1. Field of the Invention
The present invention is generally related to light fixtures and is more specifically related to mounting systems and devices used for securing light fixtures to walls, such as pre-engineered, natural stone, wet laid mortar, brick, decorative block, structural landscape walls, and retaining walls.
2. Description of the Related Art
Light fixtures are often attached to landscape walls to provide pathway lighting, task lighting, and aesthetically pleasing light patterns. Difficulties arise, however, when it later becomes necessary to remove a light fixture from a landscape wall to perform maintenance or repairs. In some instances, the landscape wall must be at least partially disassembled to remove the light fixture and/or access electrical wiring used to power the light fixture. Frequently, the electrical wiring needs to be replaced, but is embedded in a cured mortar layer or adhesive. Thus, repairing and maintaining light fixtures on landscape walls can be an expensive and time consuming process that requires the services of both a mason and an electrician.
There have been many efforts directed to providing mounting devices and systems for securing light fixtures to landscape walls. For Example, U.S. Pat. No. 7,290,904 to Miller discloses a lighting system having an elongated light fixture support flange that is positioned between the blocks of a wall. The elongated flange includes a stop member that provides an indication of when the elongated flange has been sufficiently advanced between two blocks of the wall. The elongated flange has a coupling member, and the light fixture has a bracket used for securing the light fixture to the coupling member. The bracket provides for easy removal and positioning of the light fixture relative to the elongated flange. When it is desired to perform maintenance on the light fixture, the light fixture is removed from the coupling member by sliding the bracket off of the coupling member.
U.S. Pat. No. 7,524,077 to Hartman discloses a lamp used for illuminating a wall constructed of blocks. The lamp includes a plate having a flange attached thereto, with a light fixture attached to the inner face of the flange. The lamp is integrated into a retaining wall by sliding the plate between the blocks, whereby the electrical wiring extending from the rear of the lamp runs between the block-like elements. U.S. Design Patents D564,128 and D570,037 are related to the '077 Hartman patent, and disclose ornamental designs for a light fixture and an asymmetric light fixture, respectively.
Integral Lighting of Wernersville, PA sells a flat mounting plate that is positioned beneath a cap stone of a wet mortar wall. A light fixture is positioned atop the flat mounting plate. The electrical wiring for the light fixture extends between the underside of a capstone and the upper surface of the flat mounting plate. The electrical wiring is exposed to the environment and is locked in place by the mortar layer.
U.S. Pat. No. 6,976,765 to Helenowski discloses a light source that is disposed within a block-shaped enclosure that forms a part of a wall. The enclosure is the same size and shape as one of the blocks of the wall, and may be utilized in place of one of the blocks when the wall is built. The enclosure may also be substituted for one of the blocks after the wall is built. In one embodiment, a support bar is disposed within the wall and welded to the enclosure for preventing the enclosure from being removed from the wall.
U.S. Pat. No. 5,943,827 to Okerlund discloses a retaining wall block having recesses and channels formed therein for receiving light fixtures and electrical wiring. In one embodiment, an underside of a block has a recess for a light fixture and a channel for electrical wiring. The light fixture is inserted into the recess and the electrical wiring for the light fixture is inserted into the channel.
In spite of the above advances, there remains a need for improved mounting systems and devices for securing light fixtures to walls made of blocks, bricks, natural stone or pre-engineered wall systems. There also remains a need for light fixture mounting systems and devices that facilitate the installation, repair and maintenance of the light fixtures and the electrical wiring used to power the light fixtures. In addition, there remains a need for a mounting devices and systems having storage compartments that are adapted for receiving, storing, and protecting from the environment, the electrical wiring used to power the light fixtures.
