Abstract:
An improved pull-on clip intended to position and maintain in place a reflector trim within a downlighting housing or “can” and particularly to bias the trim against an opening in a ceiling to retain a finishing flange of the trim in place about the opening. The present clip can be manually assembled to the trim by means of a snap-fastening structure provided on an attachment end of the clip, the use of tools being unnecessary for assembly of the clip to the trim. The clip facilitates lamp positioning within the can and thereby within the fixture such that optimum lamp performance is obtained. A bifurcated distal body portion of the clip provides separately flexible finger portions each having at least two points thereon, the points engaging interior walls of the trim to provide positive connection thereto such that the flexing action of the fingers exert a seating force against the trim which snugly positions the trim about the ceiling opening, thereby providing a clean appearance and positive lamp placement. The invention particularly improves on the clip of U.S. Pat. No. 5,707,143.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates generally to mounting structure for positioning and holding a reflector trim within a lamp housing of a downlighting fixture or similar lighting fixture, the invention particularly relating to an inexpensive pull-on clip of improved structure which can be rapidly assembled onto a reflector trim for mounting of the trim within a lamp housing. 
     2. Description of the Prior Art 
     Downlighting provides a flexibility not available with most other categories of lighting due to the ability to employ a variety of fixtures intended for downlight purposes to lighting situations which range from ambient to accent to wall-washing and the like. Where desired, downlighting can also be used in task lighting applications. The flexibility of downlighting is not limited to use situations but also extends to appearance and even to the use of a variety of differing lamp choices in most downlighting fixtures. With cost always a consideration in any lighting choice, it becomes necessary to provide downlighting fixtures which can be inexpensively manufactured and installed with the least intensive labor use while providing the most optimal lighting performance. Lighting fixtures so configured must also be easily and rapidly installable not only by relatively skilled labor such as in new construction but also by relatively unskilled labor such as by a home owner in a retrofit situation. Downlighting fixtures comprising varying “rough-in” structures are common in the marketplace and vary in complexity and cost. Such fixtures are manufactured and marketed by Lithonia Lighting of Conyers, Ga., Lithonia Lighting being a part of the Lithonia Lighting Group which is a division of National Service Industries, Inc. of Atlanta, Ga. In these fixtures as in downlighting fixtures produced by others, an intent has been the manufacture of effective fixtures having the best possible performance at the least possible fixture cost and the least possible involvement of installation labor. Fixtures having these desirable characteristics must include structure insertable into a lamp housing or “can” and which will positively secure lamping, a reflector trim with or without a baffle and a lamp socket within the can with positive lamp positioning and with positioning of the reflector trim snugly against a ceiling hole such that a gap does not exist between the trim and peripheral edge portions of the ceiling which surround the ceiling hole. While relatively complex and expensive mechanisms can be and are employed in at least some downlighting fixtures to produce the necessary results, the achievement of such results inexpensively and with mechanical simplicity is less than commonplace in the industry. Desirable mechanical simplicity in the industry now extends even to the very insertion of a reflector trim and lamp socket assembly into the can, standard practices in the industry essentially requiring the ability to insert such an assembly into the can in a single motion with concurrent fitting of annular flange-like portions of the tri about the ceiling hole above which the fixture is operatively mounted. In the prior art, clip-like structures riveted to the reflector trim have been used to hold the trim and socket assemblies within a can. These prior clip structures have generally required assembly to trim reflectors in a manufacturing environment and could not be reasonably attached on the job site. Clip attachment to reflector trim in the manufacturing environment further allows shipment of trim to a job site to be inefficient due to the bulky nature of reflector trim having preattached assembly clips, each trim being incapable of packaging in a nesting relation to each other such as will be possible if clips could be installed easily and rapidly on the job site. A clip capable of functioning in the manner described is disclosed and claimed in U.S. Pat. No. 5,707,143 and provides an improved mechanism for mounting a reflector trim or a reflector trim and lamp socket assembly within a lamp housing or can to achieve the results and economies alluded to herein. It is to be noted that Blaisdell et al, in U.S. Pat. No. 4,388,679; Basile, in U.S. Pat. No. 4,593,344; and Zadeh, in U.S. Pat. No. 5,440,471 also provide mechanisms which are of interest relative to achievement of the desired goals enumerated herein. 
