Abstract:
A lamp unit having an electromechanical ball including first and second electrically-conductive hemispheres separated by an insulator region, the ball being pop-fit insertable and removable anywhere along a guide track apparatus providing first and second oppositely-disposed conductor strips, the lamp unit being rotatable with respect to the conductor strips to provide on-off switching. The lamp unit-track combination provides the multiple capabilities of aiming and on-off switching, as well as lamp insertion and removal, while eliminating conventional fixturing.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The subject invention relates generally to lighting apparatus and, more particularly, to micro-miniature lighting apparatus which provides easy and flexible adjustment of lighting direction while eliminating mechanical parts typically associated with directional lamp adjustment and on-off light-switching functions. 
     2. Description of Related Art 
     Presently, in the advertising industry, emphasis is being placed on point-of-purchase advertising located in retail outlets such as grocery stores and various other retail establishments. Generally, an effort is being made to render such point-of-purchase displays more attractive so as to promote sales while the consumer is in the store. The inventors have recognized that improved microminiature lighting could readily enhance the attractiveness of point-of-purchase displays, for example, by implementing “welcoming” lighting which comes on gradually as customers approach a particular display. 
     Typical lighting applications employ lamps with associated fixturing. Typically, the lamps mechanically interlock with the fixtures, for example, by a screw-in connection, or by means of prongs which plug into a cooperating female receptacle. Variable positioning or “aiming” of lighting is provided by mechanisms employing complex mechanical interconnection such as conventional “track” lighting. On-off lamp switching is similarly achieved conventionally by mechanisms of considerable mechanical complexity. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     It is therefore an object of the invention to improve lighting apparatus; 
     It is another object of the invention to improve miniature lighting apparatus; 
     It is yet another object of the invention to provide miniature lighting apparatus particularly suited to point-of-purchase displays; 
     It is a further object of the invention to simplify lighting apparatus; 
     It is another object of the invention to provide lighting apparatus suitable for miniature track lighting applications; 
     It is another object of the invention to provide such improved lighting apparatus adaptable to numerous lighting apparatus support structures and various types of conventional individual lamps; 
     It is another object of the invention to provide improved lighting apparatus which eliminates conventional electromechanical connection between lighting fixtures and the lamps they mount; 
     It is another object of the invention to provide lighting apparatus which eliminates conventional on-off electromechanical switches; and 
     It is another object of the invention to provide lighting apparatus which provides microminiaturization in a wide variety of applications, while at the same time achieving high performance and low cost. 
     These objects and advantages are achieved according to the invention by providing a lamp unit mounting receptacle and a cooperating lamp unit. The structure of the cooperating lamp unit and receptacle permit pop-in insertion and removal of lamp units at any desired position and the capability to turn the lamp units on or off by merely turning them manually or otherwise manually changing the position of the lamp unit with respect to the receptacle or housing. The direction of illumination provided by the lamp units is also changed by simply manually pointing the lamp units in the desired direction. The invention contemplates the provision of lamp units directly pluggable into and removable from a mounting track with the entire elimination of cumbersome intervening fixturing. 
     According to one feature in accordance with the invention, an electromechanical ball conductor element is provided in the form of a separate, subminiature “lighting fixture,” into which a conventional lamp unit inserts. The combined structure of the fixture and lamp provides the multiple capabilities of aiming and on/off switching, as well as lamp insertion and removal. A second feature according to the invention is the further combining of the ball fixture and the lamp element into a single integral unit. Thus, the ball conductor element effectively becomes an integral “base” for a modified conventional lamp. According to this second aspect of the invention, the “lighting fixture” is eliminated and the structure reduced in complexity to just the ball-fitted lamp and its mounting track. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings. 