In one embodiment, a system for securing light fixtures to a wall includes at least one mounting device adapted to be affixed to a wall, such as a wet mortar wall or an engineered block wall, during initial construction. In one embodiment, the mounting device preferably has an L-shaped configuration and includes a flat, horizontally-extending plate having an elongated slot adapted to receive a securing flange projecting from a rear end of a light fixture, and a storage compartment positioned beneath the elongated slot that is adapted to receive and store electrical wires and the accompanying raceway/conduit that connect the light fixture to a power source.
In one embodiment, a series of mounting devices may be placed along the length of a wall for mounting a plurality of light fixtures to the wall. During initial wall construction, a mason may pre-position multiple mounting devices within a wet mortar layer at various locations along the length of the wall. The mounting device enables an installer to run flexible conduit to the back of each device so that electrical wires may be passed through the conduit for initial installation, or removed and replaced in the event of failure. The mounting device, and particularly the storage compartment of the mounting device, protects the electrical wires from exposure to the environment.
After the wall has been built, a lighting contractor may connect the electrical wiring with each of the light fixtures. In one embodiment, a light fixture is mounted to a wall by slipping the securing flange on the light fixture into the elongated slot of the mounting device. The friction between the securing flange and inner faces of the elongated slot holds the light fixture in place. The storage compartment of the mounting device provides a protected area for placing the electrical wiring that extends from the rear of the light fixture. Any slack electrical wiring may be folded and stored in the storage compartment. The mounting device enables an installer to easily remove, repair, replace, maintain, clean, and then re-install the light fixture in a wall.
In one embodiment, a mounting system for securing a light fixture to a wall, such as a landscape wall, engineered block wall, wet laid mortar wall, natural stone wall or retaining wall, preferably includes a mounting device having a flat plate with a top planar surface, a bottom planar surface, and an elongated slot extending between the top and bottom planar surfaces and along an edge of the flat plate. The elongated slot formed in the flat plate preferably has a length of about 4-8 inches and more preferably about 6 inches, and a width of about 0.030-0.050 inches and more preferably about 0.040 inches. The mounting device also desirably includes a storage compartment defining an enclosed area underlying the bottom planar surface of the flat plate. The enclosed area of the storage compartment is adapted for receiving electrical wiring used for interconnecting a light fixture with a power source.
The mounting system desirably includes a light fixture having a securing flange projecting therefrom that is insertable into the elongated slot of the mounting device for securing the light fixture to the mounting device. The securing flange projecting from the light fixture preferably has a thickness that closely matches the width of the elongated slot for forming a friction fit when the securing flange is inserted into the elongated slot. When sliding the securing flange into the elongated slot for securing the light fixture to the mounting device, the securing flange frictionally engages the opposing faces of the elongated slot for securing the light fixture to the mounting device. The frictional engagement holds the light fixture in place, while enabling the light fixture to be quickly removed from the elongated slot, if necessary, for replacing, maintaining and/or repairing the light fixture. After replacement, maintenance and/or repairs are completed, the light fixture may be quickly and easily re-secured to the mounting device by sliding the securing flange back into the elongated slot.
In one embodiment, the flat plate of the mounting device preferably has a leading edge and a trailing edge, whereby the top and bottom planar surfaces extend between the leading and trailing edges. The elongated slot desirably extends along the leading edge of the flat plate, and the storage compartment preferably extends between the leading and trailing edges of the flat plate.
In one embodiment, the flat plate has first and second lateral edges extending between the leading and trailing edges, and the storage compartment is located adjacent one of the first and second lateral edges of the flat plate. The storage compartment preferably has a front opening extending along the leading edge of the flat plate and a rear opening extending along the trailing edge of the flat plate. The front and rear openings provide access to the enclosed area of the storage compartment so that conduits and electrical wiring may be directed to the enclosed area.
In one embodiment, the storage compartment includes a bottom wall that opposes the bottom planar surface and a pair of opposing side walls that extend from the bottom wall to the bottom planar surface for defining the enclosed area of the storage compartment. The bottom wall of the storage compartment is preferably parallel with the top and bottom planar surfaces of the flat plate and the pair of opposing sidewalls of the storage compartment are desirably perpendicular to the top and bottom planar surfaces of the flat plate. As such, the storage compartment preferably has a square or rectangular configuration.