     The present invention intends solution to certain deficiencies of the prior art by providing a reflector trim assembly which can also include a lamp socket mountable to the trim and which can be easily and rapidly mounted with positive securement within the interior of a lamp housing or can of a downlighting fite or similar lighting fixture. The invention includes assembly clip structure of improved characteristics capable of attachment to a reflector trim on a job site without the use of tools, thereby allowing reflector trim to be compactly packaged in a nesting arrangement for shipment to the job site. The present clip can rapidly be attached to the reflector trim without damage to the trim The invention further provides for improved positive retention of the reflector trim and any associated structure within the can with positive lamp positioning for optimal lighting performance and with snug fitting of the trim against a ceiling surface about a ceiling opening through which light is directed from the downlighting fixture. The improved structure of the invention provides finger-like projections having multiple points at distal ends of the projections, the structure acting to “snug” the reflector trim against the ceiling about the opening to prevent the existence of an unsightly gap between the trim and the ceiling, thus preventing light leakage and providing a clean appearance. The advantages of the invention are realized with net cost reductions in manufacturing, product shipment and job site installation. 
     SUMMARY OF THE INVENTION 
     The invention particularly provides improvement upon the clip disclosed and claimed in U.S. Pat. No. 5,707,143, the disclosure of which is incorporated hereinto by reference. The present clip structure has in common with the clip of the patent the ability to mount a reflector trim and any associated structure within a downlighting fixture “rough-in”. The present clip can be easily and quickly pulled onto a penultimate body portion of a reflector trim and locked thereto by means of a fitting of a locking tab of the clip into an aperture formed in the reflector trim the clip thus being positively secured to the reflector trim manually and without the use of tools. Two of the “pull-on” clips are mounted one each to each side of the trim although it is to be understood that more than two of the clips could be used as desired. Regardless of the number of clips used, the clips are regularly spaced about upper portions of the reflector trim and are attachable thereto without the use of tools. The structure of the present clip allows attachment thereof to the reflector trim at a job site, thereby allowing reflector trim to be compactly packaged and shipped to the job site with optimum economy. Use of the present pull-on clips provides positive lamp positioning on single motion insertion of the reflector trim assembly into a lamp housing or can with improved fitting of a trim flange of the reflector trim assembly against ceiling surfaces about an opening above which a downlighting fixture is mounted to provide a clean appearance and to prevent light leakage. 
     The attachment end of the improved pull-on clip of the present invention particularly includes a locking tab similar to the locking tab disclosed in U.S. Pat. No. 5,707,143, with the exception that the locking tab of the present structure is taken to be approximately twice as long as the locking tab of the patent. The locking tab of the present invention is also provided with an angled lead-in element formed distally of the locking tab to facilitate assembly of the clip to the reflector trim without damage to portions of the trim over which the locking tab must pass in order to reach a slot formed in the reflector trim into which the locking tab snap-fits in order to positively mount the clip to the trim A “tighter” bend in formation of clipping elements of the clip eliminates undesirable “rocking” of the clip once assembled and reduces effective retention forces. 
     The free end of the pull-on clip is bifurcated to form two finger-like elements each having sharpened points at distal ends thereof the points “biting” into inner surfaces of the trim to effectively increase removal forces, thereby facilitating connection of the trim to the housing cam The finger-like projections of the clip are initially maintained slightly out of plane and flex independently of each other in order to improve positioning of the trim relative to the ceiling opening and to prevent dislodgment of the clip from engagement with the trim in an installed situation. 
     The pull-on clip of the invention is formed of spring steel having a thickness of approximately 0.02 inch in order to provide desired resiliency. The clip is further provided with a bend formed essentially medially of its length in order to provide the capability of snugging reflector trim portions up against a ceiling opening during a simple one-motion insertion of the reflector trim assembly into a lamp housing or can. The pull-on clip of the invention deflects on insertion into the interior of the can to hold the reflector trim assembly within the interior of the can by the spring force exerted by the clips attached to the trim. 
     Accordingly, it is an object of the present invention to provide an improved reflector trim assembly including associated structure which has pull-on clips manually mountable thereto without the use of tools and in a job site environment so that the reflector trim assembly can be inserted into a lamp housing or can in but a single motion with the pull-on clips acting to retain the reflector trim assembly within the can with positive positioning of lamping carried by the assembly and with positive engagement of annular flange-like lower portions of the reflector trim assembly about a ceiling opening above which a downlighting fixture “rough-in” is mounted, the clip having an improved attachment end for facilitating mounting of the clip to the trim and an improved bifurcated distal end which improves the ability of the clip to maintain the trim assembly within the can. 