     FIG. 1 is a perspective view illustrating apparatus according to the preferred embodiment of the invention; 
     FIG. 2 is an end view of apparatus according to the preferred embodiment of the invention; 
     FIG. 3 is a side view of a lamp unit according to the preferred embodiment of the invention; 
     FIG. 4 is a partial cross-sectional view of the embodiment of FIG. 3; 
     FIGS.  5 - 7  are cross-sectional schematic drawings illustrating insertion of a lamp unit according to the preferred embodiment; 
     FIG. 8 is an elevational view of an alternative lamp unit according to the preferred embodiment; 
     FIGS. 9 and 10 illustrate an alternative lighting unit embodiment construction according to the preferred embodiment; 
     FIG. 11 illustrates an alternate track embodiment according to the preferred embodiment; 
     FIG. 12 illustrates dummy ball apparatus employable with various embodiments; 
     FIGS.  13 - 14  and  16 - 22  illustrate alternative lamp unit mounting apparatus according to the preferred embodiment; 
     FIG. 15 is a perspective view of an alternate lamp unit embodiment; and 
     FIG. 23 is an exploded front view of one lamp unit embodiment according to the invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide easily usable, readily manufacturable, and low-cost lighting apparatus. 
     FIG. 1 illustrates a lighting apparatus  11  according to the preferred embodiment. This apparatus  11  includes a track  13  for mounting one or more lamp units, e.g.,  14 ,  16 . As will be further described, mounting track  13  and lamp units, e.g.,  14  and  16 , are constructed such that the lamp units  14 ,  16  are pluggably insertable directly into and out of the mounting track  13 . 
     As shown in FIG. 2, the mounting track  13  includes a generally flat planar top surface  15  having integrally-formed sides  17 ,  19  depending therefrom so as to generally define a channel  18  therebetween. The track  13  in a prototype embodiment is formed of  24  gauge aluminum sheet which is bent at two locations to define the sides  17 ,  19 . Other materials such as lighter gauge “spring steel” or resilient plastic may be used to provide extra lamp-holding capability. 
     A spacer  20  of rectangular cross-section is glued or otherwise positioned in the upper portion of the channel  18 , and is mounted flush against the underside of the top surface  15  of the track  13 . The spacer  20  may be fabricated of a foam insulating material such as neoprene or silicone. The sides  17 ,  19  curve gently inward and exhibit a resilient bias which normally maintains them in a selected position. 
     A resilient foam layer  21  is mounted within the channel  18  formed by the sides  17 ,  19 . As shown, the layer  21  includes respective end portions  22 ,  24  which wrap around and are preferably attached, for example, by gluing to the ends of each respective side  17 ,  19 . The layer  21  shown in FIG. 2 generally has a cross-section generally defined by the metal channel and resembling the Greek letter “omega.” 
     As further shown in FIG. 2, a light unit  14  is rotatably mounted in the channel  18  provided by track  13 . The light unit  14  generally includes a reflector lamp portion  27  and a stem  25  of rigid insulation material which forms a portion of an electromechanical ball  23 . The ball  23  provides the rotational interface with the track  13 . 
     As illustrated in FIGS. 1 and 2, respective conductors  26 ,  28  are attached to the respective interior side walls of the resilient layer  21 . The conductors  26 ,  28  typically extend the length of the track  13  and are disposed opposite one another on the walls of the layer  21 . In a prototype embodiment, the oppositely-disposed conductors  26 ,  28  are fabricated of flexible braided flat,  10  gauge wire, such as, for example, Part No. 300-31, 10-gauge copper flexible braid per Federal Specification QQ-B-575 as available from the Standard Wire and Cable Company, Rancho Dominguez, Calif. 90220. In the same embodiment, the layer  21  is fabricated of medium-density resilient neoprene foam sheet with the flexible braided conductors  26 ,  28  glued on, rather than mechanically retained. Various other resilient materials can be cut or extruded and variously fixed in place to create layer  21 . 
     FIG. 3 illustrates the lamp unit  14  rotated  90  degrees about its vertical axis from its position in FIG.  2 . In this position, it may be seen that the insulating stem  25  extends upward and is configured to conform to and mount with the hemispherical interior surface of the hemispherical conductor contacts  29 ,  30 . This construction results in a visible circular stripe  31  of rigid insulator material  25  separating the two conductive hemispheres  29 ,  30 . Assuming the electromechanical ball  23  is in the position shown in FIG. 3 and a suitable voltage is applied to the conductors  26 ,  28 , the lamp  27  is lit, i.e., it is in the “on” condition. When the electromechanical ball  23  of FIG. 3 is manually rotated to the position shown in FIG. 2, electrical contact with the oppositely-disposed conductors  26 ,  28  is broken and the lamp  27  is therefore not energized and is in the “off” state. Thus, lamp unit means according to the invention are energized merely by adjusting their position with respect to the cooperating retaining structure and conductors therein. 
