Abstract:
An adaptor kit or system for use with conventional can light fixtures to adapt the can light fixture for use as a hanger assembly for auxiliary fixtures, such as a hanging lamp, a flush-mounted lamp or the like, includes an expandable/retractable shoe assembly with surfaces to forcibly engage the inner surface of a can with sufficient engagement thereto to install an auxiliary fixture. In the preferred embodiment, the shoe assembly is defined by two individual shoes connected by threaded nut/screw assemblies so that the nut/screw assemblies can be adjusted to cause the shoes to extend outwardly to effect a usable mounting.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application 60/945,072 filed Jun. 19, 2007 by the inventor herein, the disclosure of which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to an adaptor or conversion kit or system for use with “can light” or “can fixture” assemblies to adapt the can light for other uses, including, for example, use as a hanger for a suspended or hanging lamp, a flush-mount lamp, or other devices that are designed to be attached to or modified for attachment to a can light assembly. 
     Recessed ceiling lighting fixtures are located within or recessed within a ceiling. A light bulb or other type of lamp is located within the housing and is positioned so that the lowermost point of the lamp is somewhat above, flush with, or slightly below the ceiling. Lighting fixtures of this type, also known as “can lights” or “can fixtures,” are well known in both new construction and in retrofit situations due, in part, to the unobtrusive nature of the fixtures themselves and their desirable illumination pattern. 
     A representative example of a “can light” assembly of the type used in new construction is shown in side elevation view in  FIG. 1  and is designated therein by the reference character  10 . The particular organization and structure shown is exemplary only and is representative of a widely variety of can light fixtures marketed by various manufacturers. As shown, the fixture  10  includes a frame or frame-like pan structure  12  which mounts an electrical junction box  14  and a can  16 . The can  16  and the junction box  14  are connected by a standard conduit  18  through which insulated wiring (not shown) extends from the junction box  14  to the interior of the can  16  to provide power to a lamp (not shown) within the can  16 . The frame structure  12  is mounted by adjustable hanger bar assemblies  22  (only one of which is shown) between joists (not shown) above a ceiling in which an appropriately sized opening is formed. 
     The can  16  is typically formed from thin-walled metal, such as aluminum, that is pressed into shape as a dome-like surface of revolution about a central axis A x ; in some designs, the can is formed as a cylinder and, in other designs, the can is formed from two or more pieces. The can  16  is often designed to be moved or adjusted vertically (i.e., along the up/down axis A x ) throughout a limited range of motion in its frame  12 . In general, the diameter of the open, lower end of the can for the majority of manufacturers in the can light market is between three and eight inches, although some manufacturers will provide cans with somewhat larger open, lower ends. 
     As also shown in  FIG. 1 , a lamp socket assembly  20  (shown in dotted-line illustration) is mounted on or attached to an interior surface portion of the can  16 ; electrical wires (dotted-line illustration) extend from the socket assembly  20  through an opening (not specifically shown) and through the conduct  18  to the junction box  14 . In  FIG. 1 , the lamp socket  20  is shown as a classic screw-base type socket; as can be appreciated other types of sockets, including more recent pin-type sockets can be used. 
     In a normal or typical installation, a lamp, such as an incandescent or a fluorescent lamp, (not shown) is threaded into or otherwise coupled to the socket  20  to provide illumination. In the case of the present invention and as explained below, an “adaptor”  24  is threaded into or otherwise coupled to the socket  20  in lieu of a conventional light bulb or lamp. A pair of wires W 1  and W 2  extend from the adaptor  24  and provide power as explained below. 
     Can light fixtures of the type described above are in common usage and perform their lighting function as intended. However and because can light fixtures are “single function” devices, they lack a certain flexibility for use in related functions, such as a support for a hanging or suspended lamp or lighting fixture or as a support for a flush-mounted ceiling lamp. 
     SUMMARY OF THE INVENTION 
     In view of the above, it is an object of the present invention, among others, to provide an adaptor kit or system for use with conventional can light fixtures to adapt the can light fixture for use as a hanger assembly for hanging or suspended lamps or pendant lamps, including chandeliers, and to adapt the can light assembly for other types of non-recessed lamps, including flush-mounted lamps. 
     In a preferred embodiment, surface engagement shoes are assembled into a shoe assembly providing a pair of outwardly facing engagement surfaces intended to engage inner surfaces at or adjacent the open end of a can light. The surface engagement shoes are connected by mechanisms which allow the shoes to move to a retracted position and move to an extended position by which a forcible engagement is effected. When installed within the can light, the shoe assembly can then be used as connection point for a pendant or hanging lamp, a flush-mount lamp, or other devices that are designed to be attached to or modified for attachment to a can light assembly. 