     It is another object of the invention to provide a mechanically simple and inexpensive pull-on clip which can be assembled to a reflector trim on a job site without the use of tools, thereby allowing operational economies in manufacture, product shipment and job-site installation, the pull-on clip being improved at the attachment end by the provision of a locking tab of a greater length which acts as a lead-in element which does not damage those portions of the reflector trim over which the locking tab must pass to find engagement with a slot formed in the reflector trim for receiving the locking tab, thereby to lock the tab within the slot and therefore positively mount the clip to the trim, the tab preventing the clip from being pushed back and forth and/or off the trim during installation and handling. 
     It is a further object of the invention to provide an inexpensive pull-on clip for retaining a reflector trim assembly within the interior of a lamp housing or can of a downlight fixture “roughing”, the clip being locked in place on a reflector trim by a simple and rapid linear pull-on motion of the clip relative to the trim to lock the clip in place on said trim, the improvement further comprising a bifurcated distal end having flexible finger-like elements which are preferably initially out of plane and which flex to engage sharpened points thereof with inner wall surfaces of the trim to engage the trim and to snug the trim in place about an opening formed in the ceiling. 
     Further objects and advantages of the invention will become more readily apparent in light of the following detailed description of the preferred embodiments. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a detail sectional view of a portion of a clip and reflector trim with the clip assembled to the reflector trim; 
     FIG. 2 is a perspective view of the reflector trim and the pull-on clips of the invention, one of the clips being assembled to the reflector trim and the other clip being shown in an assembly relation thereto; 
     FIG. 3A is a sectional view of an upper portion of the reflector trim taken from a point interiorly thereof and showing one of the pull-on clips assembled thereto and a second clip in an assembly relationship; 
     FIG. 3B is a detail view of the opening formed in the top of the reflector trim; 
     FIG. 4 is a side elevational view of the pull-on clip; 
     FIG. 5 is a plan view of the pull-on clip; and, 
     FIG. 6 is a detail view of the locking tab of the clip. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The invention particularly improves upon the pull-on clip disclosed and claimed in U.S. Pat. No. 5,707,143, the disclosure of which is incorporated hereinto by reference. It is to be understood that the present clip can be used in essentially all situations in which the clip of the patent finds utility and can be mounted to reflector trim in essentially the same manner. Further, the improved clip of the present invention can maintain a reflector trim and associated lamping and socket elements within a downlighting housing or can as is shown and described in the aforesaid patent. 
     Referring now to the drawings and particularly to FIGS. 1 through 3, a reflector trim is seen at  10 , the trim being essentially identical in most respects to conventional reflector trim used in optical assemblies of conventional downhighting fixtures. The reflector trim  10  essentially comprises what is known in the art as a fill optical reflector which optimizes lamp performance. Structure such as the reflector trim  10  can be formed in a variety of shapes and sizes and can be spun or drawn from materials including anodized aluminum or other aluminum alloys, steel, and the like. Trim such as the reflector trim  10  can be painted with high reflectivity coatings such as white polyester powder paint which is durable and easily cleanable. Trim such as the reflector trim  10  can be utilized with inexpensive “A” lamps, R-lamps, par lamps, halogen par lamps or other lamping as appropriate. Trim such as the reflector trim  10  is also available in various colors and finishes as is commonplace in the industry. 
     The reflector trim  10  is seen to comprise a bulbous body portion  12  having interior surfaces which are highly reflective and which define a reflective cavity which optimizes lamp performance. The trim  10  can have any number of shapes including conventional shapes available in the market. It is to be understood that the body portion  12  can be shaped other than as explicitly shown in the drawings and described herein without departing from the scope of the invention. The body portion  12  is seen to be terminated at the top of the trim  10  by means of a cylindrical cap  16  which is preferably integrally formed with the body portion  12  as is depending flange-like skirt  18  which terminates the body portion  12  about opening  20 . The skirt  18  can be formed of a substantially planar annular flange but is preferably formed in a dished-out fashion as is conventional in order that periphery  22  of the skirt  18  can effectively provide one annular edge which provides the sole loci of points which contact ceiling surfaces. 
     Planar penultimate surface  24  of the trim  10  is formed with an opening  26  centrally disposed within the circular surface  24 , the opening  26  having a circular central portion  28  bordered on diametrically opposed sides of the opening  26  by T-shaped notch portions  30 . The opening  26  is shown in detail in FIG.  3 B. Leg portions  32  of each of the notch portions  30  extend outwardly of the central portion  28 , the notch portions  30  communicating with the central portion  28  of the opening  26  at top portions of the T-shaped notch portions  30 . The opening  26  thus takes the form of a circular aperture having T-shaped projections formed in diametrically opposed relation to each other. Immediately outwardly of the leg portions  32  of each of the notch portions  30  is formed a rectangular slot  34 . The opening  26  and the slots  34  are conveniently and conventionally punched into the surface  24 . 
