Abstract:
The present invention provides methods of manufacturing a bollard light assembly that provides a choice of light output by being size-adaptable depending on the choice of light output. The methods comprise, in pertinent part, selecting an elongated light and interposing a number of lens rings and light deflectors which correspond to the length of the selected elongated light. Also provided is a lighting bollard assembly manufactured according to the methods of the present invention.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention pertains generally to lighting fixtures and, more particularly, to a method of manufacturing a lighting bollard assembly that is adaptable to accept varying lengths of lights. 
         [0003]    2. Background Information 
         [0004]    Lighting bollards (or bollard lights) are so named because in shape they tend to resemble the bollards, i.e., posts, used at wharfs and around which mooring lines are fastened. Outdoor bollard lights are a sophisticated way to illuminate pathways and other areas of a landscape. The unobtrusive design offers a unique way to dress up the exterior of a home or commercial space through soft lighting without detracting from the architectural elements of a building&#39;s facade. 
         [0005]    Traditional stacked louvered bollards are manufactured to provide a particular wattage of light within a particular louver stack atop the bollard in which the bollard is configured in a particular tubular shape. Thus, known bollard lights are manufactured as set structures that do not have the flexibility to adjust the configuration of the structures so as to accommodate varying lengths of light fixtures. 
         [0006]    Such typical bollard lights are disclosed in U.S. Pat. Nos. 6,341,877 and 7,182,547, which disclose a bollard light with a diffuser rim retrofitted around the edge of a clear diffuser so as to emit a special light color effect; and a bollard post having a lamp resting atop the post, in which the lamp includes a spaced-apart louver stack, respectively. 
       SUMMARY OF THE INVENTION 
       [0007]    It therefore would be advantageous to have a bollard light which is adaptable in structure so as to accept light bulbs of varying lengths and thus provide flexibility with respect to the choice of light output. 
         [0008]    Accordingly, an object of the present invention is to provide a method of manufacturing a lighting bollard assembly that provides a choice of light output. 
         [0009]    Another object of the present invention is to provide a method of manufacturing a lighting bollard assembly that is size-adaptable depending on the choice of light output. 
         [0010]    A further object of the present invention is to provide a lighting bollard assembly produced according to the methods of the present invention. 
         [0011]    These objectives are met by the embodiments of the present invention, which provide methods for manufacturing a lighting bollard assembly for a plurality of different elongated lights having different corresponding lengths. 
         [0012]    In an aspect of the present invention, there is provided a method of manufacturing a lighting bollard assembly for a plurality of different elongated lights having different corresponding lengths, comprising mounting a circuit structured to power any one of the different elongated lights atop a base; mounting a first clamp plate atop the circuit and the base; selecting an elongated light from the different elongated lights and affixing the selected elongated light into a light socket; selecting a number of interposed lens rings and a number of light deflectors to correspond to the length of the selected elongated light; interposing the selected number of lens rings among the selected number of light deflectors, wherein each of the selected number of lens rings is inserted into a corresponding one of the selected number of light deflectors; mounting the selected number of interposed lens rings and the selected number of light deflectors atop the circuit; mounting a second clamp plate atop the selected number of interposed lens rings and the selected number of light deflectors; mounting a hood atop the second clamp plate; and connecting together the hood, the second clamp plate, the selected number of interposed lens rings, the selected number of light deflectors, the first clamp plate and the base. 
         [0013]    The elongated lights may include, without limitation, fluorescent bulbs, each having a wattage of, for example, five, seven, nine or thirteen watts. When a five or seven watt fluorescent bulb is selected, three or four lens rings are interposed among two or three light deflectors, respectively. When a nine or thirteen watt fluorescent bulb is selected, five lens rings are interposed among four light deflectors. 
         [0014]    In another aspect of the present invention, there is provided a lighting bollard assembly produced according to the methods of the present invention. 
