BACKGROUND
1. Field
The subject disclosure relates to lighting systems and fixtures and more particularly to a wall light system, which in some embodiments is particularly adapted to illuminate aisles, steps and corridors of theaters and other venues.
2. Related Art
In the past, wall lighting has been provided in theaters and other venues to assist in safely guiding patrons to their seats.
SUMMARY
The following is a summary description of illustrative embodiments of the invention. It is provided as a preface to assist those skilled in the art to more rapidly assimilate the detailed design discussion which ensues and is not intended in any way to limit the scope of the claims which are appended hereto in order to particularly point out the invention.
An illustrative wall light system embodiment includes a single piece wall mount extrusion and a single piece lampholder, which mounts an LED-carrying circuit board. The single piece wall mount extrusion includes a vertical rear mounting surface whose interior surface has first and second projections extending therefrom, the first and second projections defining a slot for receiving a lower tongue of the single piece lampholder.
An integrally formed lampshield extends generally horizontally and downwardly from a top edge of the vertical rear mounting surface of the wall mount extrusion. In one embodiment, the lampshield includes a first horizontally extending planar section, a second planar section, integrally formed with the first horizontal planar section and angled downwardly therefrom, and a third planar section, integrally formed with the second section and angled downwardly therefrom. The interior of the lamp shield portion of the wall mount extrusion has a downwardly extending vertical projection and an inwardly extending horizontal projection, which are shaped and dimensioned to define an upper slot into which fits an upper tongue of the single piece lamp holder. In one embodiment, the lampholder and accompanying wireway covers snap into the extrusion and lend rigidity thereto.
In one embodiment; respective side light shields extend horizontally from the lampholder positioned on opposite sides of the circuit board, and a plurality of additional light shields are formed between the side shields along a lower edge of the lampholder to assist in shielding the LEDs from normal view.
In one embodiment, the circuit board is spaced apart from the front surface of the lampholder to define a gap between the front surface and the circuit board. A prying tool is further provided having a tip insertable into the gap for prying the circuit board out of the lampholder.
In an illustrative embodiment, first and second apertures are formed in the circuit board disposed opposite respective first and second apertures in the lampholder and first and second electrical conductor pins pass through the respective first and second apertures of the circuit board and lampholder to provide power to the LEDs. First and second electrical leads are connected to the first and second contact pins and run adjacent a back surface of the larnpholder. A pin retainer is provided, which is releasably mountable to the back surface of the lampholder, to retain the pins and leads in position.
With apparatus constructed according to the illustrative embodiments, a wall light may be entirely assembled at the factory by snapping a lampholder with a circuit board in place into a wall mount extrusion 13 and then snapping adjacent wireway covers in place in the extrusion. Therefore, in the field, only the single piece assembly needs be attached to a wall or other surface. This approach provides a simplified installation procedure estimated to save roughly 20 to 25% on labor costs over prior systems which require assembly of two or more extruded parts in the field.
DRAWINGS
Illustrative embodiments will now be described in greater detail in conjunction with the drawings of which:
FIG. 1 is a perspective view of an illustrative embodiment of a wall mountable light;
FIG. 2 is an exploded perspective view of the light of FIG. 1;
FIG. 3 is a partial sectional perspective view of the light of FIG. 1;
FIG. 4 is an end view of a single piece extrusion component of the light of FIG. 1;
FIG. 5 is perspective view of a retainer component of the light of FIG. 1;
FIG. 6 is a rear perspective view of a lampholder component embodiment;
FIG. 7 is a front perspective view of a lampholder embodiment;
FIG. 8 is a fragmentary bottom view of the lampholder of FIG. 7;
FIG. 9 is a fragmentary front perspective view illustrating application of a circuit board removal tool;
FIG. 10 is a fragmentary perspective view further illustrating use of the tool of FIG. 9;
FIGS. 11-15 are end views schematically illustrating steps in the insertion of a wireway cover or lampholder into a wall mount extrusion according to an illustrative embodiment;
FIGS. 16 and 17 are perspective views illustrating junction box componentry;
FIG. 18 is a perspective view of an alternate junction box embodiment;
FIG. 19 is a schematic side view illustrating an embodiment enabling precise control of light cut off; and
FIGS. 20 and 21 are plan views illustrating installation of wall light components according to an illustrative embodiment.
DETAILED DESCRIPTION
As seen in the Figures, the wall light 11 includes a single piece wall mount extrusion 13 and a single piece lampholder 15. In one embodiment, the wall mount extrusion is fabricated of rigid PVC and the lampholder is an ABS plastic molded port. Various other materials could be used in alternate embodiments.
The single piece wall mount extrusion 13 includes a vertical rear mounting surface 17, which is generally planar to flushly abut a flat adjacent vertical wall. The interior surface 19 of the rear mounting surface 17 has respective mounting holes 14, 16 therein (FIG. 1) and first and second projections 21, 23 (FIG. 3) extending therefrom. The first and second projections 21, 23 define a slot 25, which receives a lower tongue 27 of the lampholder extrusion 15. The second projection 23 has a downwardly sloping lip or ramp 24 formed at its end.
