Not applicable.
The present invention relates to lighting fixtures, and more particularly, to recessed lighting fixtures.
Recessed lighting systems are well known. Such systems provide a light source from behind the surface or a wall or ceiling, and therefore do not protrude into the room to any great degree but instead locate the light components in space behind the wall or ceiling.
Such systems are desirable for a variety of reasons, one significant one being that they do not visually intrude significantly into the appearance of the room and therefore may readily blend with almost any decor. Notwithstanding this, many recessed lights are far from being hidden from notice.
For example, many recessed lighting fixtures include a frame, a reflector, a junction box and structure for attaching the frame to the ceiling. The junction box is typically required by code, and is an enclosure mounted on the frame that functions as a receptacle for joining the wires from an electrical power source and a lamp socket in the reflector. The frame is suitably mounted to the ceiling (e.g., by a barbed insert that can be nailed into a wooden beam in the ceiling) and includes an opening through which the reflector is inserted to direct light to an area below the lighting fixture (e.g., down at an angle away from the lighting fixture or down from the lighting fixture). Different mechanisms have been used to retain the reflector in the frame. For example, the reflector may have an opening with a circumference that is larger than the opening in the frame. In such a configuration, the reflector sits on the top surface of the frame and surrounds the opening with a trim ring that is readily visible to anyone in the room. Further, the reflector visible through the wall or ceiling opening will often be silver or some other color which may functionally reflect light but will also provide an obvious visible contrast with the wall or ceiling around it.
A recessed lighting fixture of the above general type is shown, for example, in U.S. Pat. No. 6,431,723
Another reason that recessed lighting systems are desirable is that they may provide more indirect lighting, thereby reducing the glare from the light source (e.g., an incandescent lamp). However, in many such systems, the lights are often still readily visible from many different positions in the room and, particularly given the brightness of spotlights often used in such systems, can cause a person who happens to look into the fixture discomfort and some disorientation due to closing of their irises and therefore insufficient dilation of their irises when they look away from the light.
In short, while recessed lighting systems provide many different types of advantages, those long desired advantages still have not been fully provided.
Pending application Ser. No. 11/440,961, owned by the assignee of the present application, describes an improved recessed lighting fixture and particularly the mechanical construction of the fixture. The use of RGB LED's and an arcuate positioning rack are particularly described.
Additional areas for improvements include how to make the fixture flush after power was brought to the light fixture, in ceilings greater than ½″ thick. For those locations which required a trim, there was no option or construction which would accept it. Known fixtures do not improve upon the industry standard junction box, requiring more labor to install. The known fixtures use traditional style bar hangers to mount the fixture, resulting in more labor to install the fixture. Although the known fixtures offer an acceptable shielding angle, no information is provided regarding the proper lamp position when creating a flush mounted design. The LED's used in the known fixtures require power to run as well as signal power to communicate the desired intensity. This power is typically limited to one signal protocol at the factory, forcing the customer to buy compatible accessories for only that signal type, with no chance to change their mind after the installation is complete, sometimes, locking a customer into a choice which is more expensive than their needs. The life of the typical MR16 lamp used within the known fixtures can be shortened when the lamp is pushed to run at temperatures beyond its limits. This will make for frequent lamp changes which are costly and may require more fixture maintenance if the inside becomes dirty during the service. Plastering in the known fixtures is difficult due to lack of a clean break line between the plaster flange frame and the ceiling plane. This increases the time needed to install the fixture.
The present invention is directed toward further improvements in recessed lighting fixtures, particularly relating to easing installation and alternate options which include trims.
In accordance with the invention, a recessed lighting fixture comprises a base plate mountable in an opening in a room ceiling or wall, the base plate defining spaced apart front and back surfaces wherein the front surface is substantially flat and aligned with the surface of the ceiling or wall when mounted thereon, capable of being plastered and painted to match the ceiling or wall into which it is installed, said plate having an opening to allow light to pass through. A two-part, expandable housing substantially surrounds the base plate, the housing consisting of an upper and lower assembly, with the base plate secured to the lower portion and the lower portion adjustably mounted to the upper portion of the housing. A curved dome is adjustably mounted adjacent the back surface of the base plate, contained within the housing and centered on said light opening.
