Abstract:
An adjustable mount for use with light fixtures that are sealed to prevent entry of moisture and contaminants. O-ring seals are utilized to connect and seal the components of the adjustable mount so that it is not a source of moisture or loss of vacuum. The adjustable mount is a knuckle-type mount that connects a light fixture with a junction box or other source of electrical power. The adjustable mount provides a full range of vertical and rotational angles without damaging the electrical wiring that is sealed inside the mount. Frictional connections in the mount allow the lighting angle to be set without the necessity of tightening the set screws which connect the components together.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     More than one reissue application has been filed for the reissue of U.S. Pat. No.  6 , 161 , 948 . The reissue applications are application Ser. Nos.  10 / 442 , 311  ( the present application )  and  11 / 002 , 744 , which is a divisional reissue of U.S. Pat. No.  6 , 161 , 948 .  This application claims the benefit of U.S. Provisional Application No. 60/086,927 filed May 27, 1998. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The field of the present invention relates generally to devices for adjustably mounting a light for use in sealed lighting systems, such as those utilized for outdoor lighting. More specifically, this invention relates to mounting devices that allow adjustment of the direction of a light while maintaining the integrity of the sealed light system. 
     2. Background 
     It is well known that many people use lights, such as spotlights and other types of lights, in outdoor applications. These applications generally require a sealed lighting system to prevent moisture from entering the light housing, lamp or electrical wiring components of the light fixture. Often it is desirable to aim the light fixture or a series of light fixtures in a certain direction to obtain a desired effect. In order to set the direction of the light emanating from the light fixture and to be able to re-direct or adjust the direction of the light at a later date, the light mount assembly must include some type of adjustable connection that is able to maintain the integrity of the sealed system. However, in order to prevent damage to the wiring that connects the power source to the lamp, most light fixtures connections have limited adjustability. Those adjustable light mounts that have wide adjustability often have connections that do not adequately protect the wiring from damage or maintain a sealed light system. 
     The usual connection for obtaining adjustability for outdoor lighting is a knuckle joint located between the light housing and the electrical box or mounting canopy. Currently available adjustable mounts for outdoor lighting systems typically utilize a knuckle joint having opposing sides with serrated edges that are rotated to lock together to form the desired light angle. Several problems exist with these type of knuckle joints. The problems include limitation on the angles available (due to the fact that only when the serrated edges mate can the joint lock in place) and difficulty in setting the desired angle. The difficulty in setting the desired angle results from having to hold the joint together when setting the angle of the light, which either requires one person to go through several iterations to set the angle or the use of a second person to let the first person know when the lighting angle is that which is desired. Without a second person, the person setting the angle of the light must set the angle of the light, then stand back and view it and, if necessary, loosen the connection and repeat the process. Naturally, the need to utilize a second person or go through an iterative process can require significant time and effort just to set or reset an outdoor light. In many commercial uses of outdoor lights, where a number of lights may be used, this process can be very burdensome. What is needed, is an adjustable mount for outdoor lights that provides infinite adjustability and allows a single person to easily set the angle of the light while maintaining the integrity of the sealed light system. 
     SUMMARY OF THE INVENTION 
     The adjustable light mount of the present invention solves the problems identified above. That is to say, the present invention discloses a mounting device for sealed light systems that allows one person to infinitely adjust the angle of an outdoor light while providing a connection that maintains the integrity of the sealed light system. More specifically, the present invention provides a knuckle joint that provides frictional resistance to movement in order allow one person to adjustably set the lighting angle while providing a protected path through the knuckle joint for the wires that connect to the lamp. 
     The present invention comprises three principal components that can be made out of machined aluminum, such as 6061-T6, or other materials. These components are the support member, base member and stud member. The upper surface of the support member sealably connects to the light fixture housing. The side of the support member pivotally connects to the side of the base member. The bottom end of the stud member threadably connects to a junction box or the like which supplies power to electrically charge the lamp. The upper end of the stud member frictionally connects inside an opening at the bottom of the base member. Sealing members, such as O-rings, are utilized to seal the connection of the various members to each other and to the fixture housing. 
     A tapered post on the base side is sized and configured to fit within a tapered opening in the support side and provide some degree of frictional resistance to movement to make setting or adjusting the lighting angle easier than the prior art devices. Locking set screws are utilized to lock the rotational angle (the base member to stud member connection) and the vertical angle (the base member to support member connection) to obtain the desired lighting angle or effect. 
     Electrical wiring from the junction box passes through a stud opening, which traverses the entire stud member, then into the base opening and the second passageway located in the base member, and then through the first passageway in the support member to connect to the lamp. A pair of rotational stop members are utilized to prevent the adjustable mount from rotating more than 360 degrees, which would otherwise result in damage to the electrical wiring from the twisting of the wire inside the adjustable mount. 