         [0015]    In another aspect of the present invention, there is provided a method of manufacturing a lighting bollard assembly for a plurality of different elongated lights having different corresponding lengths. The method comprises mounting a circuit structured to power any one of different elongated lights atop a base, in which the base is comprised of a mounting base and an upright tube, the upright tube being of a predetermined length, such as, without limitation, two feet long, four feet long, six feet long or eight feet long. A first clamp plate then is mounted atop the circuit and the upright tube, the first clamp plate having a plurality of openings therethrough. Conductors from the circuit are inserted through at least one of the openings of the first clamp plate, into a lamp cup having a first side and a second side and a plurality of openings therethrough, and into a light socket. An elongated light from the different elongated lights is selected and affixed into the light socket. The lamp cup is mounted atop the first clamp plate. A number of interposed lens rings and a number of light deflectors are selected which correspond to the length of the selected elongated light, in which each of the selected number of lens rings is inserted into a corresponding one of the selected number of light deflectors. The selected number of interposed lens rings and selected number of light deflectors are mounted atop the lamp cup. A second clamp plate having a plurality of openings therethrough is mounted atop the adjusted number of interposed lens rings and light deflectors. A hood having a plurality of openings therethrough is mounted atop the second clamp plate. The hood, the second clamp plate, the selected number of interposed lens rings and selected number of light deflectors, the lamp cup, the first clamp plate and the upright tube and the mounting base then are connected together. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which: 
           [0017]      FIG. 1  is an elevational view of four example lighting bollard assemblies, in which (A) is a five watt lighting bollard assembly, (B) is a seven watt lighting bollard assembly, (C) is a nine watt lighting bollard assembly and (D) is a thirteen watt lighting bollard assembly in accordance with embodiments of the invention. 
           [0018]      FIG. 2  is an exploded isometric view of the components of a lighting bollard assembly, in accordance with embodiments of the invention. 
           [0019]      FIG. 3  is an exploded isometric view of two components of the bollard light assemblies of  FIG. 2 : (A) a mounting base, and (B) an upright tube. 
           [0020]      FIG. 4  is an exploded isometric view of four components of the bollard light assemblies of  FIG. 2 : (A) a terminal block, (B) a transition strap, (C) a light ballast, and (D) a first clamp plate. 
           [0021]      FIG. 5  is an exploded isometric view of three components of one of the bollard light assemblies of  FIG. 2 : (A) a lamp cup, (B) a light socket, and (C) a fluorescent bulb. 
           [0022]      FIG. 6  is an exploded isometric view of two components of the bollard light assemblies of  FIG. 2 : (A) a tube ring, and (B) a light deflector. 
           [0023]      FIG. 7  is an exploded isometric view of three components of the bollard light assemblies of  FIG. 2 : (A) a second clamp plate, (B) a set of four fasteners, and (C) a hood. 
           [0024]      FIG. 8  is an isometric view of an example thirteen watt lighting bollard assembly, in accordance with embodiments of the invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0025]    A complete understanding of the present invention will be obtained from the following description taken in connection with the accompanying drawing figures, wherein like reference characters identify like parts throughout. 
         [0026]    Directional phrases used herein, such as, for example, “upper” and “lower” and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein. 
         [0027]    As employed herein, the term “fastener” refers to any suitable connecting or tightening mechanism expressly including, but not limited to, screws, bolts and the combinations of bolts and nuts (e.g., without limitation, lock nuts) and washers and nuts. 
         [0028]    As employed herein, the term “connector” refers to any suitable electrical connection or connection mechanism capable of carrying an electrical current therein. 
         [0029]    As employed herein, the statement that two or more parts are “connected” or “coupled” together shall mean that the parts are joined together either directly or joined through one or more intermediate parts. Further, as employed herein, the statement that the two or more parts are “attached” shall mean that the parts are joined together directly. 
         [0030]    The invention is described in association with a method for manufacturing a lighting bollard assembly for a plurality of different elongated lights having different corresponding lengths. 
         [0031]    Referring to  FIGS. 1 and 2 , the lighting bollard assemblies  10 ,  10 ′,  10 ″,  10 ′″ ( FIG. 1 ) is comprised of a base  11  ( FIG. 1 ) in which the base  11  is comprised of a mounting base  12  ( FIG. 2 ) and an upright tube  14  ( FIG. 2 ); a circuit  35  ( FIG. 1 ), in which the circuit  35  is comprised of a terminal block  18  ( FIG. 2 ), a transition strap  20  ( FIG. 2 ) and a light ballast  25 ,  25 ′ ( FIG. 1 ); a first clamp plate  48  ( FIG. 2 ), a lamp cup  26 , a light socket  36  ( FIG. 2 ), a plurality of different elongated lights  62 ,  64 ,  66  ( FIG. 1 ) with different lengths; a plurality of lens rings  40  ( FIG. 2 ); a plurality of light deflectors  42 ; a second clamp plate  50  ( FIG. 2 ); a plurality of fasteners  56  ( FIG. 2 ); and a hood  52 . 
         [0032]    The different elongated lights  62 ,  63 ,  64 ,  65  can include, without limitation, fluorescent bulbs. The different fluorescent bulbs each can have wattages such as, without limitation, five watts (light  62 ), seven watts (light  63 ), nine watts (light  64 ) or thirteen watts (light  65 ). 
