Abstract:
An improvement in a recessed lighting strip that interlocks between insulated roof panels is presented herein. The recessed lighting strip uses mating interlocks to snap between the insulated panels, providing a method to place lights at each panel juncture across the width of the application, without violating the integrity of the panels themselves. The lighting strip is made from extruded plastic or aluminum that is essentially an open-topped rectangular box, shaped on the sides to interlock with foam insulated room panels that are typically 3″-6″ thick and used in the construction of patio covers, patio enclosures, sunrooms and all other residential and commercial applications which use insulated roof panels.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of design application 29/351,581 filed Dec. 8, 2009 and provisional application 61/311,475 filed Mar. 8, 2010 the entire contents of which is hereby expressly incorporated by reference herein. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable 
       INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    1. Field of the Invention 
         [0006]    This invention relates to improvements in recessed lighting. More particularly, the present recessed lighting is a strip that interlocks between insulated roof panels in patio covers, patio enclosures, sunrooms and all other residential and commercial applications which use insulated roof panels. 
         [0007]    2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98 
         [0008]    Lighting inside a patio cover is difficult because the insulated panels do not have any electrical wiring running through the insulated panels. There are products that are currently available that modify of the original foam insulated panel by drilling holes into the existing panel and lights are places into those drilled holes. Several products and patents have been issued that provide a retrofit solution to incorporate lighting into the patio covers. Exemplary examples of patents covering these products and methods are disclosed herein. 
         [0009]    U.S. Pat. No. 7,618,167 issued to Sylvain Bedard on Nov. 17, 2009 discloses a recessed light fixture, with a securing system that clamps onto a flat surface. This patent does not disclose installation as an elongated panel that is interchangeable with existing patio covers. 
         [0010]    U.S. Pat. No. 5,927,845 issued to Thomas L. Gustafson et al issued Jul. 27, 1999 and U.S. Pat. No. 6,659,623 issued to Ross Anthony Friend, issued on Dec. 9, 2003 both disclose a strip lighting system that is installed in the ground or in a receiving recess. These lighting strips are for placement on or within a ground or wall surface to provide illumination. While these patents disclose an elongated illumination strip they do not anticipate a lighting system that operates with a roof panel. 
         [0011]    U.S. Pat. No. 7,607,812 issued to Steven Kim on Oct. 27, 2009 discloses a light emitting diode panel fixture. The LED strip attaches to a light guide panel. While these patents disclose an elongated illumination strip it does not anticipate a lighting system that operates with a roof panel. 
         [0012]    What is needed is a lighting strip made from extruded aluminum that is essentially an open-topped rectangular box, shaped on the sides to interlock with foam insulated room panels that are typically 3″-6″ thick and used in the construction of patio covers, patio enclosures, sunrooms and all other residential and commercial applications which use insulated roof panels. 
       BRIEF SUMMARY OF THE INVENTION 
       [0013]    It is an object of the recessed lighting strip for insulated roof panels for the light strip to be self-contained whereby the light strip is fabricated with the light(s) and wiring that allows the light strip to be interlocked with the ceiling or wall panels. The wiring can then be connected to a junction or switch box by an electrician. The panels can be installed in both a horizontal configuration for a ceiling or in a vertical configuration for installation on a wall. In addition to providing lighting the panels can also be configured for the installation of speakers, sound connection ports or electrical switch outlets or control boxes such as switches. 
         [0014]    It is an object of the recessed lighting strip for insulated roof panels for the light strip to be configured in a plurality of compatible ceiling or wall panels. Each manufacturer of ceiling or wall panels may have a unique interlocking system that ensures that future expansion can only be made from the same manufacturer. This requires the extrusion(s) to be configured in heights of four, six, eight inches or more based upon the insulation and structural properties that are desired. A panel can vary from 2′-30′ in length, depending on individual application. The width of the ceiling or wall panels is also variable to ensure that the panel has a similar appearance. The panels can also be fabricated, coated or otherwise treated to match the color and or texture of other ceiling or wall panels. 
         [0015]    It is an object of the recessed lighting strip for insulated roof panels for the light strip for the panel to be fabricated from an extrusion process that produces the panel from plastic, aluminum or other metals or recycled materials. Most ceiling or wall panels are fabricated from aluminum or plastics to provide some structural strength. The extrusions are fabricated or can be filled with insulating material to improve the thermal, acoustical and structural properties. 
         [0016]    It is an object of the recessed lighting strip for insulated roof panels for the light strip to be fabricated to accommodate a wire chase or conduit to aid in wiring, wire protection and or electrical installation. This feature can be extruded with the panel or can be added with bonding or fastening. 