     Accordingly, the primary objective of the present invention is to provide an adjustable mount for sealed light fixtures that provides an easy to use mechanism for adjusting and setting the desired lighting angle for light emanating from the light fixture. 
     It is also an important objective of the present invention to provide an adjustable mount that allows the electrical wiring necessary to power a lamp in a sealed light system to pass through the mount with damaging the wire or compromising the integrity of the sealed light system. 
     Another important objective of the present invention is to provide an adjustable light mount that provides infinite angle adjustability and which can be adjusted and set by a single person. 
     The above and other objectives of the present invention will be explained in greater detail by reference to the attached figures and the description of the preferred embodiment which follows. As set forth herein, the present invention resides in the novel features of form, construction, mode of operation and combination of parts presently described and understood by the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings which illustrate the best modes presently contemplated for carrying out the present invention: 
         FIG. 1  is an exploded view of the adjustable mount of the present invention; 
         FIG. 2  is a side view of a typical light fixture utilizing the adjustable mount of the present invention; 
         FIG. 3  is a cross-sectional side view of the primary embodiment of the adjustable mount of the present invention; 
         FIG. 4  is a plan view of the support side of the support member; 
         FIG. 5  is a perspective view of the base member of the present invention; 
         FIG. 6  is a end view showing the base opening of the base member; and 
         FIG. 7  is a plan view of the upper surface of the support member. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference to the figures where like elements have been given like numerical designations to facilitate the reader&#39;s understanding of the present invention, and particularly with reference to the embodiment of the present invention illustrated in  FIGS. 1 through 8 , the preferred embodiment of the present invention is set forth below. The adjustable mount for sealed light fixtures of the present invention, designated generally as  10 , primarily comprises a support member  12 , base member  14  and stud member  16  connected together to form an adjustable mount  10  for a sealed light fixture  18 . As is shown in  FIG. 2 , the typical sealed light fixture  18  has a housing  20  and cap  21  which enclose lamp  24 . Housing  20  sealably connects to upper surface  24  of support member  12  utilizing a first sealing member, such as a high temperature silicone O-ring  25 , as shown in FIG.  7 . Stud member  16  threadably connects to a source of electrical power, such as an outlet box or mounting canopy  26  having electrical wires  27  that can connect to lamp  24 . 
     To facilitate adjustability of the adjustable mount  10 , support member  12  pivotally connects to base member  14 . However, for ease of use, adjustable mount  10  should include a mechanism to limit the amount of free pivotal movement for support member  12 . As best shown in  FIGS. 1 and 3 , the preferred embodiment of the present invention includes support member  12  with a tapered opening  28  in support side  30 , which abuts against base side  32  on base member  14 . Extending outward from base side  32  is a tapered post  34  that is sized and configured to tightly fit inside tapered opening  28 . Tapered opening  28  and tapered post  34  can be sized and configured so that when support member  12  is installed on base member  14 , support member  12  can be manually pivoted relative to base member  14  yet will not freely pivot, even with the additional weight of light fixture  18  attached to support member  12 . If properly sized and configured, tapered opening  28  and tapered post  34  will provide an internal compression fit that creates a positive lock when the user pivots support member  12  to aim the light emanating from light fixture  18 , such that support member  12  (and therefore light fixture  18 ) will stay in place even when the user releases his or her grip on light fixture  18  or support member  12 . 
     As best shown in  FIG. 3 , to lock the light in the desired vertical angle, a first locking mechanism, such as locking screw  22 , can be used. To ensure the integrity of the sealed light system, a second sealing member  38  should be located between support member  12  and base member  14 , as best shown in  FIGS. 1 and 4 . The preferred embodiment of the present invention utilizes a high temperature silicone O-ring as second sealing member  38 . In addition to providing a water-tight seal, second sealing member  38  places a pressure loading on the threads of locking screw  36  such that vibrations will not cause locking screw  36  to loosen, as often happens with most other knuckle connectors. To allow the electrical wire to reach lamp  22  in housing  20 , support member  12  has first passageway  40 , shown in  FIGS. 3 and 4 , that passes through the support side  30  of support member  12  to upper surface  24  of support member  12  where housing  20  connects. 
     In the preferred embodiment, base member  14  has second passageway  42 , shown in  FIGS. 3 ,  4  and  6 , that interconnects first passageway  40  with base opening  44  at the bottom of base member  14 . Second passageway  42  goes through base member  14  to allow the electrical wires to reach housing  20  and lamp  22 . Base side  32  has slot  46  to hold the electrical wires between first passageway  40  and second passageway  42  to prevent damage to the electrical wire during rotation of adjustable mount  10 . As shown in  FIG. 5 , in the preferred embodiment slot  46  encircles tapered post  34 . 