Further features and advantages of the invention will be apparent form the specification and the drawings.
The present invention resolves the issues noted above and improves the performance of recessed lighting fixtures, as is described below.
A recessed lighting fixture in accordance with the invention has a two piece housing which consists of a box style enclosure and a plaster flange frame. The box style enclosure is supported by mounting bars and the plaster flange frame is supported by the box style enclosure. When installed in a ceiling which has a thickness greater than ½″, the plaster flange frame may be adjusted by loosening mechanical fasteners and pulling the plaster flange frame down to meet the ceiling. This expands the internal volume of the fixture, which reduces internal temperatures and extends the life of the internal components. After adjusting the plaster flange frame the fasteners may be tightened to lock the position. This resolves the limitation of installing the fixture in only ½″ ceilings.
The mounting bars which support the fixture consist of two U-shaped bars. There are fasteners mounted on each corner at an angle so that the installer can drive the fasteners easier from below. There is a flange at each corner of the U-shaped bar which is formed to fit under a wooden joist. There is also one flange centered within the bar, parallel with the corner flanges, running substantially across the length of the bar. This allows the user to use the combination of flanges to level the fixture with the joists. This reduces the time which would be required if the fixture had four individual bars with four separate mounting flanges.
As the fixture is wired the junction box must be opened to install the wiring. Known recessed lighting fixtures have loose covers or covers with hinges. The disclosed recessed lighting fixture has a cover which is installed with two screws. A screw on the horizontal surface may be loosened to allow the cover, which is “L” shaped, to swing down and expose one vertical opening and a partial opening of the bottom. This allows maximum access to the junction box. If needed, the screw on the vertical surface may be loosened. When loosened, the cover will open, pivoting on the screw which is installed in the horizontal surface. This allows the door to swing open 90 degrees to the junction box. Unlike hinged doors, this has two axis of rotation and is easily removed. Hinged doors allow one axis of rotation and may be difficult to remove, due to the angle at which the door is needed to extend past the hinge.
Fixtures with multiple colors of LED's are used to display a multitude of colors. The array of colors is possible due to dimming the individual colors to show only one color or those which are possible through the mixing of colors at varying intensities. To control the intensity, controls are used to send signals to the fixtures. The fixture accepts the signal from the controller and adjusts per the signal sent. There are protocols for these signals. Two of the most popular signal protocols are DMX and 0-10 volt. State of the art fixtures are built to accept one signal only. This forces the contractor to purchase only those controls which are compatible with the signal protocol built into the fixture. The choice of controls is typically limited and often costly. This may influence the building owner to decide against purchasing a certain fixture type. The current invention is built with a module which accepts both DMX and 0-10 volt signals. This module also provides power to the LED's. The decision regarding the control can be decided the day that wiring is installed, offering more choices and a wider range of costs.
State of the art, flush mounted fixtures require the ceiling surface to be finished up to the edge of the fixture nearest the aperture. A perforated metal flange, mounted on the fixture, is typically used to define the area where the ceiling must be finished. The aperture is the hottest portion of the fixture and most building materials will dry out when installed in this manner. The dried out building material will then crack. The cracking becomes worse when a trim must be removed from the housing. The disclosed recessed lighting fixture is built to drop through the ceiling, which means the ceiling is finished to the outside edge of the housing, not the aperture. The outside edge of the housing runs 20 to 30 degrees Celsius cooler than the portion nearest the aperture. The lower temperature means that the building material used to finish the ceiling will last longer, preventing the material from being dried out. Replacing the perforated metal flange is a channel which starts at the inside edge of the flange frame. The channel provides a natural space to trowel off building material and end the finish line.