     As is further seen in FIGS. 1 through 3A, pull-on clips  35  mount to the reflector trim  10  by reception into the T-shaped notch portions  30  and the rectangular slot  34 , each one of the clips  35  mounting to a combination of one of the notch portions  30  and one of the rectangular slots  34  which portions  30  and slot  34  are located in adjacent relation to each other. A total of two of the pull-on clips  35  are used in the embodiment of the invention shown in FIGS. 1 through 3A for a given reflector trim  10  having the opening  26  configured as described. It is to be understood that the opening  26  could be otherwise configured, such as by having a greater number of the T-shaped notch portions  30  formed about the periphery of the circular central portion  28  of the opening  26 . Such notch portions  30  would preferably be regularly disposed about the central portion  28  of the opening  26  with three or four of the clips  35  being suitable for use. However, the preferred embodiment as shown utilizes two of the clips  35  arranged in diametrically disposed relationship to each other across the circular central portion  28  of the opening  26 . 
     Referring also to FIGS. 4 through 6 in addition to continuing reference to FIGS. 1 through 3B, the structure of the pull-on clip  35  can be appreciated as well as the mounting thereof to the reflector trim  10 . The pull-on clip  35  is seen to be formed of a single length of spring steel such as C-1050 steel of a thickness of 0.020 inch as an example. The grain direction of the spring steel is preferably along the longitudinal axis of the clip  35 . The material forming the clip  35  preferably has a Rockwell Hardness of between Rc 43-46, the value and the range being increased relative to the clip of U.S. Pat. No. 5,707,143 in order to prevent rocking of the clip  35  once assembled to the trim The clip  35  comprises a body portion  38  formed of a flat length of spring steel stock prior to forming of the clip  35 , the body portion  38  being formed at an attachment end  39  to have bent clipping elements  40  and  42  formed along each side of said end  39 , the elements  40  and  42  being essentially identical in structure and being formed of recurved lateral portions of the clip  35  and terminating in arcuate distal tips  44  and  46 , the clipping elements  40  and  42  being bent to a radius which causes arcuate pressure surfaces  48  and  50  to be respectively formed immediately anteriorly of said tips  44 ,  46  on respective clipping elements  40 ,  42 . The body portion  38  of the clip  35  terminates essentially medially of the length of the clipping elements  40 ,  42 , said elements  40 ,  42  extending beyond effective end  51  of the clip  35 . A locking tab  52  is formed in the body portion  38  of the clip  35  at a location between the tips  44 ,  46  and spaced from the end of the body portion  38 . The locking tab is preferably punched and formed from the material of the body portion  38  in a downward direction toward the tips  44 ,  46 . The locking tab  52  is substantially rectangular in conformation with a length approximately twice as great as the length of the rectangular slot  34  at each end of the surface  24  of the trim  10  such that the locking tab  52  passes over that portion of the surface  24  lying between the opening  26  and the rectangular slot  34  when the clip  35  is engaged within the opening as shown particularly in FIGS. 1 and 3, the locking tab  52  snap-fitting into the rectangular slot  34  as the clip  35  is pulled into place within the T-shaped notch portion  30  of the opening  26 . As the clip  35  is attached to the reflector trim  10  to engage the locking tab  52  within the rectangular slot  34 , the clipping elements  40  and  42  respectively receive portions of the surface  24  bordering and defining shoulders  54 ,  56  respectively. The shoulders  54 ,  56  contact distal interior surfaces of the clipping elements  44 ,  46  with the arcuate pressure surfaces  48 ,  50  resiliently biasing up against interior wall  62  disposed about the opening  26  interiorly of the cylindrical cap  16 . The clipping elements  40 ,  42  thus effectively engage and hold two portions of the reflector trim  10  as shown and described while at the same time the locking tab  52  is received into and engages in locking fashion within the rectangular slot  34 . Once the clip  35  is so engaged, the clip  35  can only be removed by an intentional deformation of the body of the clip  35  to disengage the locking tab from the rectangular slot  34 . 