In one embodiment, the mounting system desirably includes a conduit adapter coupled with the storage compartment. The conduit adapter preferably has at least one opening aligned with the rear opening of the storage compartment. In one embodiment, the conduit adapter includes a support plate having an inner face and an outer face, and a plug projecting from the inner face of the support plate. In one embodiment, the plug preferably has an outer perimeter that closely matches an inner perimeter of the rear opening of the storage compartment for forming a frictional engagement between the plug and the rear opening. In one embodiment, the conduit adapter is bonded to the rear opening of the storage compartment using an adhesive, glue or solvent such as PVC cement that bonds the conduit adapter to the storage compartment.
In one embodiment, the at least one opening formed in the conduit adapter preferably passes through the support plate and the plug. The system desirably includes a conduit, such as a flexible conduit, coupled with the at least one opening in the conduit adapter. The conduit desirably has a central opening adapted to receive electrical wiring that is connected with the light fixture. In one embodiment, the at least one opening in the conduit adapter preferably includes two or more openings extending through the support plate and the plug. Each of the openings is capable of receiving a conduit, and each conduit, in turn, is capable of receiving electrical wiring that extends into said storage compartment. The conduit adapter may have tubes that define the openings, whereby the conduits are insertable into the tubes for directing electrical wiring toward the mounting devices.
In one embodiment, a mounting system for securing a light fixture to a landscape wall preferably includes a mounting device having a flat plate with a leading edge, a trailing edge, and top and bottom planar surfaces extending between the leading and trailing edges, and an elongated slot formed in the flat plate, the elongated slot extending between the top and bottom planar surfaces and along the leading edge of the flat plate. The mounting device desirably includes a storage compartment underlying the flat plate, the storage compartment defining an enclosed area extending between the leading and trailing edges of the flat plate. The storage compartment preferably has a front opening extending along the leading edge of the flat plate and a rear opening extending along the trailing edge of the flat plate.
In one embodiment, a conduit adapter is preferably inserted into the rear opening of the storage compartment. The conduit adapted desirably has at least opening aligned with the rear opening of the storage compartment for providing access to the enclosed area of the storage compartment. A conduit is desirably coupled with the at least one opening. The conduit preferably has a central opening through which electrical wiring may be advanced for being interconnected with a light fixture secured to the mounting device.
In one embodiment, the mounting devices and the conduit(s) may be pre-positioned during initial construction of a wall. Later, after the wall construction has been completed, electrical wiring may be passed through the conduit(s) for providing power to the light fixtures at each mounting device. After the electrical interconnections have been made, any excess wiring may be packed into the storage compartments and the securing flanges of the light fixtures may be inserted into the elongated slots on the mounting devices. In one embodiment, the excess wiring in the storage compartment may be held in place by using the flat back side of the lighting fixture, which effectively closes the front opening of the storage compartment when the light fixture is fully inserted in the mounting device.
In one embodiment, a wall, such as a landscape wall or a retaining wall, desirably includes a top row of blocks and at least one mounting device overlies the top row of blocks. In one embodiment, a plurality of mounting devices overlies the top row of blocks and are spaced along the length of the wall.
The system may include a mortar layer having a top surface overlying the top row of blocks, whereby each mounting device is embedded in the mortar layer so that the top planar surface of the flat plate is coplanar with the top surface of the mortar layer and so that the storage compartment of the mounting device is positioned below the top surface of the mortar layer. In one embodiment, a wet mortar layer is formed atop the wall, and one or more mounting devices are embedded in the wet mortar layer so that the top planar surfaces of the flat plates of the mounting device lie in a plane defined by the top surface of the wet mortar layer. The wet mortar layer may then be allowed to cure for locking the mounting devices in place within the wet mortar layer, whereby the elongated slots and the front storage compartment openings of the mounting devices are accessible at the front face of the wall. In one embodiment, the mounting devices disclosed herein may be placed at any level or row of a wall, and are not limited to placement under a cap stone or a top or uppermost layer of a wall.