As further illustrated in FIGS. 2 and 3, at the top of the rear mounting surface 17 is formed a lampshield 31, which includes a first horizontally extending planar section 33, a second planar section 34, integrally formed with the first horizontal planar section 33 and angled downwardly therefrom, and a third planar section 36 integrally formed with the second section 34 and angled downwardly at a second angle. In one illustrative embodiment, the first and second angles are 55 and 20 degrees from the vertical, respectively.
As shown in FIG. 3, on the interior of the shield 31 is formed a downwardly extending vertical projection 35 and a horizontal projection 37. The vertical and horizontal projections 35, 37 are shaped and dimensioned to define an upper slot 38 into which fits an upper tongue 39 of the lamp holder 15. Between the upper and lower tongues 27, 39 of the lampholder 15 is positioned an integrally formed generally planar surface 41. A pair of integrally formed lampholder tongues 43, 45 extend from the front surface 41 and are disposed perpendicularly thereto.
The tongues 43, 45 and rectangular lower lip 48 may retain a circuit board 51 (FIG. 1), which mounts one or more LEDs 53. Respective generally triangularly shaped side light shields 44, 46 are located on opposite sides of the circuit board 51 and respective rectangular lower edge light shields 54, 48, 52 (FIG. 2, FIG. 7) are formed along a lower edge of the lampholder 15.
In one embodiment, the circuit board 51 may be 1½ inches long and mounts 3 LEDs 53. In another embodiment, the board 51 may mount a single 3 emitter, 20 ma RGB LED. Various other combination of LEDs of various power ratings may be used A dual circuit system may also be employed were every other LED connects to an alternate one of two transformers, thereby insuring light if one LED burns out.
Power is provided to the LEDs 53 via two power wires 63, 65 through respective contact pins 67, 69. These pins 67, 69 pass through suitable apertures 70, 72 in the lamp holder 15 and through respective holes 71, 73 in the circuit board 51, The pins 67, 69 are held in position by a pin retainer 75, which has respective prongs 76, 78 which may snap-fittingly mate with respective prongs 77, 79 protruding from the rear surface 81, of the lamp holder 15. The pin retainer 75 may be fabricated, for example, of injection molded plastic.
Respective identical wireway covers 91, 93 are also provided. They each include lower planar surfaces 95, 97 which are each shaped, dimensioned and positioned to fit into the lower slot 25 of the wall extrusion 13, as well as upper planar surfaces 99, 101, which are shaped, dimensioned and positioned to fit into the upper slot 38 defined by projections 35, 37 on the interior of the shield 31. Such wireway covers 91, 93 may be formed, for example, of injection molded plastic.
FIG. 5 further illustrates the manner in which the power wires 63, 65 interface with the pin retainer 75. In particular, the wires 63, 65 each enter and exit wire guides defined by the respective side surfaces of the prongs 76, 78 of the pin retainer 75. Additionally, a non-conductive, elongated projection 80 of rectangular side profile and rectangular cross-section is positioned between the respective conductive contact pins 67, 69 thereby insulating them from one another and preventing short circuits.
As shown in FIG. 6, each power wire 63, 65 is further supported by respective reduced height edges 101, 103 formed on either side of the tabs 77, 81. Additionally, each contact pin 67, 69 receivers underside support from a raised surface or bar 82, which in the illustrated embodiment is of rectangular cross-section. The support provided by the edges 101, 103 and the bar 82 further position the contact pin 67, 69 to extend the correct or selected length from the surface 41.
FIG. 7 illustrates an embodiment wherein first and second depressions 109, 111 are formed in the generally flat or planar front surface 41 of the lampholder 15. These depressions 109, 111 are generally rectangular and of a constant depth. The depressions 109, 111 accommodate the soldering underneath the circuit board 51 while raising the circuit board 51 slightly above the surface 41, thereby creating a gap 113, as shown in FIG. 8. The gap 113 of FIG. 8 is particularly exposed at the spaces 115, 117 between the central lower edge light shield surface 48 and the respective adjacent lower edge light shield surfaces 52, 54. In various alternate embodiments, one or more depressions of varying shapes or one or more surfaces raised above the plane of front surface 41 could be used to space the circuit board 51 apart from the front surface 41 of the lampholder 15.
As illustrated in FIGS. 9 and 10, the gaps 115, 117 permit insertion of the pointed tip 119 of a prying tool 121 into each of them to thereby pry the circuit board 51 up and out of the lampholder 15 in order to replace it, should the need arise. The prying tool 121 is constructed like a conventional screw driver with a hooked and pointed end 119 formed thereon to facilitate removal of the circuit board 51. A replacement circuit board may then be inserted by aligning the contact pins 67, 69 with the circuit board holes 71, 73 of the replacement board and then pressing the replacement board down until it snaps into the hooks 43, 45.
