Patent Application
20210148531
The present invention generally relates to joiner brackets, and more specifically to a joiner bracket system that is used to join together sections of a suspendable light fixture, using a screw or other fastener driven against a ramp of a joiner bracket.
Traditionally, many lighting systems have been sold as ready-made or pre-configured systems. In some cases, lighting systems are delivered as parts to be assembled on a job site. In such cases, a user or technician may be tasked with following a series of steps to assemble the light fixture, and to subsequently hang, mount, or otherwise place the light fixture into a desired position within a room or space. For large lighting systems—such as lighting systems in large rooms and/or in commercial settings—the assembly and installation process presents many challenges. Joining two or more independent fixture sections together to create a simple, larger fixture with a seamless connection can be difficult. If the lighting system is first assembled on the ground, then a user or technician must devise a way to lift and place a large and heavy lighting system into position. For wall-mounted, ceiling-mounted, or pendant lighting systems, assembling a large and heavy light fixture on the ground may simply not be feasible. Moreover, construction sites may not have a sufficient amount of floor space to enable a user or technician to carry out an initial ground-based assembly in the first place, or may present a potential for scratches, dirt or dents to exterior fixture components.
In other cases, a lighting system of single or multiple components may be configured for assembly while suspended or mounted. For example, multiple sections of a lighting system may be independently suspended from a ceiling, and subsequently brought together to form a substantially continuous light fixture. With each section being of a manageable size and weight, so as to be handled by one or only a few technicians, such an installation process may be carried out without the need for machinery or other assistance to lift a substantially heavy and cumbersome pre-assembled light fixture into position.
While suspended, the piece-part assembly of a light fixture can be effectively performed without the need for substantial equipment or lift assistance, there remains a few drawbacks. Further, the process of joining adjacent sections of a light fixture often involves a technician on a ladder or scaffold articulating the opposing sections, and securing the two together—typically using one or more fasteners, together sometimes within “live” electrical leads. This process can be risky to a technician, as it may be difficult to hold together adjacent sections while simultaneously locating and engaging the joining mechanism. It is therefore an object of the present invention to provide a joining system that is safe, accessible and easier to operate by a single technician.
In addition, joining systems for light fixture assemblies are often difficult to access and operate. Commonly, joining systems are preferably disposed within the housing of light fixture sections, such that they can be obscured from view and do not adversely affect the aesthetic qualities of the light fixture. While these arrangements are desirable to maintain the light fixture's aesthetic qualities and to obscure the joining system from view, they can complicate or otherwise make difficult the installation process for the light fixture. Often, an installation process can require the use of specialized or uncommon tools to reach the fasteners and operate the joining system.
Some existing fixture joining systems have been difficult to access, and often require the removal (and/or subsequent re-installation of) elements of a light fixture assembly, such as lenses, reflectors, or other parts. As a result, light fixture assemblies that use such joining systems may require a technician to perform some disassembly and re-assembly of pre-assembled fixture sections, or may prevent a manufacturer from pre-assembling sections of a light fixture that would otherwise reduce the time involved to install the light fixture. In either case, the installation of a light fixture assembly may take more time and/or be more complicated than is desired. It is therefore another object of the present invention to provide a joining system that can be partially pre-installed, and which reduces the number of installation steps to, in turn, substantially reduce the time and effort involved in assembling and installing a light fixture.
Furthermore, many existing joining systems for multiple-piece light fixtures involve the securing of connections in and through one or more components of the joining system. Often, these connection points are located along the components that reside within the light fixture, requiring the partial disassembly of a light fixture assembly and/or requiring a technician to secure fasteners in tight and dark spaces (in the absence of an existing lighted fixture) within the light fixture assembly. It is therefore yet another object of the present invention to provide a joining system that can be operated to bring together, in a facilitated manner, two or more fixture sections from the outside of the light fixture assembly.
These and other objectives and advantages of the present invention will become apparent from the following detailed written description, drawing figures, and claims.