In one embodiment, an adhesive label may be used for sealing the storage compartment and the elongated slot in the flat plate from construction debris. The label may bear the manufacturer's name or logo, and/or instructions for utilizing the light fixture mounting system. The adhesive label may be placed over the bottom wall for sealing the elongated gap in the bottom wall of the storage compartment so as to prevent concrete and other construction debris from entering the enclosed area of the storage compartment. The front flap of the adhesive label may be wrapped around the front of the mounting device for covering the front opening of the storage compartment. The free end of the front flap may be adhered to the top planar surface of the flat plate for protecting the storage compartment and at least a portion of the elongated slot formed in the flat plate. The front flap of the adhesive label may be opened and closed as necessary by peeling the front flap away from the flat plate and later re-adhering the front flap of the adhesive label to the top planar surface of the flat plate.
In one embodiment, the adhesive label may be used for holding electrical wires in place prior to the wires being electrically interconnected with a light fixture. Electrical wires may be passed through flexible conduit and the front opening of the storage compartment for being pre-positioned to extend from the front of the mounting device. The adhesive label preferably holds the electrical wires in place and seals the front of the storage compartment to prevent construction debris from entering the storage compartment and at least a portion of the elongated slot formed in the flat plate. When it is desired to secure a light fixture to the mounting device, the front flap of the adhesive label may be peeled away for exposing the front opening of the storage compartment so that the electrical wires may be electrically interconnected with a light fixture.
These and other preferred embodiments of the present invention will be described in more detail below.
Referring to
In one embodiment, the mounting device 20 desirably includes an elongated slot 32 that is formed in the flat plate and that extends between the top planar surface 24 and the bottom planar surface 26. The elongated slot 32 desirably extends along the leading edge 28 of the mounting device. As will be described in more detail herein, the elongated slot 32 is adapted to receive a securing flange projecting from a rear surface of a light fixture.
The mounting device 20 preferably includes a storage compartment 34 that is positioned below the flat plate 22. The storage compartment 34 preferably defines an enclosed area 36 extending between the leading edge 28 and the trailing edge 30 of the flat plate. In one embodiment, the storage compartment may have a rectangular or square shape. The storage compartment 34 desirably includes a front opening 38 accessible at the leading edge 28 of the flat plate 22 and a rear opening 40 accessible at the trailing edge 30 the flat plate 22.
Referring to
As will be described in more detail herein, the storage compartment 34 is preferably adapted to receive electrical wiring that is used for connecting a light fixture with a power source. The electrical wiring is preferably stored in the enclosed area 36 defined by the outer side wall 42, the inner side wall 44 and the bottom wall 46. The enclosed area 36 protects the electrical wiring from the environment, such as the surrounding blocks and mortar layer in which the mounting device is disposed. The enclosed area 36 also provides a space for packing and/or storing the electrical wiring connected to a light fixture.
In one embodiment, as a securing flange on a rear of a light fixture is inserted into the elongated slot 32, any wiring forming a connection between the light fixture and a power source may be inserted into the enclosed area 36 of the storage compartment 34. Any slack or excess wiring forming the electrical connection with the light fixture may be folded and stored in the storage compartment.
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Although only one mounting device 20 is shown in
In one embodiment, the elongated slot 32 is adapted to receive a securing flange 90 projecting from a rear of a light fixture 92. The securing flange 90 is adapted to slide into the elongated slot 32 for holding the light fixture 92 to the wall 80. The electrical wiring 94 interconnecting the light fixture 92 with a power source may be packed into the storage compartment 34. The storage compartment 34 preferably provides a protected area for minimizing exposure of the electrical wiring 94 to the surrounding environment (e.g. blocks, mortar, moisture, air).