         [0033]    Referring to  FIG. 3 , the mounting base  12  has a lower end  13  with a plurality of openings  19  therethrough and an upper end  17  with a center opening  37  therein. The upright tube  14  has a lower end  16  and an upper end  15  with a center opening  39  therein. 
         [0034]    Referring to  FIG. 4 , the transition strap  20  has a lower end  21 , an upper end  22 , a first side  23  and a second side  24 . The light ballast  25  has an upper end  57  and a lower end  58 . The first clamp plate has an upper end  72  which has an opening  74  therethrough and four peripheral openings therein, and four legs  73 , in which each leg  73  has an opening therein  76  (two openings are shown). 
         [0035]    Referring to  FIG. 5 , the lamp cup  26  has an upper end  27 , a lower end  28 , a first side  29 , a second side  30 , a center opening  31 , four peripheral openings  32  at the upper end  27  and four openings  34  (two openings are shown) at the lower end  28 . 
         [0036]    Referring to  FIG. 6 , the light deflector  42  has an upper end  44  having four ears  45  therein and a center opening  46  therethrough. Each of the ears  45  has an opening  47  therein. 
         [0037]    Referring to  FIG. 7 , the hood  52  has an upper end  51  and a lower end  53  having four openings  54  (one opening is shown) therein. The second clamp plate  50  has an upper end  84  having a center opening  86  therethrough and four peripheral openings  87  therein and two legs  85  (one leg is shown), each leg  85  having an opening therein  88 . 
         [0038]    Referring again to  FIGS. 1 and 2 , embodiments of the present invention provide a method of manufacturing a lighting bollard assembly  10 ,  10 ′,  10 ″,  10 ′″ ( FIG. 1 ), comprising mounting a circuit  35  ( FIG. 1 ) structured to power any one of the different elongated lights  62 ,  63 ,  64 ,  65  ( FIG. 1 ) atop a base  11  ( FIG. 1 ); mounting a first clamp plate  48  ( FIG. 2 ) atop the circuit  35  and the base  11 ; selecting an elongated light  62 ,  63 ,  64  or  65  from the different elongated lights  62 ,  63 ,  64 ,  65 , affixing the selected elongated light  62 ,  63 ,  64  or  65  into a light socket  36  and inserting the light socket  36  into the center opening  31  in the upper end  27  of the lamp cup  26 ; selecting a number of interposed lens rings  40  ( FIG. 2 ) and a number of light deflectors  42  to correspond to the length of the selected elongated light  62 ,  63 ,  64  or  65 ; interposing the selected number of lens rings  40  among the selected number of light deflectors  42 , wherein each of the selected number of lens rings  40  is inserted into a corresponding one of the selected number of light deflectors  42 ; mounting the selected number of interposed lens rings  40  and the selected number of light deflectors  42  atop the circuit  35 , the first clamp plate  48  and the lamp cup  26 ; mounting a second clamp plate  50  ( FIG. 2 ) atop the selected number of interposed lens rings  40  and the selected number of light deflectors  42 ; mounting a hood  52  atop the second clamp plate  50 ; and connecting together the hood  52 , the second clamp plate  50 , the selected number of interposed lens rings  40 , the selected number of light deflectors  42 , the lamp cup  26 , the first clamp plate  48  and the base  11 . 
         [0039]    Referring to  FIGS. 2 and 3 , the method further comprises inserting the lower end  16  of the upright tube  14  ( FIG. 3B ) into the opening  37  in the upper end  17  of the mounting base  12  ( FIG. 3A ). 
         [0040]    Referring to  FIGS. 2 and 4 , the method further comprises affixing the terminal block  18  ( FIG. 4A ) to the lower end  21  of the transition strap  20  ( FIG. 4B ) and affixing the lower end  58  of the light ballast ( FIG. 4C ) to the upper end  22  of the transition strap  20 . 
         [0041]    Referring to  FIGS. 2-5 , the method further comprises inserting the lower end  28  of the lamp cup  26  ( FIG. 5A ) into the transition strap  20  ( FIG. 4B ) by inserting the first side  29  of the lamp cup  26  into the first side  23  of the transition strap  20  and inserting the second side  30  of the lamp cup  26  into the second side  24  of the transition strap  20 . Conductors  49  ( FIG. 2 ), such as, without limitation, insulated electric wires, are inserted from the terminal block  18 , through the transition strap  20 , the light ballast  25 , the center opening  74  in the first clamp plate  48 , the center opening  31  of the lamp cup  26 , and into the light socket  36  ( FIG. 5B ). The lower end  21  of the transition strap  20  is inserted into the opening  39  in the upper end  15  of the upright tube  14 . Each of the legs  73  of the first clamp plate  48  is inserted into the opening  39  in the upper end  15  of the upright tube  14 . 