     It will also be appreciated that lamps according to the preferred embodiments also possess aimability. Thus, for example, in FIG. 3, the vertical axis of the lamp unit  14  may pivot to the position indicated by dashed lines  222 ,  224  or to any point along the arc between those lines. With the vertical axis pivoted to line  222 , the lamp unit may be rotated 360 degrees such that line  222  traverses the surface of a cone. Such a rotation may be achieved through any line along the arc of aimability defined between the vertical axis and line  222 . 
     FIG. 4 illustrates a cross-section of the lamp unit  14  of FIG.  3 . First and second conductors  37 ,  39  provide respective electrical conductive paths from plug-type contacts  33 ,  35  of a conventional lamp unit to the conductive hemispheres  29 ,  30 . As may be seen, the conductors  37 ,  39  are embedded in the rigid insulator material  25  which, as already noted, electrically separates and insulates the hemispheres  29 ,  30  from one another. The rigid insulator material  25  used in the aforementioned prototype embodiment is epoxy. However, it may be any other suitable ceramic, glass, or other insulative or dielectric material. The rigid insulator material  25  may be applied and formed into its shape by hand or by other conventional molding techniques. 
     The hemispherical conductor contacts  29 ,  30  of a prototype unit were formed of sections of brass half-balls soldered to short wire leads that connected to the pins of an MR-11 lamp or to the contacts of a bayonet socket. End plug contacts  33 ,  35  or their equivalent may be provided by many conventional lighting units such as MR-11, MR-16, and various other halogen units such as Model AR-48 and the T-3 and T-4 halogen display lamps and other lamps where directionality is desirable. 
     While a rigid insulator  25  is employed in various embodiments under discussion, resilience could be built into the insulator structure of an equivalent embodiment, for example, by building a resilience factor into a high temperature rubber or using other “springy” materials. The resilience provided by the resulting ball structure would offset, to a selected extent, the resilience required to be provided by the cooperating channel structure. 
     FIGS.  5 - 7  illustrate the manner of inserting and removing one or more lamp units, e.g.,  14 ,  16 , as desired, anywhere along the track  13 . As shown, the opening in the channel  18  is slightly smaller than the diameter of the electromechanical ball  23 . For example, the opening may be ¼-inch across, while the ball  23  is ½-inch in diameter. Thus, as the ball  23  is forced into the foam-lined sides  17 ,  19 ; the sides  17 ,  19  are spread apart against their resilient bias (FIG.  6 ). The ball  23  then snaps snugly into the channel  18  in a position in which it is gripped and cannot be easily pulled out, but in which it rotates freely for maximum flexibility in positioning or aiming the lamp units, e.g.,  14 ,  16 . If lamp removal is desired, the lamp unit, e.g.,  14 , is gripped and sufficient downward force manually applied to pull the lamp unit  14  out of the channel  18 . 
     In the embodiment under discussion, the resiliency of both the foam and channel materials operates to receive and retain the ball  23 . In other embodiments, the foam layer  21  may be avoided by providing a channel  18  formed of an elastomer or other material with sufficient resiliency and memory to achieve the desired results. 
     The lamp unit  16  comprises an independent fixture and is shown in more detail in FIG.  8 . As there shown, a rigid insulator extension arm  43  positions or “offsets” an electromechanical ball  46  at an obtuse angle θ to the vertical axis of generally cylindrical conventional lamp fixture  41 . The fixture  41  mounts a conventional lamp unit  49  in turn-and-release fashion, i.e., a bayonet mount. The obtuse angle θ may be, for example, 120 degrees, and the length of the extension of the ball  46  on the order of one inch, yielding enhanced flexibility in positioning or aiming the lamp unit  16 . This “offset” feature could, of course, be incorporated into a one-piece integral lamp unit, an example of which is illustrated in FIG.  15 . The electromechanical ball  46  may be constructed identically to ball  23  of FIGS. 2 and 3. 