To accomplish the aforementioned objectives, embodiments of the present invention provide for a joining system that includes a joiner bracket having formed therein a depressed ramp region. A joiner fastener, such as a screw, may be driven against the angled walls of the joiner bracket ramp, which translates vertical movement (e.g., downward) of the screw into horizontal or longitudinal movement of the joiner bracket. The conversion of vertical to longitudinal movement by way of a ramp may be leveraged in order to provide a joining system for joining together a pair of fixture sections of a light fixture assembly. The joiner bracket may be rigidly affixed to one fixture section, with the portion of the joiner bracket having the ramp region extending beyond an end of that fixture section. The extending portion of the joiner bracket may be positioned within an adjacent fixture section, with the ramp region being positioned below an aperture of the adjacent fixture section. The joiner fastener may be driven through the aperture of the adjacent fixture section and against the joiner bracket ramp to, in turn, pull the fixture sections together, as fasteners are being engaged. The fastener that drives against the ramp of the joiner bracket may be advantageously accessible from the outside of the light fixture assembly, making the installation process easier, simpler and safer, as compared to traditional joining systems.
In some cases, the screw ramp and joiner fastener may produce a force that is unevenly applied across the height of the fixture sections. For example, the screw ramp joiner may pull together the upper ends of a pair of fixture sections, resulting in a substantial gap remaining between the lower ends of the pair of fixture sections. To address this problem, some embodiments of the present invention may include a joiner bracket having a top section with two portions—with one portion being angled or sloped at a slight angle relative to the other portion. The sloped portion of the joiner bracket may include a finishing bore or boss. The joining system may further include a finishing screw or other fastener that can be driven through a fixture section and into the finishing bore of the joiner bracket. As the finishing screw is driven through the sloped portion of the joiner bracket, that sloped portion of the joiner bracket may be pulled upwards toward the fixture section. This upward force, together with the rigid coupling of the joiner bracket to the adjacent fixture section, produces a torque that pulls the lower ends of the pair of fixture sections toward each other for closing the gap between the pair of fixture sections.
According to a first aspect of the present invention, there is provided a lighting fixture system that includes a first fixture section having a proximal end and a distal end opposite the proximal end, a first sidewall and a second sidewall each extending between the proximal and distal ends of the first fixture section, and a top portion extending between the first and second sidewalls of the first fixture section. The top portion of the first fixture section includes a boss extending therethrough. The proximal and distal ends of the first fixture section define a longitudinal direction. The lighting fixture system also includes a second fixture section having a proximal end and a distal end opposite the proximal end, a first sidewall and a second sidewall each extending between the proximal and distal ends of the second fixture section, and a top portion extending between the first and second sidewalls of the second fixture section. The proximal end of the second fixture section is adapted for positioning adjacent to the distal end of the first fixture section. The lighting fixture system further includes a joiner bracket adapted for positioning within at least a portion of the first fixture section and at least a portion of the second fixture section. The joiner bracket may be rigidly coupled to the second fixture section and have a portion extending beyond the proximal end of the second fixture section toward the distal end of the first fixture section. The portion of the joiner bracket extending beyond the proximal end of the second fixture section includes a ramp that is angled relative to the top portion of the first fixture section. Additionally, the lighting fixture system includes a fastener configured to extend through the boss of the first fixture section and engage against the ramp of the joiner bracket to produce a force in the longitudinal direction toward the proximal end of the first fixture section. When the joiner bracket is rigidly coupled to the second fixture section, engaging the fastener with the ramp of the joiner bracket pulls the second fixture section toward the first fixture section.
In some embodiments according to the first aspect, the boss of the first fixture section is a threaded boss, and the fastener is a threaded fastener.
In some embodiments according to the first aspect, the fastener is a first fastener, and the portion of the joiner bracket contained within the second fixture section includes one or more bores. The lighting fixture system may also include one or more second fasteners extend through the one or more respective bores and into the second fixture section to rigidly couple the fastener to the second fixture section.
