Abstract:
A recessed fixture housing in which the major components are designed with taper fits to allow the components to be pressed together in assembly to create an air-seal engagement construction. The fixture housing also provides a junction box accessible from either the room side or the attic side of a fixture, while maintaining a sealed fixture housing. Further, a recessed fixture frame for use with a housing of maximal size to be installed between building structural members with mounting bars having protruding tabs. Mounting bar brackets are inset from each frame side an amount sufficient to accommodate the tabs between the building structural member and the bracket.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to recessed fixtures, and particularly to an improved fixture frame allowing the frame and fixture housing to be mounted flush with ceiling support members. 
     2. Description of Prior Art 
     As an energy conservation measure, many buildings are being constructed with a continuous vapor/air-flow barrier between conditioned (heated or cooled) spaces and unconditioned spaces (attics, wall cavities, etc.). The intent of the barrier is to retain conditioned air within the building&#39;s outer envelope thereby reducing heating/cooling energy costs and to reduce the seepage of moisture into unconditioned spaces where condensation would damage materials. To meet this demand, it is becoming increasingly popular for recessed fixtures, such as recessed lighting fixtures, to be constructed with sealed housings to reduce airflow through the fixture. The Model Energy Code, Washington State Energy Code and many local ordinances require lighting fixtures with sealed housings that comply with prescribed leakage testing conducted in accordance with ASTM E283 “Standard Test Method for Rate of Air Leakage Through Exterior Windows, Curtain, Walls, and Doors” standards. Additionally, many utilities offer rebate programs that promote sealed fixtures. 
     Further complicating sealed fixture design are requirements that fixture wiring be accessible at a junction box at each fixture for installation and maintenance purposes. Additionally, sealed fixtures rated for both ceiling and no-ceiling access must allow for a sealable opening in the housing to access the junction box from either the room side or the attic side of the fixture. 
     Commercially available sealed lighting fixtures are typically provided with gaskets, tapes and/or chemical sealant applied at the seams and holes in their housings. These sealing methods involve costly materials, complicate fixture assembly and may degrade over time and may not properly reseal. 
     To properly dissipate heat generated by a lamp (bulb), sealed recessed light fixtures require housings having sufficient volume. It is an industry standard to provide mounting bars to mechanically attach recessed fixtures to building structural members. These bars have length exceeding the width of the fixture mounting frame because the mounting frame is usually rectangular. Buildings have structural members spaced at distances prescribed by code. These factors sometimes conflict with each other and a fixture having maximal volume for heat dissipation has a mounting frame size which will not allow mounting bars to fit between building members. 
     SUMMARY OF THE INVENTION 
     Thus, it is an object of the present invention to provide a recessed fixture housing which does not require the use of gaskets, tapes or chemical sealant materials to create a sealed housing. 
     It is another object of the present invention to provide a recessed fixture which eliminates the need for additional components to achieve or surpass air-seal requirements as defined in ASTM E283. 
     It is a further object of the present invention to provide a recessed fixture housing in which the major components are designed with taper fits to allow the components to be pressed together in assembly to create an air-seal construction. 
     It is another object of the present invention to provide a sealed recessed fixture housing having a junction box which is accessible from either the room side of the fixture or the ceiling side of the fixture. 
     It is another object of the present invention to provide a recessed fixture frame for use with a housing of maximal size to be installed between building members arranged with minimal spacing. 
     Preferably, the recessed fixture housing of the present invention has a mounting frame section having a bottom and a raised wall extending therefrom, a housing wall section having a bottom rim, a top rim, and a side wall, said side wall having a junction box opening, a housing cover section having a top and a skirt depending therefrom, and a junction box. The mounting frame raised wall and housing wall section bottom rim are in an air-seal engagement, and the housing wall section bottom rim and said housing cover section skirt are also in an air-seal engagement. The junction box is received within said junction box opening; and the junction box and side wall are also in an air-seal engagement, said air-seal engagement sealing the junction box opening. 