     Referring now particularly to FIG. 6 as well as continuing with reference to the remaining drawings, the locking tab  52  is seen to be provided with a lead-in element  53  which terminates body portion  58  of the locking tab  52 . The body portion  58  is seen to extend from the plane of the clip  35  at an angle whereas the lead-in element  53  substantially lies in a plane which is essentially parallel to the plane in which a surmounting portion of the clip  35  lies. The lead-in element  53 , due to its essentially upwardly bent relation to the plane of the body portion  58  rides over that portion of the surface  24  lying between the opening  26  and the rectangular slot  34  and does not gouge, deform or otherwise damage that portion of the surface  24  as indicated. It is to be understood that the distal end of the lead-in element  53  could be further upturned to prevent presentation of an end structure which could damage the surface  24 . However, the slightly bent nature of the lead-in element  53  relative to the body portion  58  of the locking tab  52  suffices to allow for ease of assembly of the clip  35  to the trim  10  without damage to any portion of the surface  24 . The length of the locking tab  52  relative to corresponding structure in U.S. Pat. No. 5,707,143 is substantially twice that of the corresponding structure in the patent. The additional length of the locking tab  52  of the present invention is desirable in order to provide a lead-in which mounts the clip  35  to the trim  10  without damage to the trim  10 . 
     The clip  35  differs from the clip of U.S. Pat. No. 5,707,143 in another respect relative to the inside radius at which the clipping elements  40  and  42  are bent, the preferred inside radius being 0.025 inch. The newly chosen radius reduces unnecessary movement of the clip in a vertical direction. 
     As is best seen in the drawings, and particularly FIGS. 1,  2  and  5 , the body portion  38  of the clip  35  bends substantially upwardly at  64  at a preferred angle of approximately 15° to form spring section  66  which then bends downwardly at  68  to form distal section  70 , the angle of the distal section per se to horizontal preferably being approximately 16° although fingers  76 ,  78  forming major portions of the distal section  70  preferably lie in different planes. The length of the spring section  66  is greater than the extended lengths of the clipping elements  40 ,  42  and anterior flat section  72  of the clip  35 . The spring section  66  preferably has a length approximately 25 per cent greater than the length of the portion of the clip  35  disposed anteriorly of the bend at  64 . The distal section  70  of the clip  35  preferably has a length approximately 30 to 35 per cent greater than the length of the distal section  66 , these relative lengths being otherwise dimensioned as desired but being preferred in order to accomplish intended results. The distal section  70  is notched at  74  to define the fingers  76 ,  78  and thus to bifurcate the distal section  70 . Points  80  and  82  are respectively formed on the distal ends of the fingers  76 ,  78 , the points  80 ,  82  providing effective contact with structure within which the reflector trim is received. Those portions of the clip  35  formed by bending of the body portion  38  at  64  and at  68  to form the spring section  66  and the distal section  70  respectively function to facilitate a “snugging up” of the skirt  18  of the reflector trim against ceiling surfaces. 
     The clips  35  engage interior surfaces  14  of the trim  10  by virtue of the points  80 ,  82  of the fingers  76 ,  78  digging into the material forming said surfaces  14  and essentially connecting the clip  35  thereto. A single point could be formed on one each of the fingers  76 ,  78 . The flexing nature of the fingers  76 ,  78  as well as other portions of the clips  35  bias the trim  10  and any structure connecting thereto upwardly within a housing or can to position the reflector trim  10  such that a gap cannot occur between the skirt  18  of the trim  10  and an opening formed in a ceiling above which the present structure is mounted as part of a downlighting fixture. Essentially, the clip  35  functions in a manner similar to the operation of the clip  36  described in U.S. Pat. No. 5,707,143, as to the free end of the clip  35 . However, the fingers  76 ,  78  provide improved operation of the clip  35  with the multiple points  80 ,  82  on the respective fingers  76 ,  78  providing improved engagement with the interior of the housing can and resistance to removal of the trim from the can. The reflector trim  10  provided with the clips  35  not only accomplishes this reflecting function but also its trimming function by virtue of the operation of the clips  35 . 
     The structure thus described is seen to provide the advantages referred to hereinabove and in U.S. Pat. No. 5,707,143. In particular, the clips  35  themselves can be inexpensively manufactured and are not intended to be assembled to a reflector trim such as the trim  10  in a manufacturing environment. Accordingly, a number of the reflector trims  10  can be nested together during shipment to a job site. It is to be understood that various lamp housings and pan assemblies can be utilized without departing from the scope of the invention 
     The embodiments of the pull-on clip of the invention shown and described herein function to provide substantial advantages in the art especially in combination with a reflector trim assembly comprising a reflector trim such as the reflector trim  10  and pull-on clips such as the clips  35 . Further, the invention provides substantial advantages to the operation and use of an assembly such as the aim assembly comprises with a socket assembly (not shown in the drawings) which also utilizes pull-on clips such as the clips  35 . It is therefore to be noted that the invention can be embodied other than as explicitly illustrated and described herein without departing from the scope of the invention, the inventive scope being defined by the recitations of the appended claims.