The following invention relates to indoor ceiling lighting for integration into a grid ceiling. More particularly, this invention relates to lighting which replaces a T-bar and also functions structurally as a T-bar while also providing lighting.
Lighting for indoor spaces is often provided in a manner suspended from the ceiling. Such light positioning avoids using up floor space and minimizes shadowing, and also provides ample lighting for the reading of documents and other items which are generally facing upward with the light from the ceiling lighting shining thereon. Often ceilings in business and commercial work spaces are suspended from upper portions of a space. One common way to provide a suspended ceiling is to provide a grid of elongate T-bars (also referred to as “cross-tees”). These T-bars have a cross-section in the form of an inverted “T,” including a vertically oriented spine and a horizontally oriented shelf which extends horizontally in either direction from a lower portion of the spine. Ceiling tiles are provided within the spaces between the T-bars and within the grid. Edges of the ceiling tiles rest upon the shelves of the T-bars.
Ends of the T-bars are either attached to mid-portions of other T-bars or are attached to a wall, at least indirectly, if they are at an edge of the ceiling. The T-bars are typically not sufficiently strong to span open spaces within the room without sagging. Thus, various mid-portions of this grid formed by the T-bars have suspension wires or other suspension elements coupled thereto and then connected to elevated portions of the space, so that the overall grid, as well as the weight of the ceiling tiles is adequately supported.
A common prior art way to provide lighting within such a suspended ceiling is to take a space which would ordinarily contain a ceiling tile, and instead fit a lighting module within that space. This results in lighting elements which are generally square or rectangular in shape, matching the shape of the spaces within the grid. While generally effective, such a simple arrangement has a variety of drawbacks. First, ceilings end up with an appearance which is dominated by spaces within the grid which are taken up by lighting elements or other elements (such as HVAC air distribution registers, and other equipment). The ceiling then takes on more of a functional role, rather than an aesthetic role, with appearance attributes of the ceiling not being optimized.
Workers within commercial and industrial spaces can experience fatigue due to the nature of the work being performed. Employers desire to have satisfied employees who enjoy their work environment. Thus, it is not a trivial matter to provide as desirable a workspace as possible. While designers can provide a variety of aesthetically pleasing ceiling tiles and T-bar grid arrangements, these efforts are to some extent undermined by the large number of spaces within the grid which are filled with square and rectangular prior art lighting elements.
It is known to provide lighting within the shelf at the lower portion of a T-bar element, within the grid of the suspended ceiling. Examples of such lighting integrated into T-bars include those disclosed in U.S. Pat. Nos. 8,177,385; 10,145,536; 10,222,049; 10,309,638; and 10,317,042. When lighting is integrated into the T-bars themselves, this leaves the spaces between the T-bars free to provide a more aesthetically pleasing appearance, and gives the designer more opportunities to provide an aesthetically pleasing appearance for the ceiling. Typically, when lighting is provided within an underside of a T-bar, the lighting is more for accents, rather than to provide the main lighting for the space. This is because the surface area provided by the under surface of the T-bars is relatively small. If the lights are intense enough to light the entire space with the desired amount of light, and this lighting is concentrated within the under surfaces of the T-bars, the lighting can be too bright for the health and/or enjoyment of workers and others who may occasionally inadvertently gaze directly up at the lights or view excessively intense light reflected off of surfaces beneath such lights. Furthermore, the concentrated lighting can create a significant concentration of heat which can be difficult to manage.
Accordingly, a need exists for ceiling lighting which can be integrated into a suspended ceiling without taking up entire spaces within a grid formed by the T-bars, but which is larger in surface area then just the underside of the T-bars themselves. Such lighting also would need to easily integrate into adjacent T-bars within the grid and provide the grid with requisite rigidity for supporting adjacent ceiling tiles, without necessarily requiring additional vertical suspension wires and other elements adjacent to the lighting to provide adequate support for gravity loads associated with the ceiling.
With this invention, a lighting element for a suspended ceiling is provided which integrates into adjacent T-bars in all of the different ways required to allow for the T-bar grid of the suspended ceiling to be maintained. The lighting element replaces a T-bar segment between adjacent T-bars, providing both lighting functionality and providing the structural support functionality which was provided by the T-bar that the lighting element replaces. The structural support provided includes structural support to hold up the lighting element itself, structural support added to the grid, so that overall grid strength is maintained, and structural support for adjacent ceiling tiles resting upon portions of the lighting element of this invention. Furthermore, the lighting element has a greater width than just a width of the T-bar itself. For instance, the lighting elements can be 4 inches wide in one embodiment (or greater, such as 6 inches wide).