     Additionally, the preferred recessed fixture frame of the present invention has a pair of mounting bar assemblies having bar sections, mounting stubs at the ends of the bar sections, tabs protruding from the bar section, and notches between each tab and mounting stub. Each mounting bar assembly is slidably attached to the mounting bar brackets of a mounting frame section. The mounting frame section is narrow enough to fit between a building&#39;s structural members. The mounting frame section mounting bar brackets are inset from each side an amount sufficient to accommodate the mounting stubs and tabs of each mounting bar assembly between the building structural member and the bracket. 
    
    
     BRIEF DESCRIPTION OF THE FIGURES 
     FIG. 1 is a top view of recessed fixture housing of the present invention. 
     FIG. 2 is a sectional view taken along line  2 — 2  of FIG.  1 . 
     FIG. 3 is a partial sectional view of detail  3  of FIG. 2, without fasteners or a collar tab. 
     FIG. 3 a  a partial sectional view of detail  3  of FIG.  2 . 
     FIG. 4 is a perspective exploded view of a portion the recessed fixture housing of FIG. 1, taken from outside the junction box area of the fixture housing. 
     FIG. 5 is a perspective exploded view of a portion of the recessed fixture housing of FIG. 1, taken from inside the junction box area of the fixture housing. 
     FIG. 6 is a top view of a recessed fixture frame of the present invention. 
     FIG. 7 is a top view of the recessed fixture frame of FIG. 6 installed between building structural members. 
     FIG. 8 is a partial perspective view of the recessed fixture frame mounting bar assembly of FIG. 6 installed on an inverted “T” bar structural member. 
     FIG. 9 is an enlarged exploded view of a pivotable mounting stub member of the recessed fixture frame of FIG.  6 . 
     FIG. 10 is a top view of the mounting frame section of the recessed fixture frame of FIG.  6 . 
     FIG. 11 is a side view of the mounting frame section of FIG.  10 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A. Fixture Housing 
     As shown in FIGS. 1 and 2, the recessed fixture housing of the present invention has four major components, namely a mounting frame section  10 , a housing wall section  12 , a housing cover section  14 , and a junction box  11 . 
     Mounting frame section  10  has a central opening  16 , through which a reflector (not shown) or other appliance may be installed. In the preferred embodiment, central opening  16  is circular and sized to accept a standard recessed fixture reflector. It should be recognized, however, that central opening  16  may be of any size or shape which mounting frame section  10  will accommodate. 
     As shown in FIG. 3, mounting frame section  10  also has a raised wall  18  extending upward from the mounting frame section  10 . The raised wall  18  has a slight inward cant or taper. In the preferred embodiment, raised wall  18  is frustoconically shaped. Other shapes, however, may be utilized. 
     Additionally shown in FIG. 3, housing cover section  14  has a top piece  20  and a skirt  22  extending downward from the top piece  20 . The skirt  22 , similar to the raised wall  18 , also has a slight cant or taper outward from top piece  20 . Likewise, in the preferred embodiment, skirt  22  is frustoconically shaped, but other shapes may be utilized. 
     The housing wall section  12  of the preferred embodiment is cylindrically shaped, the shape being coincidental to the shape of mounting frame section raised wall  18  and housing cover section skirt  22 . The housing wall section  12  has a side wall  24  and an open top and bottom. Housing wall section  12  is outwardly flexible along its bottom rim  26  and inwardly flexible along its top rim  28 . Most importantly, housing wall section  12  is sized such that the bottom rim  26  perimeter is smaller than the outer perimeter  70  of the mounting frame raised wall  18 , but larger than the inner perimeter  72  of the mounting frame raised wall  18 . Further, housing wall section  12  is also sized such that the top rim  28  perimeter is smaller than the outer perimeter  74  of the housing cover skirt  22 , but larger than the inner perimeter  76  of the housing cover skirt  22 . Preferably, housing wall section bottom rim  26  is sized to meet raised wall  18  midway between its outer perimeter  70  and inner perimeter  72 . Likewise, housing wall section top rim  28  is sized to meet housing cover skirt  22  midway between its outer perimeter  74  and inner perimeter  76 . 
