Cove lighting

A light apparatus is mounted to a surface of a building. The apparatus has at least one elongate mounting extrusion engaged to the surface. At least one elongate trim extrusion is mounted to the mounting extrusion and extending forward therefrom. The trim extrusion has a forward edge and an upwardly and rearwardly sloping surface extending from the edge. At least one light source is mounted to at least one of the mounting extrusion and trim extrusion.

BACKGROUND OF THE INVENTION

The invention relates to electric lighting. More particularly, the invention relates to light fixtures for indirect lighting.

Well-developed fields exist in indirect lighting and architectural lighting fixtures. A particular area of indirect lighting is known as cove lighting. In a typical cove lighting situation, an upwardly open channel structure is built along a wall near the ceiling. The wall may be a side wall of the room, a sidewall of a recess in the ceiling, a side surface of a beam, or the like. Light bulbs are mounted within the channels so that the emitted light escapes generally upward to directly light the wall and ceiling above and, indirectly, an interior of the room and its contents. The channels are built with conventional building techniques involving framing, sheetrocking/plastering, and the like.

Alternatives involve elongate fixtures used for cove lighting. Such fixtures typically include an elongate bulb within an elongate reflector positioned so that light from the bulb and reflector does not directly pass to objects within a room but, rather, is first diffusely reflected from a ceiling, wall, or other architectural feature. Such fixtures may be assembled end-to-end in lieu of placing fixtures within a preexisting channel. Exemplary systems are shown in U.S. Pat. Nos. 4,881,156, 5,550,725, 7,249,870 and 7,658,518. Although its prior art status is unclear, a so-called “edgeless cove” lighting system from Whitegoods Lighting Ltd. has a tapering edge extrusion having a recess which receives wallboard forming the underside of the cove perimeter.

SUMMARY OF THE INVENTION

Accordingly, one aspect of the invention involves a light apparatus mounted to a surface of a building. The apparatus has at least one elongate mounting extrusion engaged to the surface. At least one elongate trim extrusion is mounted to the mounting extrusion and extends forward therefrom. The trim extrusion has a forward edge and an upwardly and rearwardly sloping surface extending from the edge. At least one light source is mounted to at least one of the mounting extrusion and trim extrusion.

Another aspect of the invention involves a light apparatus having at least one light source. First means is installable to a building wall for mounting a remainder of the apparatus to the wall. Trim means presents a rearwardly-diverging edge portion.

Another aspect of the invention involves a method for assembling a light apparatus to the surface of a building. At least one mounting extrusion is screwed to the surface. At least one trim extrusion is downwardly hinged to the at least one mounting extrusion. A plurality of light sources are assembled to at least one of the trim extrusions and mounting extrusions.

Another aspect of the invention involves a light apparatus comprising at least one light source. First means is installable to a vertical surface of a blocking member, the cove wall of a building for mounting a remainder of the apparatus to the wall and for receiving a skim coat across a junction with a wallboard member. Trim means is mountable to the first means.

Another aspect of the invention involves a method for assembling a light apparatus to a vertical surface of a blocking member of a cove of a wall of a building. At least one mounting extrusion is secured to the surface. At least one trim extrusion is mounted to the at least one mounting extrusion. A plurality of light sources are assembled to at least one of the trim extrusions and the mounting extrusions. At least a wallboard piece is secured above the mounting extrusions.

DETAILED DESCRIPTION

FIG. 1shows a light fixture assembly20mounted to a surface22of a wall24. The wall may be a wall of a room, a wall of a ceiling cove26, a side of a structural beam, or the like or combinations. The exemplary cove26is above a main portion28of the room. The fixture assembly may be positioned adjacent to and slightly below a ceiling or ceiling portion30. For convenient reference, a forward direction500is defined as away from the wall. An upward direction is shown as502. With left and right defined from the point of view of a person standing upright and facing in the forward direction, the fixture assembly may extend from a left end to a right end. The assembly may include one, two, or more individual fixture units or subsystem units assembled or otherwise arranged end-to-end. This bi-direction504of assembly is identified as longitudinal. In the exemplary cove mounting situation, the ceiling portion30is along the cove26and a ceiling portion34is laterally beyond the cove.

The exemplary fixture assembly provides the appearance of an integral part of the building. In the exemplary implementation, at least portions of the fixture assembly are installed prior to installation of adjacent wallboard, finish plastering, and the like. Specifically, the exemplary fixture assembly presents a continuation36of the ceiling34beyond the cove with the continuation extending across the opening of the cove26. The fixture further presents an aesthetically sharp edge (corner when viewed in section)40at the cove opening. The exemplary fixture further provides a tapering region42rearwardly diverging from the edge40. The exemplary tapering region42has an underside44and an upper surface46. In the exemplary implementation, the underside44is generally horizontal whereas the upper surface46extends off horizontal at an angle θ. The exemplary surface46has a length LS(when measured in transverse section from the edge40to a rear end/edge48). Exemplary LSis 50-200 mm, more particularly, 80-150 mm. An exemplary θ is 20-50°, more narrowly, 30-45°.