The lighting element preferably has a substantially constant cross-sectional form which is generally elongate between two ends. These ends are spaced apart by a distance spanned by T-bars within the grid of the suspended ceiling where the lighting element is to be utilized. For instance, if the ceiling has parallel T-bars spaced two feet from each other in two separate perpendicular directions, so that the spaces filled by ceiling tiles are approximately 2′×2′, then the lighting element could be approximately two feet long. In a common and typical embodiment, the lighting element would be double the length of the individual spaces within the grid ceiling, so that in the above example, the lighting element would be four feet long. In other embodiments, the lighting element can be provided two, four, five, six or eight feet long to match current common suspended ceiling systems (or other lengths).
The constant cross-sectional form can be provided by extrusion, such as from aluminum. Such a basic extruded structure can provide structural support for the lighting element. In addition, the lighting element would include lighting electronics, such as elongate LED modules, light diffusing structures for appropriately diffusing the light produced by the lighting electronics, and associated wiring for providing power and control signals to the lighting electronics associated with the lighting element. The lighting element can also include end caps which close off ends of the structure and enclose the lighting electronics.
In particular, in one embodiment described by way of example, the extruded structure or other structure associated with the lighting element includes within the singular extruded contour two lateral cross-tees and a channel for holding a central cross-tee (or the central cross-tee could be part of a single extrusion without the lateral cross-tees). The central cross-tee and the two lateral cross-tees are each parallel with each other and each generally include some form of planar spine (or plate) extending substantially vertically up from lower portions of the cross-tees, which are generally in the plane of the underside of the suspended ceiling. Each of these cross-tees also preferably include at least some form of shelf at a lower portion thereof. For the central cross-tee, these shelves can support edges of a planar diffuser spanning open lower portions of the lighting element through which light shines down into the space beneath the ceiling where the lighting element is installed. For the two lateral cross-tees, shelves extend laterally away from a central vertical elongate plane (in which the central cross-tee is located), to support edges of ceiling tiles which are adjacent to the lighting element.
The cross-tees are joined together by diagonal spans which extend from an inboard side of each of the lateral cross-tees upwardly and inwardly to an upper portion of the housing. These diagonal spans are preferably substantially planar in form. The lateral cross-tees also include a downwardly extending diffuser support foot which extends downwardly and then inwardly to define an inwardly facing gap which faces the central cross-tee and can support an outer edge of a diffuser, while an inner edge of the diffuser is supported by the shelf at the lower portion of the central cross-tee.
Beneath the diagonal spans and adjacent to the central cross-tee, a flange is provided which extends somewhat downwardly away from the diagonal spans, with faces of these flanges generally facing a center of each of the openings provided lateral to opposing sides of the cross-tee and beneath the diagonal spans. Two openings are provided, one on either side of the central cross-tee. Each of the flanges can support lighting electronics on the surface thereof, so that light shining from the lighting electronics faces downwardly at the openings. These openings are typically each spanned by diffusers. The lighting electronics are preferably in the form of high intensity LED lights, which are provided at appropriate spacing extending from each of the ends of the lighting element. The flanges also add rigidity and strength to the overall assembly.
An upper portion of the extruded structure housing, above the central cross-tee, preferably extend up above the diagonal spans and can include heat transfer fins thereon, as well as holes for supporting mounting screws for mounting an end cap, and also can support suspension elements which extend up from the lighting element to assist in supporting the lighting element and adjacent portions of the grid beneath upper portions of the space where the grid ceiling is mounted. Other screw mounting holes for mounting end caps can be formed into the extrusion at midpoints of the diagonal spans. Because aluminum is easily extruded, and relatively soft metal, and not particularly galvanically active, a variety of different kinds of screws formed of harder metal materials can self tap into such holes (or C channels which provide a large portion of a hole), such as to hold an end cap on to an end of the lighting element, or for attachment of other structures to an end of the lighting element.
The central cross-tee most preferably is a separate extrusion from other portions of the extruded structure making up the structure for the lighting element. This central cross-tee fits tightly into a central underside channel in the extruded structure including the lateral cross-tees. A screw vertically from above can engage the central cross-tee and fasten it to the other extruded structures (or it can be held by friction, welding, adhesive, etc.). The central cross-tee can come in at least two forms. In one form the central cross-tee has a lower shelf to support inner edges of two diffusers at a lower surface of the lighting element. In another form the spine of the central cross-tee has no shelf (and can be a little shorter or eliminated altogether) and a single diffuser spans the entire space between lower portions of the two lateral cross-tees. Such a single diffuser can be larger than the two diffusers combined, to provide more light surface. Such an embodiment could be served by a single LED module or more than two LED modules or other light sources. In both forms, a standard 22″×24″ ceiling tile can be used adjacent to the lighting element, so that custom ceiling tile cutting can be minimized or eliminated.