Directional light sources must be operated at their proper temperature in order to achieve the full life of the lamp. State of the art fixtures use lamp housings which have ventilation. Ventilation lowers lamp temperatures and extends life. The ventilation typically allows light and heat to escape. The disclosed recessed lighting fixture keeps light from escaping and reflecting off of the dome, but still allow heat to escape. The disclosed recessed lighting fixture covers the back side of the lamp and a portion of the mounting ring into which the lamp mounts. The cover surrounding the back of the lamp maintains a space between the mounting ring and the cover. This space allows cooler air to enter and the hotter air escapes out the backside through the hole cut for the socket to enter. This cover is black, greatly reducing reflections; it also blocks all direct light from the lamp.
Referring initially to
The box style enclosure 26 is generally of parallelepiped shape having a peripheral side wall 30 closed by a top wall 32 to define an interior space 34. The box style enclosure 26 is open at the bottom to provide bottom access to the interior space 34.
A frame 36 surrounds the box style enclosure 26 and includes opposite longitudinally extending perforated plates 38, defining drywall anchor screens, connected by opposite transversely extending channel sleeves 40. Brackets 41 extend upwardly from each channel sleeve 40 and are secured to the peripheral side wall 30 to secure the frame 36 to the box style enclosure 26. The channel sleeves 40 slidably receive opposite U-shaped mounting hanger bars 42. The mounting hanger bars 42 include end tabs 44 each having a fastener 46 for securing the housing assembly 22 to ceiling joists J. A flange 45 is provided on an underside of each mounting hanger bar 42 to level the fixture 20 with the joists J. A plurality of threaded fasteners 48 are threadably received in the channel sleeves 40 for securing the mounting hanger bars 42 relative to the box style enclosure 26 to provide appropriate centering when mounting the housing assembly 22 between the joists J.
Referring also to
To install the fixture 20, as shown in
Once the housing assembly is properly installed, as described, the appropriate electrical connections can be made via the junction box 50, as described below.
Referring to
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The base plate 76 is loosely attached to the plaster flange frame 28 using the four screws 84 extending through the openings 82 into corresponding threaded openings 98 in the flange 72. After all four screws 84 are started, they can all be tightened securely so that a front surface of the base plate 76 is substantially flat and aligned with the drywall. Thereafter, the lamp can be tested to ensure that it is properly installed and appropriately adjusted, as described below. A channel greater than 0.060″ is formed between the base plate 76 and the plaster flange frame edge 74.
Referring to
The light orientation can be adjusted as described relative to
As shown in
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Thus, as is described, the PDS 204 can control the LED sections 202 from either a DMX control or a 0 to 10 volt analog signal.
Although the fixture 20 is described mounted in a drywall ceiling, the fixture 20 could similarly be wall mounted and could be used with other surfaces, including plaster or other types of surfaces, as will be apparent.
Thus, in accordance with the invention, there is described a recessed lighting fixture comprised of several elements beneficial to finishing the installation of a flush-mounted fixture in a plaster or drywall installation. The recessed lighting fixture allows the base plate to be mounted flush with the ceiling/wall in multiple ceiling/wall thicknesses, ease the alignment and leveling of the fixture, and reduce the amount of parts which may be lost or damaged at the job site, and increase the wattage rating when UL listed for use in IC rated applications. The combination of these features allows for the housing to be installed in multiple ceiling/wall thicknesses with reduced labor compared to present inventions.
The recessed lighting fixture comprises a base plate mountable in an opening in a room ceiling or wall, the base plate defining spaced apart front and back surfaces wherein the front surface is substantially flat and aligned with the surface of said ceiling or wall when mounted thereon, capable of being plastered and painted to match the ceiling or wall into which it is installed, said plate having a hole to allow light to pass through. A two-part, expandable housing substantially surrounds the base plate, the housing consisting of an upper and lower assembly, with the base plate secured to the lower portion and the lower portion adjustably mounted to the upper portion of the housing. A curved dome is adjustably mounted adjacent the back surface of the base plate, contained within the housing and centered on said light opening.