     In a more specific form, a pair of surface engagement shoes are provided having engagement surface that approximately conform to the inner surface of the can. The surface engagement shoes are connected by threaded screw and threaded nut assemblies so that the shoes extend away from one another when the screw/nut assembly is adjusted in one direction to forcibly engage inner surfaces of the can to effect an installation of the adaptor kit therein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  is a side-elevational view, in partial cross-section, of a generalized or representative can light assembly; 
         FIG. 2   a  is a top view of a representative surface-engagement shoe; 
         FIG. 2   b  is end view of the representative surface-engagement shoe of  FIG. 2   a;    
         FIG. 2   c  is a bottom view of the representative surface-engagement shoe of  FIG. 2   a;    
         FIG. 2   d  is a side view of the representative surface-engagement shoe of  FIG. 2   b  taken along line  2   d - 2   d  in  FIG. 2   b;    
         FIG. 2   e  is a side view of the representative surface-engagement shoe of  FIG. 2   b  taken along line  2   e - 2   e  in  FIG. 2   b;    
         FIG. 3   a  is a detail of a preferred threaded shaft/adjustment sleeve assembly; 
         FIG. 3   b  is a detail of another threaded shaft/adjustment sleeve assembly; 
         FIG. 4   a  is a plan view of a pair of surface-engagement shoe assembled together to form a shoe assembly; 
         FIG. 4   b  is a side view of the shoe assembly of  FIG. 4   a;    
         FIG. 5  is an isometric view of a shoe assembly positioned for insertion into the lower end of a representative can; 
         FIG. 6   a  is a plan view of a cover plate; 
         FIG. 6   b  is a plan view of a cross-bar; 
         FIGS. 7   a  and  7   b  are details views of another threaded shaft/adjustment sleeve assembly; 
         FIG. 8  is view similar to that of  FIG. 4   b  showing a variant thereof; and 
         FIGS. 9   a  and  9   b  are views similar to that of  FIG. 2   a  showing variants thereof. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     A preferred embodiment of the present invention is assembled from a plurality of surface-engagement shoes  26 , as shown in  FIGS. 2   a - 2   e . Each shoe  26  is formed from a band of sheet-metal that is shaped to have a generally or approximately circular curved portion  28  that subtends a selected arc from a center. In general, the curved portion subtends a 90-150 degrees of arc; although smaller and larger values are within the scope of the invention. Selected lengths at the opposite ends of the curved portion  28  are bent inward along a chord line to form flanges  30  and  32 . If desired, strengthening ribs, as represented at  34 , can be provided for each flange  30 . Additionally, at least one mounting tab  36  having a threaded hole  38  is provided at a position along the curved portion  28 . In the example shown in  FIGS. 2 and 3 , the curved portion  28  is formed on a diameter line of about four inches and is intended for use with cans  16  having a lower, open end with a diameter of about four inches; as can be appreciated the radius of the curved portion  28  can be adjusted to accommodate diameters larger than or smaller than four inches. 
     As shown on the left in  FIG. 2   a , the flange  30  is provided with an externally threaded screw  40  (or similar component) that is threaded into an appropriately threaded hole (not shown) with the screw  40  tightened in place and, if desired, additionally held in place with a thread-locking material (e.g., “Loctite”), to provide a fixed-in-place threaded stud. 
     As shown on the right in  FIG. 2   a , the flange  32  is provided with a freely rotatable coupling sleeve  42 . The coupling sleeve assembly  42  includes an internally threaded elongated hex-nut  44  that is mounted to the flange  30  for rotation about the long axis of the hex-nut  44 . 
     As shown in the enlarged detail of  FIG. 3   a , an attachment cap  46  includes an unthreaded shank portion (unnumbered) immediately adjacent the hex-head of the cap  46  and an externally threaded portion (unnumbered) in engagement with the internal threads of the coupling sleeve  44 . The attachment cap  46  is passed through a clearance hole  48  in the flange  30  and threaded into one end of the coupling nut  44  and tightened sufficiently that the screw  46  will not loosen in normal use; if desired, a thread locking compound can be used. In general, the axial length of the unthreaded shank portion of the attachment cap  46  is somewhat larger than the thickness of the flange  30  and the diameter of the unthreaded shank portion of the attachment cap  46  is somewhat smaller than that of its mounting hole  48  to provide a “loose” fit. Thus, as shown by the arrows in the detail of  FIG. 3   a , the coupling sleeve  44 , in addition to being rotatable about its long axis, can be translated slightly up/down along its long axis and can be moved slightly side-to-side. A variant of the structure shown in  FIG. 3   a  is shown in  FIG. 3   b ; as shown, the attachment cap  46  of  FIG. 3   a  has been replaced by a screw  46 ′ that achieves substantially the same function. 