     A rotational limiting mechanism is necessary to prevent base member  14  from rotating more than 360 degrees to avoid twisting and, ultimately, breaking or otherwise damaging the electrical wiring. In the preferred embodiment, shown in  FIGS. 1 and 6 , the rotational limiting mechanism includes first rotational stop member  48  inside base opening  44  of base member  14  and second rotational stop member  50  at the upper end  52  of stud member  16 . First rotational stop member  48  interacts with second rotational stop member  50  to limit the amount base member  14  can rotate relative to stud member  16 . 
     Base opening  44  has an inner wall  54  which interacts with upper end  52  of stud member  16  when adjustable light mount  10  is assembled to limit the free rotation of base member  14 . The outer diameter of upper end  52  should be sized and configured to frictionally interact with inner wall  54  so that it limits the free rotation of base member  14 . To provide for further frictional limitation and seal the upper end  52  of stud member  16  can be provided with a third sealing member  56  to seal the base member  14  to stud member  16  connection. As with the other sealing members, third sealing member  56  can be a high temperature silicone O-ring that encircles upper end  52  of stud member  16  to provide a frictional, sealed connection with inner wall  54  in base member  14 . Upper end  52  of stud member  16  and third sealing member  56  should be sized and configured such that the frictional resistance created within base member  14  is sufficient to prevent unwanted rotation of base member  14  (and therefore light fixture  18 ) to allow the user to set the rotational angle he or she desires for the light emanating from lamp  22 . To prevent unwanted movement of third sealing member  56 , upper end  52  of stud member  16  should be configured to include an O-ring slot (not shown) or other mechanism for holding third sealing member  56  in place. A second locking mechanism is needed to lock the position of base member  14  relative to stud member  16  once the desired light position is obtained. In the preferred embodiment, second locking mechanism is a set screw  58  going through base member  14 , as shown in  FIG. 3 , and operatively connecting to stud member  16 . 
     Lower end  60  of stud member  16  should be suitable for connecting the light mount  10  to a junction box or mounting canopy, shown as  26  on FIG.  2 . The typical connection will be a threaded lower end  60 , shown in  FIG. 1 , that can be threadably connected to the junction box or mounting canopy  26  utilizing integral nut  62 , or a similar tightening mechanism. Fourth sealing member  64 , such as an O-ring, ensures the integrity of the sealed light system by sealing the lower end  60  of stud member  16  to junction box  26  connection. Stud member  16  has a stud opening  66  through its center to allow the electrical wires to pass through stud member  16  to base member  14 , support member  12  and lamp  22 . As shown in  FIG. 7 , upper surface  24  of support member  12  can have one or more first screw receiving sockets  68  to connect support member  12  to housing  20 . Tapered opening  28  can have a second screw receiving socket  70 , shown in  FIG. 4 , for receiving locking screw  36  to connect base member  14  to support member  12 . Base member  14  can have a set screw opening  72 , shown in  FIG. 3 , for receiving set screw  58  that is utilized to fixedly connect base member  14  to stud member  16 . 
     In use, adjustable light mount  10  is placed between housing  20  and junction box or support canopy  26  such that housing  20  connects to support member  12  and stud member  16  connects to junction box  26 . The electrical wires from junction box  26  passes through stud opening  64  in stud member  16  into base opening  44 , second passageway  42  and then slot  46  in base member  14  and then through first passageway  40  in support member  12  to lamp  22  in housing  20  of light fixture  18 . Due to the frictional resistance between support member  12  and base member  14  and between base member  14  and stud member  16 , the user can fully rotate the light fixture to obtain the desired angle for the light without having to use the iterative steps described in the prior art or a second person. In addition, the lack of serrated edges or gears allows the user to have infinite adjustability for the lighting angle. 
     Third sealing member  56  allows the user to have full rotational capability for light mount  10  while maintaining the integrity of light mount  10  to junction box  26  connection. Once the desired rotational angle is obtained for the light mount  10 , the user can lock base member  14  to stud member  16  with set screw  58 . After setting the base member  14  to stud member  16  rotational angle, the user then can set the vertical angle of the light mount  10  by adjusting the base member  14  to support member  12  connection. Once the desired vertical angle is obtained, the user can lock it into place with locking screw  36 . Naturally, the order of setting the angles can be reversed. This simple aim and lock capability for use with a sealed light system provides significant benefits over the prior art. 
     While there are shown and described herein certain specific alternative forms of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to modification with regard to the dimensional relationships set forth herein and modifications in assembly, materials, size, shape, and use.