The spines on the two lateral cross-tees add rigidity to the lighting element. Furthermore, in embodiments where the lighting element is longer than spaces between T-bars in the grid ceiling, intermediate slots can be supplied within these spines, which can carry clips or other fasteners at ends of other T-bars, so that these other T-bars can connect to these spines and help to integrate and rigidify the overall grid ceiling which incorporates the lighting element. If the lighting element is twice the length of spaces between adjacent T-bars, one such slot would be provided within each of these fins at a midpoint of each spine. If the lighting element is longer than double this short spacing between adjacent T-bars (or some other length), a larger number of slots would be provided, typically at regular (e.g. two foot) intervals, and where desired for attachment of ends of adjacent perpendicular T-bars, for connection to the lighting element through the spines of the lateral cross-tees.
The ends of the lighting element can be attached to mid-portions of other T-bars, such as by utilizing an appropriate clip or other fastener connected to the central cross-tee at an end (or both ends) thereof, and then passing into a slot within a spine of a T-bar to which the lighting element is mounted (or hanging over a spine with clips). These clips and other fasteners for connecting the lighting element into the grid ceiling can be similar clips and/or fasteners as those used in other grid ceiling and suspended ceiling systems, and can include appropriate adapters as necessary to allow the lighting element to be compatible with a variety of different known suspended ceiling systems. End caps are shown which accommodate these clips or other fasteners. For lighting elements with no central cross-tee, fasteners can extend from at least one (and typically both) of the lateral cross-tees, with the end caps accommodating placement of such fasteners. Such end caps also preferably have a clear (or other decorative) lower cover portion, which can be exposed slightly below the shelves of the T-bars in some embodiments. A horizontal flange is provided extending from a lower portion of the end caps, and just above any “lower portion,” such as that mentioned above. The flange rests upon a rest shelf of a T-bar adjacent to the end of the lighting element, keeping it supported and aligned vertically within the grid ceiling.
Accordingly, a primary object of the present invention is to provide a light integrated into a suspended ceiling without the light taking up a large amount of ceiling surface area.
Another object of the present invention is to provide a light within a suspended ceiling which has more surface area than that of a lower surface of a T-bar, but less than a surface area of a ceiling tile between T-bars in the suspended ceiling.
Another object of the present invention is to provide a light within a suspended ceiling which includes a housing which is attachable to other T-bars within the suspended ceiling.
Another object of the present invention is to provide a light within a suspended ceiling which attaches to other elements of the suspended ceiling in a manner similar to the way that T-bars and ceiling tiles within the suspended ceiling are already configured to attach, for ease of integration of the light into the suspended ceiling.
Another object of the present invention is to provide a light for a suspended ceiling which replaces at least a portion of a T-bar within the suspended ceiling while maintaining function of the T-bar, including attachability to other T-bars, support for ceiling tiles, and assistance in maintain planar rigidity of the suspended ceiling.
Another object of the present invention is to provide a light for a suspended ceiling which has a unique and desirable aesthetic appearance, and which can facilitate a variety of interesting and functional ceiling lighting configurations.
Another object of the present invention is to provide a light for a suspended ceiling which is easy to install using mostly existing fasteners.
Another object of the present invention is to provide a light for a suspended ceiling which accommodates heat transfer away from LED lighting modules sufficient to maintain optimal performance for the lighting modules and minimizing heat transfer into air-conditioned space beneath the light.
Another object of the present invention is to provide a light for a suspended ceiling which has high rigidity and resistance to bending loads, such as bending loads associated with weight of the light itself and weight of T-bars and ceiling tiles to some extent carried by the light.
Other further objects of the present invention will become apparent from a careful reading of the included drawing figures, the claims and detailed description of the invention.
Referring to the drawings, wherein like reference numerals represent like parts throughout the various drawing figures, reference numeral 10 is directed to a lighting element (
In essence, and with particular reference to
A diagonal span 50 extends from lower portions of each of the lateral cross-tees 20, up to an upper portion 70 where the two diagonal spans 50 come together. Flanges 60 extend from the diagonal spans 50 within an interior of the housing, which flanges 60 support an LED module 62 therein which acts as a preferred form of light source for the lighting element 10. A central cross-tee 80 can optionally be provided either as part of the extrusion 12 or as a separate element attachable to the extrusion 12 and within the housing. The central cross-tee 80 can add rigidity to the lighting element 10 and also carry inner edges 42 of diffusers 40 on either side of the central cross-tee 80 which is oriented within a central elongate vertical plane midway between the lateral cross-tees 20. Ends of the central cross-tees can also carrier fasteners such as a tab 90. A clip 100 provides an alternate form of fastener for an end of the lighting element 10, which tab 90 or clip 100 act as fasteners for carrying ends 14 of the lighting element 10 relative to other portions of the suspended ceiling.