     Also shown in FIG. 3, in the preferred embodiment, the mounting frame raised wall  18  is formed as the outer face of an inverted v-shaped groove  34 . 
     Flexibility of the housing wall section rims  26 ,  28  of the preferred embodiment is achieved by fabrication of the section by rolling an approximately 0.032 inch thick sheet of aluminum or galvanized steel such that the cylindrical shape is formed. A seam will be formed where the ends of the sheet meet. A seal may be formed at the seam by forming a step down portion on one end, and setting the other end into the step. Fasteners may then be used to hold the seam together. 
     Assembly may be accomplished by placing the housing cover section skirt  22  over the housing wall section flexible top rim  28 , and the housing wall section flexible bottom rim  26  over the mounting frame section raised wall  18 . By applying a downward force on the housing cover section  14 , housing wall section flexible top rim  28  will flex inward slightly, allowing the housing cover section  14  to seat on the housing wall section  12  with housing cover skirt  28  compressing housing wall section flexible top rim  22  and creating an air-seal engagement. By air-seal engagement, it is meant that the engagement between the elements meets the reduced airflow requirements set forth herein. 
     The downward force on the housing cover section  14  will be further transmitted through housing wall section causing housing wall section flexible bottom rim  26  to flex outward slightly, allowing housing wall section  12  to seat on the mounting frame section  10  with housing wall section flexible bottom rim  26  compressing mounting frame section raised wall  18  and creating an air-seal engagement. 
     As shown in FIG. 3 a,  the preferred embodiment utilizes sheet metal screws  30  through housing cover section skirt  22  and into housing wall section  12  to hold housing cover section  14  downward and in compressive contact with housing wall section  12 . Also, specifically in the preferred embodiment, collar tabs  32  extend upward from mounting frame section  10 , providing a member through which sheet metal screws  30  may hold housing wall section  12  downward in position over mounting frame section  10 . Collar tabs  32  are also shown in FIG.  11 . Housing wall section  12  could, however, also be held downward in position over mounting frame section  10  by otherwise fastening housing wall section  12  to mounting frame section  10 , such as directly to mounting frame section raised wall  18 . 
     Also shown in FIGS. 1 and 2 is junction box  11 , which is recessed into housing wall section junction box opening  13 . 
     As shown in FIG. 4, junction box  11  has an inner door  15 , an outer door  17 , a junction box plate  19 , and sides  21 . 
     Sides  21  have ribs  23 . Ribs  23  serve to strengthen the rigidity of the junction box  11 . Junction box  11  is slightly wider than the width, w o , of the housing wall section junction box opening  13 , such that the side edges of junction box opening  13  seat in ribs  23  along the inside edge of the junction box sides  21 . Thus, side edges of junction box opening  13  provide slight compression against junction box sides  21 , further strengthening the rigidity of junction box  21  for attachment of conduit (not shown) or the pulling of electrical wires (not shown) into junction box  11 . 
     Junction box plate  19  has wings  35  which extend wider than the width, w o , of the housing wall section junction box opening  13  and attach to mounting frame section junction box bracket  36 , as shown in FIG.  2 . As shown in FIGS. 4 and 5, junction box plate  19  has an upturned bolt holding tab  25  which holds bolt  27 . 
     Inner door  15  has arcuate flanges  29 , bolt receiving hole  31 , and wiring hole  33 . Inner door  15  is slightly wider than the width, w o , of the housing wall section junction box opening  13  in order to cover the junction box opening  13  completely. Arcuate flanges  29  are contoured to the surface of the housing wall section  12 . 