In some embodiments according to the first aspect, the first fixture section further includes a first rail positioned along the first sidewall of the first fixture section, and the second fixture section further includes a first rail positioned along the first sidewall of the second fixture section. In these embodiments, the joiner bracket further includes a first sidewall and a second sidewall, with the first sidewall of the joiner bracket having formed therein an offset having a shape that is complementary to the first rail of the first fixture section and the first rail of the second fixture section.
In some embodiments according to the first aspect, the fastener is a first fastener, and the joiner bracket also includes a finishing aperture, in which the first fixture section further comprises a finishing bore. In these embodiments, the lighting fixture system further includes a finishing fastener adapted to extend through the finishing bore and the finishing aperture of the joiner bracket.
In some embodiments according to the first aspect, the lighting fixture system also includes an outer bracket configured for positioning along at least part of the top portion of the first fixture section and at least part of the top portion of the second fixture section.
In some embodiments according to the first aspect, the first fixture section also includes at least one lipped channel extending longitudinally along the top portion of the first fixture section. In these embodiments, the outer bracket is adapted to slideably engage with the at least one lipped channel of the first fixture section. In some instances, the lighting fixture system may further include a cable gripper coupled to the outer bracket, with the cable gripper being adapted to maintain a suspension cable therethrough for suspending the light fixture system from a ceiling
In some embodiments according to the first aspect, the first fixture section further includes a first rail positioned along the inner walls of the top portion of the first fixture section. In these embodiments, the joiner bracket further includes an elongated male projection adapted to slideably engage with the first rail of the first fixture section, to facilitate alignment of the joiner bracket with respect to the first fixture section.
In some embodiments according to the first aspect, the ramp of the joiner bracket comprises a first angled wall and a second angled wall that converge to form an oblique corner.
In some embodiments according to the first aspect, the portion of the joiner bracket contained within the proximal end of the second fixture section has a first top surface, and the portion of the joiner bracket that extends beyond the proximal end of the second fixture section has a second top surface. The first top surface may be angled relative to the second top surface.
According to a second aspect of the present invention, there is provided a joiner system for joining the distal end of a first fixture section to the proximal end of a second fixture section, the first fixture section including an aperture formed therethrough. The joiner system includes a joiner bracket adapted for positioning within at least a portion of the first fixture section and at least a portion of the second fixture section. The joiner bracket may be rigidly coupled to the second fixture section and having a portion extending beyond the proximal end of the second fixture section toward the distal end of the first fixture section. The portion of the joiner bracket that extends beyond the proximal end of the second fixture section includes a ramp that is angled relative to the top portion of the first fixture section. The distal end of the first fixture section and the proximal end of the second fixture section define a longitudinal direction. The joiner system also includes a fastener configured to extend through the aperture of the first fixture section and engage against the ramp of the joiner bracket to produce a force in the longitudinal direction toward the proximal end of the first fixture section. When the joiner bracket is rigidly coupled to the second fixture section, engaging the fastener with the ramp of the joiner bracket pulls the second fixture section toward the first fixture section.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments and features will become apparent by reference to the drawing figures, the following detailed description, and the claims.
For a better understanding of the invention, and to show how the same may be implemented, there will now be described, by way of example, specific embodiments, methods and processes according to the present invention with reference to the accompanying drawings in which:
There will now be described by way of example, several specific modes of the invention as contemplated by the inventor. In the following description, numerous specific details are set forth in order to provide a thorough understanding. It will be apparent however, to one skilled in the art, that the present invention may be practiced without limitation to these specific details. In other instances, well known methods and structures have not been described in detail so as not to unnecessarily obscure the description of the invention.
Embodiments of the present invention provide for a joiner system for adjoining adjacent light fixture sections. As described above, joining together sections of a light fixture can be challenging, dangerous, and sometimes require the use of specialized tools to operate a joining system—particularly in situations where sections of a light fixture assembly are suspended separately, and joined together while suspended to form a complete light fixture assembly. Some joining systems may be relatively inexpensive and simple to manufacture, but such systems often require a technician to perform difficult maneuvers. For example, joiners are often positioned within the inner walls of a light fixture to obscure them from view after installation, which makes them difficult to access and operate safely, and often leads to frustration, misalignment and/or possible injury. Other more robust joining systems have attempted to improve upon the installation process for the technician, but the increased mechanical complexity of such systems typically renders such systems significantly more expensive and less reliable than simpler alternatives. The joiner systems shown and described herein address these problems using a ramp and fastener system that translates downward movement of a fastener into horizontal movement that pulls together adjacent fixture sections, enabling a set screw construction that is easily accessible from outside of the light fixture assembly.