     The mounting tab  36  is formed as a bent portion of the sheet metal from which the shoe  26  is formed; the threaded hole  38  is provided with a thread diameter and a pitch as typically used in lighting and lamp assemblies. 
     As shown in  FIGS. 2   d  and  2   e , the curvilinear band  28  can be provided with various slots  48 , holes  50  and notches  52  to assist in securing the adaptor kit in place during installation or for providing access openings for various tools used during the initial manufacture and/or assembly of the shoes  26 . 
     As shown in  FIGS. 4   a  and  4   b , two of the shoes  26  described above are assembled together to form a shoe assembly SA. As shown on the right in  FIG. 4   a , the coupling nut  44  of the upper shoe  26  is threaded into engagement with its fixed-in-place threaded screw  40  (not shown) on the lower shoe  26 , and, in a similar manner and as shown on the left in  FIG. 4   a , the coupling nut  44  of the lower shoe  26  is threaded into engagement with its fixed-in-place screw  40  (not shown) of the upper shoe  26 . As can be appreciated, rotating both coupling nuts  44  in such a way to unthread them relative to their fixed-in-place screws  40  will cause the shoes  26  to move away from one another toward an extended position, as represented by the dotted-lines in  FIGS. 4   a  and  4   b . In effect, each coupling nut  44  and its respective screw  40  function as a “screw jack” to move the two shoes  26  apart or away from one another to an extended position, and, conversely, to a retracted position when the coupling nuts  44  are counter-rotated. 
     The shoe assembly SA of  FIGS. 4   a  and  4   b  is installed in a can  16  as shown in  FIG. 5 . As shown, the shoe assembly SA of  FIGS. 4   a  and  4   b  is positioned adjacent the open end of the can  16  with the mounting tabs  36  facing away from the open end of the can  16  and with the coupling nuts  44  adjusted so that the shoes  26  are sufficiently retracted that the shoe assembly SA can fit within the open end of the can  16 . The shoe assembly SA is positioned at the open end of the can  16 , inserted into the open end of the can  16 , and held in place; the coupling nuts  44  are both appropriately rotated to cause the shoes  26  to move away from one another toward an extended position. At some point in this process, one or more portions of the peripheral surfaces  28  of the shoes  26  will contact the inside diameter surface of the can  16  to effect a frictional interengagement therewith. In general, the shoes  26  are extended to the point that a substantially rigid relationship is established such that the shoe assembly SA is frictionally locked in place such that more than 10-80 pounds of force would be required to pull the shoe assembly SA from the can  16 . 
     In general, the coupling nuts  44  can be rotated using the installer&#39;s fingers and further tightened using an appropriately sized fixed or adjustable open-end wrench or gripping tools, such as a pair of pliers. In some cases, the extended shoes  26  can cause a deformation of the lower end of the can  16 ; in general, some deformation is acceptable. 
     After the shoe assembly SA is installed, one or more self-tapping screws (not shown) can be inserted to any of the holes  50  or slots  52  formed in each shoe  26  to further secure the shoe assembly SA in place. 
     Once the shoe assembly is installed in place, an appropriate cover or cross-bar is installed; an example cover plate  54  and an example cross-bar  54 ′ are shown in  FIGS. 6   a  and  6   b , respectively. As shown, the cover plate  54  in  FIG. 6   a  is generally circular and includes slots  56  and a center hole  58 . In the similar manner, the cross-bar  54 ′ also includes slots  56  and a center hole  58 . The cover plate  54  or cross-bar  54 ′ is installed using conventional screws that pass through the slots  56  and engage with the threaded hole  38  in each mounting tab  36  to secure the parts together. The central hole  58  threaded to accept standard-sized externally threaded pipe (e.g., ⅛-IP or ¼-IP) as used in the lighting industry; the threaded pipe is hollow so that the electrical wires W 1  and W 2 , mentioned above in relationship to  FIG. 1 , can be passed through the threaded pipe to extend from the bottom of the pipe for connection to the lamp or light assembly. Additionally, the connection plate  54  or cross-bar  54 ′ can include miscellaneous holes for attaching various devices (i.e., the hardware supplied with various hanging lamps, flush-mount lamps, and/or other lighting fixtures or devices, etc.). 