         [0017]    It is still another object of the recessed lighting strip for insulated roof panels for the lighting strip to be fabricated from any ferrous or non-ferrous metals besides aluminum, or any material such as plastic, carbon fiber or fiberglass capable of being formed into the required shape while maintaining a requisite strength and weather resistance. 
         [0018]    Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         [0019]      FIG. 1  shows an isometric view of a first preferred embodiment of the recessed lighting strip. 
           [0020]      FIG. 2  shows an isometric view of a second preferred embodiment of the recessed lighting strip. 
           [0021]      FIG. 3  shows an isometric view of a third preferred embodiment of the recessed lighting strip. 
           [0022]      FIG. 4  shows an isometric view of a forth preferred embodiment of the recessed lighting strip. 
           [0023]      FIG. 5  shows an isometric view of a fifth preferred embodiment of the recessed lighting strip using the strip from  FIG. 4 . 
           [0024]      FIG. 6  shows an isometric view of a first preferred embodiment of the recessed lighting strip. 
           [0025]      FIG. 7  shows an isometric view of the recessed lighting strip fabricated out of sheet metal. 
           [0026]      FIG. 8  shows a sectional view of a panel with mating foam cores. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]      FIGS. 1 to 5  show various configurations of an extruded profile that creates various embodiments of the initial shows that forms the lighting strip. Each profile is uniquely configured to mate with the insulated roof panel from different manufacturers. In  FIG. 5  the lighting strip is configured from an assembly of three pieces where the bottom piece  24  is the extrusion that is shown in  FIG. 4 . 
         [0028]    A lighting strip  10  is preferably made from extruded aluminum of a thickness between 0.0625″ and 0.1875″, between 6″, 8″ and 12″ wide and between 3″, 6″ and 8″ high, depending on version. The light strip is essentially an open-topped rectangular box, shaped on the sides to interlock  30 - 33  with foam insulated room panels (3″-8″ thick) used in the construction of patio covers, patio enclosures, sunrooms and all other residential and commercial applications which use insulated roof panels. While these specific dimensions are stated they are variable based upon the insulated wall or roof panel they are mated with. 
         [0029]    In a single piece body construction with a solid bottom (as shown in  FIGS. 1-4 ), the solid bottom  40  is cut and fitted with one to eight or more listed recessed light fixture having 4″-8″ diameter circular recessed lights  70 , wired in series, then capped with a separate weather resistant top  50  as shown in  FIG. 6 . 
         [0030]    End cap(s)  60  (front and rear) may be attached for additional weather resistance. Either end cap  60 , as well as the top cap  50 , can be fitted with an electrical junction box  80  (as shown in  FIG. 7  to allow wiring to the home and to additional lighting strips. Products will vary from 2′-30′ in length, depending on individual application. 
         [0031]    All elements listed prior to this are essential to the finished product. Dimmer switches could be added to the lighting circuit to vary the amount of light at any one time. Special orders could be placed for color matching the extruded framework to existing panels. 
         [0032]    One to eight or more listed recessed light fixture  70  is fitted into holes  41  cut in a framework  40  of extruded aluminum and then wired in series. This wired construct is then capped with a weather resistant top  50 . The sides of the finished construct are shaped during the extrusion process to provide an interlocking  30 - 33  connection between foam insulated panels marketed for roof construction in patio covers, patio enclosures, sunrooms and a wide range of residential and commercial applications. The front and rear of the box are fitted with protective weather resistant caps  60 , and either can be fitted with the electrical connection point or junction box  80  to join the strip to the home lighting circuit and/or another light strip. 
         [0033]    The shape of the body is two-fold. The interior box construction allows for the cutouts for insertion of the recessed lighting fixtures and all associated wiring. Wiring for any additional accessory items such as speakers, security cameras, etc. would also be run inside this interior space. The exterior shape of the sides provides for the connection between the construct itself and the insulated foam panels previously mentioned for construction purposes. The aluminum extrusion would be capped  50  with a separate aluminum top cap  50  which is insulated on the interior. This top cap  50  is to be caulked  51  and attached with screws  52  to provide weather resistance. Lighting strips made from materials other than aluminum will have appropriate caps constructed of a like or similar strength material to ensure the required strength/span limitations are met or exceeded. End caps  60  will provide additional weather resistance, and also allow for the attachment of an electrical junction box  80  to allow for connection to the home/business&#39; electrical power and/or additional lighting strips. 