An example joiner includes a depressed “screw ramp” region formed along its top section, which includes an angled wall or walls that serve to translate downward movement of a screw or other fastener into longitudinal forces that pull together sections of a light fixture assembly. By rigidly coupling the joiner bracket to one section of a light fixture, the “pulling” forces applied to that joiner bracket by way of a joiner fastener through another section of the light fixture causes the two fixture sections to be joined together. Other brackets, fasteners, and/or other elements may be provided to reinforce the joint and improve robustness and longevity of the joining system.
The present application addresses the realization that a joiner may include an angled “ramp” section that can convert a force in one direction (e.g., a downward vertical direction) into a force in an orthogonal horizontal direction (e.g., a longitudinal direction). As many joining systems for light fixture assemblies attempt to bring together two elongated horizontally displaced light fixture sections, this realization enables the construction of a screw ramp joiner system in which the screw or fastener that effectuates the joining of the two fixture sections can extend above or below the light fixture, and therefore be relatively easy to access and operate without using specialized tools that can reach into the inner cavity of the light fixture assembly. The use of a ramp and fastener over more complex mechanical systems (e.g., gear systems such as a rack-and-pinion gear) for converting motion from one axis to another enables joiner systems according to the present disclosure to be manufactured at a relatively low cost, while also reducing the number of components that have the potential to fail.
As described herein, upwardly illuminating light fixtures may be referred to as “indirect” (e.g., illuminating the ceiling), downwardly illuminating light fixtures may be referred to as “direct” (e.g., illuminating the floor or other surfaces beneath the light fixture), and upwardly and downwardly illuminating light fixtures may be referred to as “bidirectional.”
As described herein, the term “screw” generally refers to any type of actuatable fastener, and does not necessarily refer solely to a threaded fastener. For example, bolts, pins, cams, and/or other types of fasteners may be suitable for use in a joiner system based on the principles disclosed herein. Accordingly, any element shown and/or described herein as a screw-based element, such as a screw ramp or a screw ramp joiner, is not limited to threaded fasteners and may use other suitable non-threaded fasteners. The use of the term “screw” throughout the present disclosure is provided for explanatory purposes, and should not be construed as limiting the scope of the present application in any way.
As described herein, the term “screw ramp” refers to a wall or walls formed within a joiner or bracket at a non-right angle relative to its adjacent surfaces, such that a force applied against the angled wall or walls is translated from the direction of the force to a direction that is orthogonal to the direction of the force. The screw ramp may be substantially smooth, or may have features formed in the walls to increase friction or otherwise enhance the engagement between a fastener and the wall or walls of the screw ramp. For the purposes of the present application, a “screw ramp” refers generally to a feature, surface, wall, or some combination thereof that in operation translates a force applied thereto in one direction to another direction.
The following description of
Fixture sections 110 and 120 may each be formed as an extruded aluminum housing, for example, and incorporate one or more rails, lips, channels, bores, threaded screw holes, and/or other features to which various elements may be affixed or with which various elements may engage. For example, rails 113, 114, 123, and 124 (see, e.g.,
The channels formed in fixture sections 110 and 120 may also serve as anchor points for affixing light sources (e.g., light emitting diodes, or LEDs) or other elements to the outer surface of the top portions of fixture sections 110 and 120, which may direct light upwardly (in the positive z-direction) to produce an “indirect” lighting effect, and/or for affixing light sources to the inner surfaces of fixture sections 110 and 120 to direct light downwardly (in the negative z-direction) to produce a “direct” lighting effect. In some embodiments, bores, holes, and/or bosses may extend through the top surfaces of fixture section 110 and/or fixture section 120, through which a screw or other fastener may extend to engage with components within fixture section 110 and/or fixture section 120.