     In the embodiment described above, a rotatably mounted coupling nut  44  cooperates with its respective screw  40  to move the shoes  26  toward or away from each other. Other arrangements are equally suitable, for example, in the variant shown in  FIG. 7   a , the elongated coupling nut  44 ′ is formed with internal left-hand threads at one end and internal right-hand threads at the other end. Appropriate left-hand and right-hand fixed-in-place threaded stub-stafts  40 R and  40 L are provided in each flange to engage the coupling nut  44 ′ and accomplish the “screw jack” function described above. As shown in  FIG. 7   b , the stub-shafts can be installed in the flanges by providing each stub-shaft with a tapered, unthreaded end with longitudinally aligned fins. The end of the stub-shaft is then forced into an undersized hole in the flange to effect a ‘staking’ of the stub-shaft to the flange. If desired, the end portion of the stub-shaft can then swaged to fix the stub-shaft in place on the flange. In a similar manner to the “screw jack” arrangement described above in relationship to  FIGS. 4   a  and  4   b , each coupling nut  44 ′ of  FIGS. 7   a  and  7   b  also functions as a “screw jack” to move the two shoes  26  apart or away from one another to an extended position, and, conversely, to a retracted position when the coupling nuts  44 ′ are counter-rotated. 
     In the preferred embodiment described above, the surface  28  of each shoe  26  is shown as a relatively smooth curved surface; as can be appreciated, other non-smoothly curved variants are possible and fall with the definition of the shoes having surface portions thereof approximately conform to the interior curvature or radius surface of the can  16 . For example and as shown on the right in  FIG. 8 , one or more continuous (or interrupted) ribs can be provided on the surface  28  along the major dimension of the surface  28 , or as shown on the left in  FIG. 8 , along the minor dimension of the surface  28 . As shown on the right in  FIG. 8 , the ribs can have various configurations including, but not limited to, a rounded configuration  60 , a square-edged configuration,  62  and/or a pointed configuration  64 . In addition, spike-like extension can also be used. Also and as shown on the left in  FIG. 8 , various friction-enhancements can be provided, such as repeating concentric-circle patterns  66  or cross-hatching patterns  68  formed in/on the surface  28  as well the application of chalks, mastics, and/or pressure sensitive adhesives or other compounds to enhance the engagement of each shoe  26  with the inner wall surface at or near the lower end of the can  16 . 
     If desired, a peripheral flange or flanges  70  can be used along one or both edges of each shoe  26 . 
     As shown in  FIG. 9   a , that portion of the shoe  26  that engages with the inner wall surface at or near the lower end of the can  16  can take the form of a partial polygonal configuration to provide “corners”  72  that can be viewed as “biting” into the can  16  to enhance engagement and also defining surface portions thereof that approximately conform to the interior curvature or radius surface. While  FIG. 9   a  shows six such corners  72 , other arrangements are suitable including the three corner organization of  FIG. 9   b . The corners  72  can be sharp edged or radiused, as desired. Further variants include but are not limited to sinuous, scalloped, and zig-zag type configurations. 
     In the embodiment of  FIGS. 2   a - 2   e  described above, the curved portion of the shoe  26  that comes into contact with the can  16  is continuously curved at some radius that approximates that of the can. The arrangement of  FIGS. 9   a  and  9   b  is not continuously curved but, as shown by the curved dotted-lines, also approximates the radius of the can by effecting contact at plural points at the corners  72 . Thus, both the embodiment of  FIGS. 2   a - 2   e  and  FIGS. 9   a - 9   b  can be said to approximate the radius (or the diameter) or approximately conform to the interior surface of the can into which the shoe assembly SA is fitted. 
     In the embodiment of  FIGS. 2   a - 2   e  described above, the shoe  26  is provided with an externally threaded stub-shaft  40  on one of the flanges and the rotatably mounted sleeve nut  44  on the other flange; this configuration is preferred shoes of this configuration can be assembled to each other. If desired, one shoe can have a externally threaded stub-shaft  40  on each of its mounting flanges and the other shoe can have a rotatably mounted sleeve nut  44  on each of its flanges. 
     While the preferred embodiment has been disclosed as manufactured from sheet metal, as can be appreciated, molded of formed plastic and/or fiber-reinforced plastics can be used exclusively or in combination with metal sub-parts. 
     As will be apparent to those skilled in the art, various changes and modifications may be made to the illustrated embodiment of the present invention without departing from the spirit and scope of the invention as determined in the appended claims and their legal equivalent.