         [0034]    Aluminum is extruded into the desired shape to allow interlocking with foam insulated panels, and of a size to contain the required number of recessed light fixtures. 
         [0035]    The lighting strip  10  can be made from any ferrous or non-ferrous metals besides aluminum or any material such as plastic, carbon fiber or fiberglass capable of being formed into the required shape while maintaining a requisite strength and weather resistance. Holes  41  are cut to an appropriate size for the insertion of desired circumference lighting fixtures  70  and these are wired in series and sealed in their respective holes, with an appropriate amount of wiring extended for attaching to a power circuit and/or another lighting strip. A separate top cap  50  is shaped for attachment and attached with caulking  51  and screws  52  to provide additional weather resistance. End cap(s)  60  are caulked  51  and attached with screws  52  to provide additional weather resistance and to provide an attachment point for an electrical junction box  80  to allow connection to a power circuit or to additional lighting strips. 
         [0036]    Different sized or colored lights, dimmers, effects (strobes, etc.) could be used. The shape of the box could be altered to allow the lighting to be cast at an angle, such as instead of a flat bottom it could be “V” shaped. Also, directional lighting adapters could be placed in the fixed sockets to project the lighting in alternate directions. Light fixtures could be placed closer or farther apart. The lighting strip could be made taller and/or wider, allowing for upward directional lighting as well as downward, also horizontal “security” or “mood” or “area” lighting could shine outward from the strip. Entertainment or security options such as music or communications speakers as well as security or internet cameras could be installed inside the lighting strip with the lights. The interior of the lighting strip  10  provides additional space for additional wiring. It is also contemplated that heat lamps could either replace or be used in conjunction with regular lighting to provide heat or other health benefits. The lighting strips  10  can also be placed vertically as a wall structure in order to space light evenly throughout a space, for example, a paint booth or photographic studio. 
         [0037]      FIG. 5  shows an isometric view of a fifth preferred embodiment of the recessed lighting strip using the strip from  FIG. 4 . In  FIG. 4  the recessed lighting strip is an extruded shape  40  having an essentially flat bottom surface, a left surface and a right surface that are essentially perpendicular with said essentially flat bottom  40 . The left surface is configured to connect through a compliant coupling  34  to an upper left surface  25 . The right surface is configured to connect through a second compliant coupling  35  to an upper right surface  26 . The left surface, the upper left surface  25 , the right surface and the upper right surface  26  are configured with complementary interlocking features  30 - 33  that are configured to interlock with roof or wall panels. The extruded bottom shape further can have at least one hole to accept an electrical device such as, but not limited to a light, heat lamp or speaker. 
         [0038]    This invention would be used to provide recessed lighting for a patio cover, patio enclosure, sunroom and all other residential and commercial applications which use insulated roof panels, by having this invention installed concurrently with, and as part of, the construction/decoration project. Retrofitting an existing structure/application would also be possible with some disassembly of the original, and reassembling while placing the lighting strips between the insulated foam panels. 
         [0039]    The embodiment shown in  FIG. 7  is fabricated from bent sheet metal top  50  and bottom  53  pieces that are shown mated with standard roof panel members  54 . The lighting fixture  70  is shown inserted through the bottom sheet metal panel with an electrical junction box  80  mounted on the outside of the sheet metal top cover  50 . The outer ears  55  of the sheet metal top cover bend over the mated bottom pieces  54 . The sheet metal top  50  cover is sealed with caulking  51  and further secured with screws  52 . 
         [0040]      FIG. 8  shows a sectional view of a panel with mating foam cores. This cross section shows the metal top  50  mated onto the extruded frame. The light strip is essentially an open-topped rectangular box, shaped on the sides to interlock  30 - 33  with foam insulated room panels (3″-8″ thick)  82 . The height  81  of the metal top  50  is generally dictated by the height of the lighting fixture  70  plus some additional clearance for convection cooling when the lighting fixture  70  is secured into the bottom  40  of the extruded shape. The metal top  50  is secured or screwed  52  to the extruded housing through a lip  83  that is created between metal top  50  and the extrusion. 
         [0041]    Thermal breaks in the form of a compliant coupling  34  bridges or joins the open-topped rectangular box. The connection between adjoining sections are sealed  51  or caulked to eliminate an air gap between interlocks  30 - 33  and lock adjoining male and female parts  54  together. The width dimension of the light panel is preferably 6 inches across  84  but other wider and narrower dimensions are contemplated. 
         [0042]    Thus, specific embodiments of a recessed lighting strip that interlocks between insulated roof panels have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.