To install a wall light unit constructed according to the illustrative embodiments, the lampholder 15 with circuit board 51 and LEDs 53 in place is snapped into the wall extrusion 13. Wireway covers 93, 97 are then installed and suitable end caps 121, 122 with mounting tabs 124, 126 (FIG. 1) are attached. The extrusion 13 is then attached by suitable fastening devices inserted through holes 14, 16 and tabs 123, 124 to a wall or other surface. The electrical connectors are then plugged-in.
FIGS. 11-15 further illustrate the manner in which the lampholder 15 and adjacent first and second wireway covers 91, 93 snap into the wall mount extrusion 13, according to one embodiment, particularly illustrating insertion of the first wireway cover 91. As shown in FIG. 11, the upper planar surface 101 of the wireway cover 91 is first inserted into the upper interior slot 38 of the wall mount extrusion 13. The lower planar surface 97 of the cover 91 is then rotated towards, and into abutment with, the tip 123 of the flat downward sloping surface 24 of the second interior projection 23 (FIG. 12). As shown in FIGS. 13 and 14, the vertical wall of the extrusion 13 is then manually bent slightly in the direction of the arrow 125 to space it away from the tip 128 of the lower planar surface 97, while, at the same time, the tip 128 is manually pushed up the ramp 24 until the lower planer surface 97 snaps into the slot 25, as shown in FIG. 15, thereby fixing the wireway cover 91 in position in the extrusion 13. The lampholder 15 is similarly snapped into position by first inserting the planar upper tongue 27 into the upper interior slot 38, bending the extrusion in the direction of arrow 125, and thereafter snapping the lower planar tongue 39 into the lower slot 25.
In one embodiment, by proper selection of materials and dimensioning, the wireway covers 97, 99 are designed to add structural stiffness to the extrusion 13 thereby assisting in holding the combined structure to the tolerances necessary to avoid exposing the LEDs 53 to normal view. In one embodiment, the wireway covers 97, 99 may be fabricated from rigid PVC.
FIGS. 16 and 17 illustrate junction boxes for use with wall light fixtures 13. As shown, the junction boxes 103, 105, 107 include respective rectangular bases 109 with respective feet 111 projecting horizontally from the lower edge of each base 109. Respective left, central and right covers 113, 115, 117 attach to the base members 109 via screws or other suitable fasteners 121. The covers 113, 115, 117 are shaped to match the contours of the adjacent wall mount extrusions 13 so as to provide a smooth seamlessly appearing front surface over the entire length “L” of the fixture. Kickouts, e.g., 118, are provided to permit entry of a power feed through the end of the junction box cover 117. In one embodiment, the junction boxes may be fabricated of die casting zinc alloy such as, for example, Zamak 3.
FIG. 18 illustrates an alternate tab and slot fit junction box embodiment where tabs 114 located on a top edge of a base member 120 engage slots 118 formed on a top edge of a cover member 115. Tabs 116 further overlap the side edge of an adjacent wall mount extrusion 13 and align the base member 120 with the extrusion 13.
FIG. 20 illustrates use of a “left” junction box 113. In the application shown, a transformer 127 is located in a theatre projection booth 129 and its power cable 131 passes through a front wall 133 and into the junction box 113 where the cable 131 is connected to the cable of a wall light 11, which, in the illustrative application, is furnished in standard eight foot lengths. A “joiner” 135 interfaces between a first eight foot section 11 and a second eight foot section 11, which are each attached to a side wall 139. In FIG. 21, a power cable 143 exits from, for example, a location in the middle of a theatre side wall 141, in which case a central junction box 115 is employed.
With apparatus constructed according to the illustrative embodiments, wall lights 11 may be entirely assembled at the factory by snapping the lampholders 15 with circuit boards 51 in place into the wall mount extrusions 13 and then snapping adjacent wireway way covers 91, 93 in place in the extrusions 13. Therefore, in the field only the single piece assembly needs to be attached to a wall or other surface. This approach provides a simplified installation procedure estimated to save roughly 20 to 25% on labor costs over prior systems which require assembly of two or more extruded parts in the field.
Another advantage of the illustrated construction is that positive control of the light emitted by the LED lamps, e.g. 53, may be achieved such that the bottoms of the lamps are not normally visible to patrons. The precise light control facilitated by the illustrative embodiments is further illustrated in FIG. 19. To provide effective light control, it is desirable to hold a tolerance of +/−0.005 inches on dimension “D1”, which establishes alight cut off point and the size of light passage or light transmission arc a1. Provision of a single piece extrusion 13 and other structural features, together with a “trim off” feature, enables holding the tolerance on D1 to the desired value. According to the trim-off feature, an extra amount of material 301 is formed at the end of the light shield portion 31 of the single piece extrusion 15 during the extrusion process. Precise machine trimming-off of the portion 301 then permits holding the tolerance on D1 to the desired +/−0.005 inches.
Those skilled in the art will appreciate that various adaptations and modifications of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
Patent Application
20110222268
