixtures comprising a housing that includes indicia and at least one illumination source that illuminates the indicia and a mounting device that connects the housing to the junction box. Other embodiments of the present invention may include methods for mounting an electrical fixture to a junction box without the use of special tools.
The present invention provides canopy mounting devices that cover junction boxes of various configurations and provide a pleasing, finished appearance to a resulting installation. Canopy mounting devices of this invention provide reliable mounting of exit signs and the like to junction boxes disposed in or on ceilings or walls and may be installed without requiring special tools. Certain embodiments of a canopy mounting device include a universal mounting plate integrally formed with a connector of the mounting device such that direct mounting to junction boxes of different configurations is possible. Screws or other fasteners that connect the junction box to the sign housing through the universal mounting plate element are covered by outer portions of a canopy element of the mounting device in a finished installation such that the screws and fasteners are not visible. Additionally, certain embodiments may include structure capable of accommodating not only appropriate mountings of junction boxes within ceilings or walls but also inappropriate mountings, such as when junction boxes are recessed too deeply within a ceiling or wall or mounted with junction box edges extending outwardly from the ceiling or wall.
Illuminated signs and the like, such as exit signs and combination emergency lighting/exit sign fixtures, take a variety of forms and may be configured for use with canopy mounting devices of the present invention. One example of such a sign housing with which canopy mounting devices of this invention may be used is a housing frame disclosed in U.S. Pat. No. 5,988,825 to Masters et al., entitled “Housing Frame for Illuminated Signs Having Multiple Configurations,” which is incorporated herein by reference in its entirety. Another example is of a fixture that may be used with canopy mounting devices of this invention is a combination emergency lighting unit/exit sign fixture disclosed in U.S. Pat. No. 5,797,673 to Logan et al., entitled “Emergency Lighting Unit/Exit Sign Combination,” which is incorporated herein by reference in its entirety. Other illuminated sign housings available in the marketplace may also be used with canopy mounting devices of this invention, provided such sign housings have openings in the housing frame that can receive canopy mounting devices according to this invention.
Referring now to the drawings and particularly to
Frame 16 includes an opening 24 formed in its top portion. Opening 24 may be formed in either end or side of frame 16 to facilitate connection of mounting device 10 in a side-mounted or wall-mounted installation. Mounting device 10 includes a canopy element 26 and a connector 28. Canopy element 26 has a generally circular shape, as shown in
Canopy element 26 is generally the visible portion of mounting device 10 once mounting device 10 is mounted to both exit sign 12 and junction box 13. Canopy elements 26 and 27 do not have holes formed therein for the receipt of screws or other fasteners as is necessary in mounting existing canopy mounting devices.
Mounting device 10 is connected to junction box 13 by using universal mounting plate 30. Two screws (not shown) extend through apertures 32 formed in universal mounting plate 30 in known patterns and facilitate connection of mounting device 10 to junction boxes of various configurations. Junction boxes of differing structure and having screw-receiving apertures (not shown) typically formed in metal tabs integral with the junction boxes, such that screws from a mounting plate connect with a junction box through apertures such as apertures 32, are well known to those skilled in the art. However, existing mounting devices generally utilize a universal mounting structure that is a separate metal piece connected by two screws to a junction box and then connected by two other screws to a canopy element of the mounting device. Two of these screws are eliminated in the embodiment shown in and described with reference to
Referring now also to
As best seen in
Ridges 48 function sequentially as connector 28 is pushed through opening 24 of frame 16 to locate mounting device 10 and particularly canopy element 26 up against a ceiling, such as ceiling 52 as shown in
As shown in
Another embodiment of a canopy mounting device according to the present invention is shown in
Mounting device 60 includes a canopy element 82 and a connector 84 that has an integrally-formed universal mounting plate 86. Mounting plate 86 has a plurality of apertures 83 through which screws 90 or similar fasteners may be inserted to connect mounting plate 86 directly to junction box 64. Apertures 83 are shown most clearly in
A pair of redundance fittings 100 are spaced outwardly of body 92 and adjacent thereto. Each of redundance fittings 100 has a base 102 (shown in
Insertion of redundance fittings 100 into side openings 78 and 80 results in an inward flexing of arms 106 and barb members 108. Insertion of fittings 100 a sufficient distance causes barb members 108 to pass beyond edges 79 such that barb members 108 spring outwardly due to a release of compression on flex arms 106, thereby causing each of detent surfaces 110 to fit over edges 79. Fittings 100 maintain mounting device 60 in place prior to installation of structure, which is further described below, that functions to positively lock mounting device 60 to exit sign 62. Additionally, fittings 100 provide a back-up fastening function.