More specifically, and with continuing reference to
The extrusion 12 includes lateral cross-tees 20 near lateral edges of the extrusion 12. Each lateral cross-tee 20 includes a spine extending from a tip 22 at an uppermost portion of the spine to a root 24 at a lowermost portion of the spine, and where the spine of each lateral cross-tee 20 joins with other portions of the extrusion 12. The spine preferably includes at least one slot 25 therein, preferably located at a midpoint in the lateral cross-tee 20. This slot 25 is sized and shaped to receive a fastener F, such as a tab at an end of an adjacent T-bar T, so that the lateral cross-tees 20 can integrate into and carry adjacent portions of a suspended ceiling (see
The lateral cross-tees 20 also include a shelf 26 extending away from a centerline of the extrusion. Each shelf 28 is generally complimentary in form to a ceiling tile of a typical T-bar T, so that the ceiling tiles C (
A support foot 30 extends down from each lateral cross-tee 20 and defines a lowermost (and most lateral) portion of the extrusion 12 of the lighting element 10. Each support foot 30 has a top 32 general connected to an underside of the shelf 26, and extending down to a tip 34 at a lowermost portion of the support foot 30. Inside portions of the support foot 30 include an inwardly facing gap 36. The gap 36 is sized to receive and outer edge 44 of a diffuser 40.
A pair of diffusers 40 are provided in this example embodiment which are translucent in character, allowing light L to be transmitted therethrough in a diffuse manner and to illuminate objects within a room beneath the suspended ceiling. In one embodiment, a pair of diffusers 40 are replaced with a single large diffuser 45 extending all of the way between inwardly facing gaps 36 in each support foot 30 of the extrusion 12 (see
The diffusers 40 include an upper surface 46 opposite a lower surface 48. The upper surface 46 faces the chamber 64 and the lower surface 48 is visible when viewing the lighting element 10 from below. By providing a diffuser, high intensity LED lights have their intensity averaged out and diffused over the surfaces of the diffusers to provide a larger surface area of lesser intensity light, rather than highly focused very bright lights, which might be damaging or less pleasing for individuals and/or equipment located in a space beneath the suspended ceiling including the lighting element 10. Surfaces of the chamber 64 above the diffusers 40 can be reflective in nature, either by including a reflective layer/coating, or merely being formed of a material having reflective properties, such as extruded aluminum, so that light from LED modules 62 which is initially directed in an unproductive direction other than downwardly, will reflect about within the chamber 64 with most intensity maintained, until the light L strikes the diffuser 40 and is then transmitted through the diffuser 40 to provide productive light L into a space beneath the lighting element 10. In this way, a large proportion of light emanating from the LED modules 62 ends up as productive light illuminating space beneath the suspended ceiling including the lighting element 10 therein.
A pair of diagonal spans 50 extend from the lateral cross-tees 20 to an upper portion 70 of the extrusion 12 defining an upper portion of the housing. The diagonal spans 50 are preferably thin elongate portions of the extrusion 12 which are generally planar in form. A lower end 52 of each diagonal span 50 is adjacent to the root 24 of each lateral cross-tee 20. Upper ends 54 of the diagonal spans 50 are adjacent to the upper portion 70. A screw support slot 55 (or a hole) can be provided within the diagonal span 50, such as near a midpoint, which is sized to receive a threaded shaft of a screw therein, such that an end cap 110 or other structures can be readily attached to the housing through the screw support slot 55 in the diagonal span 50.
In this embodiment, the screw support slot 55 is integrated into the extrusion 12 for simplicity. However, such a screw support slot 55 (or hole) could be provided as a separate structure attachable to the diagonal span 50 or other portions of the extrusion 12, or could be formed into the diagonal span 50 or other portions of the extrusion 12 in a second milling and/or tapping step. The upper end 54 of the diagonal span 50 preferably ends with an upper flat so that central portions of the extrusion 12 adjacent to the upper portion 70 have a flat surface oriented within a horizontal plane near central portions of the housing.