     FIG. 9 illustrates a lamp embodiment in which a generally spherical insulator ball  55  is constructed with an interior opening designed to be plug-fitted, glued, or fused onto a lamp unit  57 . The structure of FIG. 9 includes conductor wires  59 ,  61  and conductive hemispheres  51 ,  53 . As shown in FIG. 10, the conductor wires  59 ,  61  are respectively welded onto the conductive hemispheres  51 ,  53 . Thereafter, the insulator ball  55  is attached to the neck of the lamp  57  with the wires  59 ,  61  recessing in respective grooves (not shown) on either side of the ball  55 . The conductive hemispheres  51 ,  53  are then attached to the sides of the ball  55 . FIGS. 9 and 10 also illustrate a hat portion  58  on the ball. This element  58  is illustrative of a mechanism which could be provided in some embodiments to catch either of the oppositely-disposed conductors in order to prevent the lamp units from being popped out in response to hyper rotation, e.g., rotation beyond the axis of aimability. 
     FIG. 11 illustrates an alternative mounting track for lamp units such as  14 ,  16  in which the lamp units pop-fit into suitably-sized apertures or holes  136  in a horizontal track member  120 . The track member  120  is suspended by first and second side channel arms  127 ,  129 . The first side channel arm  127  is shown in a “bent-out” position for illustrative purposes, but normally would be mounted at a 90-degree angle to the plane of the track  120  and parallel to the side channel arm  129 . Electro-mechanical balls, e.g.,  23  (FIG. 2) interface with the parallel wire braided conductors  123 ,  125  in the same manner as the embodiment of FIGS. 1 and 2. 
     FIG. 11 thus illustrates a structure wherein holes  136  in an elastomeric extrusion serve to provide additional lamp retention. A number of track sections  120  may be adapted to snap together into a tubular shape with holes  136  for lamps distributed along the length. 
     In order to facilitate bending of a track member such as track member  120  without jeopardizing the conductors  123 ,  125 , “dummy” insulator balls  126  such as shown in FIG. 12 may be provided. The dummy ball  126  includes a sphere  130  formed of insulator material, a stem  132 , and a cap  134 . The cap  134  facilitates gripping, insertion, and removal of the dummy ball  126 . Such balls  126  are located in each hole  136  of track  120  or similar track structures in an area where the track  120  is to be bent to a curved shape. 
     FIGS. 13 and 14 illustrate embodiments  142 ,  144  of a “peanut” accessory providing additional aiming capability. The accessory  142  of FIG. 13 employs an electromechanical ball like ball  23  of FIGS. 1 and 2. The insulator material  25  forms into an exterior arm  151  from which depends a socket  155  having an opening  159  therein. The opening  159  contains suitable conductors for establishing electrical connection to the electromechanical ball of a lamp unit such as lamp unit  14  of FIG.  1  and is shaped interiorly to provide rotational positioning and on/off switching of the lamp unit. Suitable electrical connections within the insulator material  25  provide electrical interconnection from the respective hemispheres  17 ,  19  of a lamp unit, e.g.,  14 , to respective conductive hemispheres  162 ,  164 . The accessory  144  of FIG. 14 may be constructed identically to accessory  142  of FIG. 13 with the exception that the socket  153  and its opening  157  are rotated 90 degrees from the position of the socket  155  and opening  159  of FIG.  13 . 
     FIG. 16 schematically illustrates in cross-section another support track  131  structure in which electromechanical balls rotatably snap-fit into suitable mounting holes  128  along its length. FIG. 17 illustrates a similar cross-sectional structure  130  having mounting receptacles  133  for electromechanical balls  23 . 