         [0042]    Referring to  FIG. 7 , the method further comprises attaching together the hood  52  ( FIG. 7C ) and the second clamp plate  50  ( FIG. 7A ) by mounting the hood  52  atop the second clamp plate  50 ; aligning the two openings  54  (only one opening is shown) in the lower end  53  of the hood  52  with a corresponding one of the two openings  88  (only one opening is shown) in the two legs  85  of the second clamp plate  50 ; employing a press nut  81  at each of the openings  88  in each of the legs  85  of the second clamp plate  50 ; and inserting a bolt  82  in each of the openings  54  in the lower end  53  of the hood  52 , each of the bolts screwably attaching into a corresponding one of the nuts in the legs of the second clamp plate  50 . 
         [0043]    Referring to  FIGS. 4-7 , the method further comprises connecting together the second clamp plate  50 , the selected number of interposed lens rings  40  ( FIG. 6A ) and the selected number of light deflectors  42  ( FIG. 6B ), the lamp cup  26  and the first clamp plate  48  by inserting a fastener  56  ( FIG. 7B ) into one of four peripheral openings  87  in the upper end  84  of the second clamp plate  50 , into a corresponding one of the four openings  47  in the four ears  45  of the selected number of light deflectors  42 , into a corresponding one of four peripheral openings  32  in the upper end  27  of the lamp cup  26 , and into a corresponding one of the four peripheral openings  75  in the upper end  72  of the first clamp plate  48 . 
         [0044]    Referring to  FIGS. 3-5 , the method further comprises attaching the lamp cup  26  and the first clamp plate  48  to the upper end  15  of the upright tube  14  by placing four openings  41  in the upright tube  14 , inserting the four legs  73  of the first clamp plate  48  into the upright tube  14 , mounting the lamp cup  26  atop the first clamp plate  48 , aligning the four openings  34  (two openings are shown) in the lower end  28  of the lamp cup  26  with the four openings  76  (two openings are shown) in the four legs  73  of the first clamp plate  48  and with the four openings  41  in the upright tube  14 , inserting a press nut  81  into each of the openings  76  in the legs  73  of the first clamp plate  48 , and inserting a bolt  82  into each of the openings  34  in the lower end  28  of the lamp cup  26 , into a corresponding one of the openings in the upright tube  14 , and into a corresponding one of the openings  76  in the legs  73  of the first clamp plate  48 , each of the bolts screwably attaching into a corresponding one of the press nuts in the openings  76  of the legs  73  of the first clamp plate  48 . 
         [0045]    Referring to  FIGS. 2 and 8 , the method further comprises attaching the lower end  13  of the mounting base  12  to a surface  68  by inserting bolts  82  into each of the four openings  19  in the lower end  13  of the mounting base  12  and fixedly attaching each of the bolts to the surface  68 . The surface may include, without limitation, wood, concrete or asphalt. 
         [0046]    Referring to  FIGS. 1 ,  2  and  5 , the method further comprises interposing three lens rings  40  ( FIG. 2 ) and two light deflectors  42  when a five watt fluorescent bulb  62  ( FIG. 1A ) is selected for use in the bollard light assembly  10  ( FIG. 1A ); interposing four lens rings  40  ( FIG. 2 ) and three light deflectors  42  when a seven watt fluorescent bulb  63  ( FIG. 1B ) is selected for use in the bollard light assembly  10 ′ ( FIG. 1B ); interposing five lens rings  40  ( FIG. 2 ) and four light deflectors  42  when a nine watt fluorescent bulb  64  ( FIG. 1C ) is selected for use in the bollard light assembly  10 ″ ( FIG. 1C ); and interposing five lens rings  40  ( FIG. 2 ) and four light deflectors  42  when a thirteen watt fluorescent bulb  65  ( FIG. 1D ) is selected for use in the bollard light assembly  10 ′″ ( FIG. 1D ) 
         [0047]    In another embodiment of the present invention, there is provided a lighting bollard assembly  10 ,  10 ′,  10 ″,  10 ′″ ( FIG. 1 ) manufactured according to the methods of the present invention. 
         [0048]    While specific embodiments of the present invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the claims appended and any and all equivalents thereof.