Within the housing and beneath the diagonal span 50 and upper portion 70, a flange 60 is provided. This flange 60 is provided in pairs, with one beneath each of the diagonal spans 50. The flanges 60 extend downwardly and inwardly away from the diagonal spans 50 and toward a central vertical channel 76, to provide an elongate plane for support of a light source therein. The flanges 60 have a lower surface facing the diffusers 40 and upon which an elongated LED module 62 is mounted, in this embodiment. The LED module 62 is elongate in form and includes separate individual LEDs, such as high intensity LEDs, at periodic locations (such as one every inch) along the elongate LED module.
In a typical embodiment, the LED module 62 is in the form of a printed circuit board with the LEDs themselves surface mounted on the printed circuit board. The board provides appropriate electronics to support the LEDs themselves and to cause the LEDs to emit light in accordance with their design. Electric power to the LED modules is typically provided from above, by forming holes passing through the upper portion 70 or diagonal span 50 and through the flange 60. However, wiring could be provided in a variety of different orientations, such as through the ends 14.
Arms 61 hold inside edges of the flange 60 and extend up to the upper portion 70 and the upper flat 56 of each diagonal span 50. These arms 61 are spaced apart so that a channel 76 is located therebetween. The arms 61 are preferably oriented within vertical planes. Space 63 is provided above the flanges 60 which is generally enclosed. In one embodiment, the space 63 could be configured to be open at the ends 14 (or through other ports) to facilitate natural convection heat transfer for removal of heat away from the LED modules 62. As an option, a fan could be integrated into (or along a path including) this space 63 above each flange 60, so that forced convection cooling could be facilitated. The ends 14 being generally above the ceiling tiles C (
While the pair of flanges 60 are shown with the channel 76 therebetween which supports an upper portion of a central cross-tee 80, as an alternative, the flanges 60 could be generally horizontal and a single LED module (or more than two) could be mounted thereon without the channel 76 and without the central cross-tee 80 being provided. A single LED module 62 or some other form of light source could be mounted upon such a flange or other structure within the housing without a central cross-tee 80, and emitting light down upon a single large diffuser 45 (
The central cross-tee 80 is preferably provided as a separate structure which connects to the housing, but could be provided as part of the extrusion 12 and fully integrated into the housing. In this embodiment, the central cross-tee 80 includes a head 82 which is sized to fit within the channel 76. This head 82 could have a friction fit within the channel 76 or could be held in place by adhesive or fasteners. A plate 84 extends down from the head 82 to lower legs 86. The plate 84 is generally a planar structure oriented within a vertical plane and along a central elongate vertical plane of the overall lighting element 10. Thus, the central cross-tee 80 is positioned to bisect the housing into two separate lateral halves, with the central cross-tee 80 generally at a midpoint between the lateral cross-tees 20 in this embodiment.
The lower legs 86 extend horizontally away from the lower end of the plate 84. Outwardly facing gaps 88 at tips of the lower legs 86 hold inner edges 42 of the diffusers 40. Most preferably, an elevation of these outwardly facing gaps 88 matches an elevation of inwardly facing gaps 36 in each support foot 30 beneath each lateral cross-tee 20, so that the two diffusers 40 are parallel with each other and oriented horizontally spanning the two chambers 64 and lower openings 66 of the housing (
Central upper portions of the housing of the lighting element 10 are defined by an upper portion 70 which joins the upper end 54 of each diagonal span 50 together. This upper portion 70 can include a spine extending vertically upward and with heat transfer fins 72 extending horizontally from either side of such a spine. A screw support slot 74 similar to the screw support slots 55 in the diagonal spans 50 can be provided at an upper portion of this spine in the upper portion 70, so that screws 75 (
With reference to
In
This disclosure is provided to reveal a preferred embodiment of the invention and a best mode for practicing the invention. Having thus described the invention in this way, it should be apparent that various different modifications can be made to the preferred embodiment without departing from the scope and spirit of this invention disclosure. When embodiments are referred to as “exemplary” or “preferred” this term is meant to indicate one example of the invention, and does not exclude other possible embodiments. When structures are identified as a means to perform a function, the identification is intended to include all structures which can perform the function specified. When structures of this invention are identified as being coupled together, such language should be interpreted broadly to include the structures being coupled directly together or coupled together through intervening structures. Such coupling could be permanent or temporary and either in a rigid fashion or in a fashion which allows pivoting, sliding or other relative motion while still providing some form of attachment, unless specifically restricted.
This application claims benefit under Title 35, United States Code § 119(e) of U.S. Provisional Application No. 63/021,771 filed on May 8, 2020.
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9879850 | Porciatti | Jan 2018 | B2 |
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D834239 | Porciatti | Nov 2018 | S |
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Number | Date | Country | |
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20210348730 A1 | Nov 2021 | US |
Number | Date | Country | |
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63021771 | May 2020 | US |