     FIG. 19 particularly illustrates an alternate manner for providing electricity to an electromechanical ball  23  using conductor structures  171 ,  173  providing arcuate surfaces  169 ,  170  for mating with the ball  23 . Each conductor  171 ,  173  may comprise a respective outer 12-volt conductor  175 ,  177 , respective elastomeric foam insulator layers  176 ,  178  encased by the outer conductors  175 ,  177 , and a respective 120-volt centrally-located inner conductor wire  179 ,  180 . Each conductor  171 ,  173  thus comprises a coaxial structure. The elastomeric insulator portion  176 ,  178  facilitates snapping the coaxial structures into relatively rigid receptacles  191 ,  193  formed in a track member  194 . The outer conductors  171 ,  173  may be formed of wire braid conductor. The 120-volt inner conductor  179 ,  180  may be used to power other circuitry such as 120- to 12-volt transformers located along the track run, or provide other voltages for various other circuits. 
     FIG. 20 illustrates another track embodiment wherein a track unit  221  has a cylindrical or pipe shape. An anterior cylindrical section  222  includes suitable openings  223  for receiving electromechanical balls, e.g.  23 ,  46  in pop-fit fashion. To this end, section  222  is preferably a medium to medium hard density elastomer or other material selected to lend sufficient resilience to the holes  223  that they dilate to receive a ball, e.g.,  23  and then return to position to retain the ball. The cylindrical section  222  is shown attached to a plastic tube  224 , but could be integrally formed as a single tubular extrusion. 
     The plastic tube  224  is shown in the “assembled” state in FIG.  20 . The tube  224  is made of relatively flexible plastic sheet and provided with a hook-and-catch fastening mechanism including a hook portion  225  and catch portion  226  at opposite side edges of the sheet. The hook  225  and catch  226  may be of uniform cross-section down the length of tube  224 . When unhooked, the tube  224  opens up so that each side lays out, similar to the position in which side channel arm  127  is illustrated in FIG.  11 . In such position, installation of the respective oppositely-disposed conductors  227 ,  228  within receiving arms  229 ,  231  is readily accomplished. If desired, a snap-on tubular retainer  233 , preferably of plastic or metal, may be provided to further secure the tube  224  in the assembled position shown in FIG.  20 . 
     Those skilled in the art will appreciate the great variety of mounting mechanisms and adaptations for apparatus constructed according to the invention which are readily apparent from the above-described embodiments. FIG. 18 illustrates one example in which a track unit  13  is integrally mounted to an extension arm  140 , which may be an aluminum extrusion forming the upper header of a display rack, wherein the foam track unit  141  occupies a ¾-in. by ¾-in. space, for example. Another example is an application to an overhead truss structure, such as shown in FIGS. 21 and 22, where cumbersome conventional track lighting units are replaced by suitably-configured lamp unit holders and lamp units according to the invention. Track apparatus such as track  13  may be conveniently bent and shaped by hand to meet various shaping requirements in sundry applications. 
     It will be observed that lighting apparatus according to the preferred embodiments provides great flexibility in the positioning of the lamp units within the track and the positioning of the track units themselves. Furthermore, lamps may be individually turned on and off by merely manually twisting or turning the lamp without the necessity for complicated on-off mechanisms, thus providing, for example, for the creation of different lighting effects from the same installation. Apparatus according to the invention is particularly suited for use with or deployment of various subminiature accessories such as lenses, filter holders, glare shields, decorative shrouds, etc. 
     With reference to FIG. 23, it will be appreciated from the foregoing that one aspect of the invention provides an electromechanical ball conductor element  201  as a separate, subminiature “lighting fixture,” into which a conventional lamp  203  inserts and rigidly attaches. The combined structure of fixture  201  and lamp  203  provides the multiple capabilities of aiming and on/off switching, as well as lamp insertion and removal. A second aspect according to the invention is the further combining of the ball fixture  201  and lamp element  203  into a single integral unit, for example, such as unit  204  shown in FIG.  15 . In FIG. 15, the ball conductor fixture, e.g.  201 , effectively becomes an integral “base” for a modified conventional lamp. The end result is that the “lighting fixture” is eliminated and the structure reduced in complexity to just the ball-fitted lamp, e.g.  204 , and its mounting track  205 . While the foregoing discussion of the preferred embodiments has shown a ball or spherical shape as providing the electrical interface with various lamp unit receptacle means, a cylindrical-shaped element could also provide this interface, although with reduced-aiming flexibility. 
     Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment 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.