In this example embodiment, outer bracket 150 includes cable gripper hole 157 (see
Screw ramp joiner 130 also includes screw ramp 134, which is angled (in the negative z-direction and in the positive y-direction) and extends downwardly from the top section of screw ramp joiner 130. In the particular implementation shown in
In some implementations, one or more components of the light fixture system may include scoring, marks, or other indications to assist a technician in the alignment of the components during the installation of light fixture assembly 100. For example, as shown in
An initial installation step (or a pre-assembly step performed by a manufacturer) may involve slideably positioning screw ramp joiner 130 along rails 123 and 124 of fixture section 120, such that approximately half of screw ramp joiner 130 is contained within the inner walls of fixture section 120 (see
Similarly, another installation or pre-assembly step may involve slideably positioning outer bracket 150 along lipped channels 115 and 116 of fixture section 110, such that a portion of outer bracket 150 extends beyond the end of fixture section 110 (see
With screw ramp joiner 130 in a desired position, such as the position shown in
In some cases, fixture sections 110 and 120 may be suspended proximate to each other from a ceiling or the like. In such cases, fixture section 110 may also “rest” on screw ramp joiner 130, such that frictional forces maintains fixture section 110 temporarily in position without the need for a technician to hold fixture sections 110 and 120 manually in place.
Once fixture sections 110 and 120 are positioned adjacent to each other—with screw ramp joiner 130 extending into the inner walls of fixture section 110, and outer bracket 150 extending into and along lipped channels 125 and 126 of fixture section 120—joiner screw 154 may be driven through hole 155 in outer bracket 150, bore 118 of first fixture section 110, and against screw ramp 134 of joiner bracket 130. As joiner screw 154 is driven against the angled walls of screw ramp 134, screw ramp joiner 130 is “pulled” in toward first fixture section 110 (in the negative x-direction). Accordingly, the extent to which joiner screw 154 is driven downwardly can control the relative longitudinal positioning of fixture sections 110 and 120. In this manner, an operator or technician may engage joiner screw 154, observe the movement of fixture sections 110 and 120, and stop turning the joiner screw 154 once fixture sections 110 and 120 are sufficiently adjacent to each other and form—a joining operation that is performed by turning a relatively accessible and easy-to-reach fastener.
In some embodiments, an additional fastener, such as finishing screw 156, may be provided to further increase the strength of the joining system. As shown in
As shown in
With fixture sections 110 and 120 immediately adjacent to each other, as illustrated in
In an example implementation—such as the implementation shown in
While the asymmetric, partially-sloped top section of screw ramp joiner 130 may beneficially enable the joiner to exert additional forces or torques to facilitate the joining of fixture sections 110 and 120, the slight angle may also enable the joiner system to tolerate slight vertical misalignment during the installation process—to increase the likelihood that the joining system functions properly within a range of manufacturing tolerances. Once joiner screw 154 and finishing screw 156 are sufficiently driven into place, as is illustrated in
As shown in
As shown in
In some implementations, such as the embodiment shown in
Although
Although certain example methods and apparatus have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatuses, and articles of manufacture fairly falling within the scope of the appended claims, either literally or under the doctrine of equivalents.
It should be understood that arrangements described herein are for purposes of example only. As such, those skilled in the art will appreciate that other arrangements and other elements (e.g. machines, interfaces, operations, orders, and groupings of operations, etc.) can be used instead, and some elements may be omitted altogether according to the desired results. Further, many of the elements that are described are functional entities that may be implemented as discrete or distributed components or in conjunction with other components, in any suitable combination and location, or as other structural elements described as independent structures may be combined.
While various aspects and implementations have been disclosed herein, other aspects and implementations will be apparent to those skilled in the art. The various aspects and implementations disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope being indicated by the following claims, along with the full scope of equivalents to which such claims are entitled. It is also to be understood that the terminology used herein is for the purpose of describing particular implementations only, and is not intended to be limiting.