Referring to
In one embodiment, a flexible conduit 98 provides a protected passageway for the second electrical wiring 96. The flexible conduit 98 may be pre-positioned during construction of a wall and prior to coupling the light fixture 92 to the second electrical wiring 96. The flexible conduit 98 preferably remains in place after construction of the wall and installation of the light fixture 92. If it is necessary to repair and/or replace the light fixture 92 or the electrical wiring 94, 96, the second electrical wiring 96 may be withdrawn through the flexible conduit 98 and replacement electrical wiring advanced through the conduit 98 for passing through the tube 70A and into the enclosed area 36 of the storage compartment 34.
Although the present invention is not limited by any particular theory of operation, it is believed that utilizing a flexible conduit 98 will enable replacement wiring 94 to be readily passed through the conduit 98 and into the enclosed area 36 of the storage compartment 34, thereby facilitating replacement, repair and/or maintenance of the electrical wiring and the light fixture.
After a period of time, it may be necessary to remove the light fixture 92 from the mounting device 20 for repairing and maintaining the light fixture, or replacing the light fixture with a new light fixture. In those instances, the light fixture 92 may be pulled away from the mounting device 20 so that the securing flange 90 may be retracted from the elongated slot extending along the leading edge of the flat plate 22. As the light fixture 92 is pulled away from the mounting device 20, the electrical wiring 94 is pulled through the first opening of the storage compartment 34, as shown in
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After the electrical wiring has been passed through the flexible conduit 98 for reaching the storage compartments of each of the mounting devices 20A-20E, the electrical wiring passed through the conduit may be electrically interconnected with the wiring permanently attached to the respective light fixtures 92A-92E. Any slack remaining in the electrical wiring may be folded, packed and/or inserted into the storage compartments of the respective mounting devices, as shown and described above in
The mounting devices and systems disclosed herein may also be used in landscape walls made of engineered blocks. Referring to
The engineered block 200 includes a second channel 206 that extends from a rear face 208 of the block toward a front face 210 of the block 200. The second channel 206 is also adapted to receive conduit for electrical wiring. The engineered block 200 also desirably includes a central cavity 212 formed in the top surface 202 that is adapted to receive the mounting device 120.
Referring to
In one embodiment, an engineered block is supplied from a block manufacturer with a recessed cavity adapted to receive a mounting device. After an installer arranges the engineered blocks at a desired height and spacing, the installer may break away some of the material on some of the blocks. The material may be broken away, such as by using a chisel, saw, or other tool of the trade, for exposing the mounting device and enabling the leading edge of the mounting device to be aligned with the front face of the wall. The mounting devices may be secured to the blocks using adhesive materials commonly used in the wall construction industry.
In one embodiment, a wall may be built using the engineered blocks shown and described above in
In one embodiment, a contractor may break away the front face section 285 of an engineered block 200 when it is desired to position a light fixture in the block. If a light fixture will not be secured to the engineered block, then the front face section 285 will not be removed. In one embodiment, a block manufacturer preferably includes the front face section 285 in each block that is manufactured and sold. When constructing a wall using the engineered blocks 200, an installer can modify any of the blocks by removing the front face section 285, which enables the contractor to position a mounting device within the block for securing a light fixture to the block.
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In one embodiment, a label may be used for sealing the storage compartment and the elongated slot in the flat plate from construction debris. The label may bear the manufacturer's name or logo, and/or instructions for utilizing the light fixture mounting system. Referring to
The adhesive label may be used for holding electrical wires in place prior to the wires being electrically interconnected with a light fixture.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, which is only limited by the scope of the claims that follow. For example, the present invention contemplates that any of the features shown in any of the embodiments described herein, or incorporated by reference herein, may be incorporated with any of the features shown in any of the other embodiments described herein, or incorporated by reference herein, and still fall within the scope of the present invention