     Thus, inner door  15  may be placed over housing wall section junction box opening  13  such that its sides and the edges of arcuate flanges  29  fit flush against the inside of housing wall section  12 . Bolt  27  is received by bolt receiving hole  31 . Wing nut  35  may then be tightened against inner door  15  forcing the inner door sides and the edges of arcuate flanges  29  tightly against the inside of housing wall section  12 , creating a air-seal along the housing wall section/inner door interface. Further, inner door  15  reinforces housing wall section  12  in the area of housing wall section junction box opening  13 . 
     Wiring hole  33  will accommodate wiring, as shown in FIG. 2, to the interior of the fixture housing. A wiring strain relief  36  will serve, in addition to relieving wiring strain, to further restrict the flow of air through the fixture housing. 
     Thus, wiring to the fixture may be accessed from either the room side or the attic side of the fixture through either junction box inner door  15  or outer door  17 , while maintaining a strongly rigid junction box  11  and substantially air-tight fixture. 
     B. Fixture Frame 
     As shown in FIG. 6, a preferred embodiment of the recessed fixture frame of the present invention has a mounting frame section  10  and mounting bar assemblies  40 . 
     Each mounting bar assembly  40  has a bar section  42  which has opposing ends  44 . Located at each end  44  is a mounting stub  46 ,  48 . 
     In use, as shown in FIG. 7, mounting stubs  46 ,  48  will be perpendicular to bar section  42  in order to abut building structural members  50 . Mounting stubs  46 ,  48  may then be attached to building structural members, such as ceiling joists  50  by fasteners  52 , which are preferably screws or nails. 
     In the preferred embodiment, mounting stubs  48  are pivotably attached to bar section  42  to aid in installation. This design is described in detail in U.S. Pat. No. 5,957,573, incorporated herein by reference. Thus, FIG. 6 shows mounting stubs  48  in a pivoted position as used during installation, while FIG. 7 shows mounting stubs  48  in their final non-pivoted position after installation. FIG. 9 provides an enlarged exploded detail view of the mounting stub pivot mechanism. 
     As shown in FIGS. 6 and 7, bendable tabs  54  protrude from the bar section  42  a short distance from each mounting stub  46 . As shown in FIG. 8, bendable tabs  54  are used when installing the recessed fixture frame on an inverted “T” bar structural member  56 . Bar section end  44  has a notch  58  between tab  54  and mounting stub  48 . Notch  58  is sized to accept inverted “T” bar structural member bead  60 . Thus, mounting bar assembly  40  may be positioned over inverted “T” bar structural member  56  such that notch  58  engages inverted “T” bar structural member bead  60 . Bendable tab  54  may then be bent under inverted “T” bar structural member bead  60  to lock the mounting bar assembly  40  onto the inverted “T” bar structural member  56 . 
     As shown in FIG. 6, mounting frame section  10  has a mounting frame plate  62 , opposing side sections  64  and opposing end sections  66 . Mounting frame plate  62  has a predetermined maximum width, w, measured between opposing sides  64 , such that the mounting frame section  10  may fit between ceiling joists  50  or inverted “T” bar structural members  56 . 
     As shown in FIG. 10, the mounting frame section  10  of the preferred embodiment also has a circular central opening  68  for receiving the fixture appliance (not shown), such as a reflector/lamp assembly, of a recessed fixture. It should be understood that the opening  68  may be of any shape or location in the mounting frame section  10 . However, a circular shape and central location has been selected for the preferred embodiment to allow compatibility with standard circular reflector trims and to provide optimal spacing from the fixture housing for dissipation of heat generated by a lamp. 
     As shown in FIG. 9, mounting frame section  10  also has mounting bar brackets  70  extending upward from the mounting frame plate  62  at each end section  66 . A critical feature of the invention is that mounting bar brackets  70  are inset from each side  64  an amount sufficient to accommodate the mounting stubs  46 ,  48 , notches  58  and tabs  54  of each mounting bar assembly  40 . 
     This detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom for modifications will become obvious to those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the present invention and scope of the appended claims.