As shown in
Assembly of mounting device 60 to exit sign 62 begins by inserting respective assemblies 122 into side openings 78 and 80 in frame 68 of exit sign 62. Each assembly 122 includes a body 92, a hook 96, a guide element 98, two fittings 100, and a cam plate 116. Guide elements 98 and guide elements 112 guide connector 84 into openings 78 and 80 and to fit therewithin.
A cam locking pin 124 is shown in
Referring now to
Referring to
Wiring (not shown) from junction box 64 may extend through opening 94 of body 92, then through a central opening 87 in canopy element 82, and finally through central opening 76 formed in housing 66 of exit sign 62. The wiring functions conventionally within the interior of exit sign 62, as well understood by those skilled in the art. Openings 94, 87, and 76 are generally aligned so that wiring may easily be pulled from junction box 64 into the interior of exit sign 62. The location of actuator tab 128 of cam locking pin 124 in a fully assembled configuration prevents extension of wiring from a junction box through openings in housing 66 that would provide an undesired pathway for such wiring.
The locations of various structural elements of mounting device 60, when assembled with exit sign 62 and junction box 64, are shown in
As best seen in
Referring now to
However, it is necessary to accommodate the various junction box mounting positions shown in
In
Additional embodiments, other than those shown in the drawings, according to this invention are described below. Connective structure, such as that carried by body 92 of mounting device 60, may be formed as part of an exit sign, such as exit sign 62, or the like. In such a configuration, a simple plate corresponding to plate 86 of connector 84 may have apertures that receive the connective structure carried by exit sign 62. In other words, the male portion of such an arrangement would be carried by exit sign 62 while the female portion would be located on a plate corresponding to plate 86, such a plate being attachable to a junction box such as junction box 64.
The foregoing description of the exemplary embodiments of the invention has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to explain the principles of the invention and their practical application so as to enable others skilled in the art to utilize the invention and various embodiments and with various modifications, as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present invention pertains without departing from its spirit and scope.
Number | Name | Date | Kind |
---|---|---|---|
3402494 | Gray | Sep 1968 | A |
3478455 | Fremont | Nov 1969 | A |
3665626 | Lund et al. | May 1972 | A |
3772527 | Darling et al. | Nov 1973 | A |
3924344 | Davis | Dec 1975 | A |
3931689 | Shine | Jan 1976 | A |
4071749 | Balogh | Jan 1978 | A |
4162779 | Van Steenhoven et al. | Jul 1979 | A |
4222093 | Garcia | Sep 1980 | A |
4255746 | Johnson et al. | Mar 1981 | A |
4355479 | Thornton | Oct 1982 | A |
4449168 | Ewing | May 1984 | A |
4466208 | Logan, Jr. et al. | Aug 1984 | A |
4561203 | MacDonald, Jr. et al. | Dec 1985 | A |
4600972 | MacIntyre | Jul 1986 | A |
5018290 | Kozek et al. | May 1991 | A |
5174642 | Brohard et al. | Dec 1992 | A |
5247756 | Johnstone | Sep 1993 | A |
5272605 | Johnstone | Dec 1993 | A |
5376020 | Jones | Dec 1994 | A |
5461550 | Johnstone | Oct 1995 | A |
5526251 | Andre et al. | Jun 1996 | A |
D379373 | Logan et al. | May 1997 | S |
5727867 | Johnstone | Mar 1998 | A |
5735498 | Jue et al. | Apr 1998 | A |
5768814 | Kozek et al. | Jun 1998 | A |
5797673 | Logan et al. | Aug 1998 | A |
5988825 | Masters et al. | Nov 1999 | A |
6082031 | Heaton et al. | Jul 2000 | A |
6142648 | Logan et al. | Nov 2000 | A |
6241369 | Mackiewicz | Jun 2001 | B1 |
20060278766 | Wang | Dec 2006 | A1 |
Number | Date | Country |
---|---|---|
0412281 | Feb 1991 | EP |