The exemplary fixture assembly20is shown in an exemplary mounting situation mounted (e.g., screwed) directly to a blocking member50forming a lower forward edge of a wall substructure of the cove wall. The exemplary blocking member50is a piece of dimensional lumber (or metallic substitute) transversely horizontally extending (e.g., in the longitudinal directions of the fixture). The exemplary blocking member may be mounted to additional framing members (not shown). The exemplary blocking member50has, in section, an upper surface (top)52, a lower surface (underside)54, a front surface56, and a rear surface58. In the exemplary implementation, wallboard60(e.g., gypsum board, plasterboard, or the like) of the wall24(providing a lateral wall/perimeter of the cove) extends partially along the front face56and wallboard62extends along the lower face54(providing the ceiling outboard of the cove). The exemplary wallboard60, in vertical section, extends from an upper edge (not shown) to a lower edge64and has front and aft surfaces. Similarly, the wallboard62extends from a rear edge (not shown) to a front edge66and has upper and lower surfaces. In the longitudinal direction504, the wallboard60and62may be represented by multiple edge-to-edge pieces ultimately secured via conventional techniques.

The assembly20may comprise several subsystems. A first exemplary subsystem is a wall-mounting subsystem80. The exemplary subsystem80includes an end-to-end array of mounting members82. Exemplary mounting members82are extrusions (e.g., of an aluminum alloy) having a convoluted profile so as to form the gross features shown and described. Adjacent twos of the members82are joined by connector plates84(e.g., aluminum, steel, or plastic) spanning their junctions. The members82may be secured to the wall24by fasteners86(FIG. 2, e.g., screws, toggle fasteners, or the like). Further structural details of the exemplary subsystem80and members82are discussed below. In this particular implementation, the members82are secured to a lower portion of the forward surface56of the blocking member proximate the lower surface54.

A second subsystem is an electrical subsystem90(FIG. 1). The exemplary electrical subsystem includes a light source. An exemplary light source may include one or more receptacles. The exemplary electrical subsystem includes units having aft and front receptacles96carrying bulbs98(e.g., “seamless”-type fluorescent tubes) for emitting light. The receptacles are mounted on and carried by a gear tray100which in the exemplary embodiment is attached to the wall-mounting subsystem. InFIG. 1, a ballast102is shown carried by the tray100. Receptacle/tray/ballast combinations may be longitudinally arrayed end-to-end. In several alternative variations, a single ballast may power more than just the adjacent bulb(s). In other variations, there may be more complex interrelationship of the bulbs such as longitudinal staggering of receptacles for conventional tubes to reduce dark spots. Various permutation of known and unknown electrical connections may be used to connect the ballasts to external power (potentially including various daisy chaining of individual units, slaving of individual units, and the like). Additionally, alternative light sources may include light emitting diode (LED) strips or other lighting technologies instead of fluorescent tubes.

A third subsystem is a trim subsystem140mounted to the wall-mounting subsystem and provides a structure for forming the edge40and tapering region42. As is discussed further below, the exemplary trim subsystem140includes a plurality of extrusions142(e.g., also aluminum alloy) mounted to the extrusions82.

FIG. 2shows further details of the extrusion82. The exemplary extrusion82has a rear portion150for mating with the blocking member surface56. The exemplary extrusion82has a forward portion152for mating with the associated trim extrusion(s). An underside of the extrusion82has an aft portion154then a portion156immediately forward thereof and upwardly offset/stepped. In the installed condition, the portion154is adjacent/flush to the blocking member underside54. The stepping allows an aft portion of the extrusion(s)142to be accommodated by the step so that its underside is flush with the surface portion154and blocking member underside54. At a forward end, the forward portion152includes a hinge moiety160for engaging a complementary moiety of the trim extrusion(s). The exemplary extrusion82(as extruded) at the moiety160defines a pivot channel162having an axis520. Essentially coaxial with the channel162is an annular segment groove/channel164(discussed below).

The surface portions154and156are along the underside of a generally stepped lower horizontal web structure of the extrusion. In the portion150, a vertical web170extends upward from the lower horizontal web to an upper rail structure172comprising an upper wall174and a lower wall176spaced therefrom by a channel178. In the exemplary configuration, the web170connects to the wall176and is forwardly shifted from the surface56to define an open channel180having slightly inwardly protruding upper and lower rims so as to provide a slot for capturing the plates84. As is discussed further below, surfaces of the walls174and176adjacent the channel178may be extruded with serrations for providing a biting engagement with skim coat. In installation, the rear portion of the mounting extrusion82is butted up against the surface56and one or more screws86are screwed through the web70and into the blocking member50or other structure. The extrusion82may be pre-formed (as extruded) with grooves vertically defining the screwing locations (e.g., for self-drilling screws or for aligning drill bits) or may be pre-drilled post extrusion.

FIG. 3shows further details of the trim extrusion142. Each trim extrusion extends from a rear edge200to a forward edge202(which defines the edge40). A rear portion (when in the installed condition)204is formed as a horizontal web extending forward from the edge200. An inclined wall206extends from the forward edge202to a rear edge206which defines the edge48. In the exemplary embodiment, a hinge moiety210extends upward from the web204and includes a pivot bead212complementary to and receivable by the channel162. A coaxial partially annular finger214is complementary to the channel/slot164. During installation, the trim extrusion is angled front-up and shifted (translated) in a generally upward/rearward direction to insert the bead212into the channel162(FIG. 4). Thereafter, it is rotated front downward (clockwise as viewed inFIG. 5) to rotate the projection214into the channel164. This rotation may be stopped by an upper surface220of the web204along a rear portion222thereof coming up against the surface portion156so that the rear portion222is accommodated by the step and the underside224of the web204is flush/coplanar with the surface portion154. At this point, engagement of the projection214with an outer surface of the channel164prevents the trim extrusion from falling out of its installed position. The trim extrusion may, however, be further secured by fasteners such as screws230(FIG. 5). Exemplary screws230pass through pre-drilled holes in the hinge moiety160(e.g., through an upper web thereof) so that the end of the screw, when installed, locks between the bead212and the projection214.

A variation is shown in the cross-section ofFIG. 8wherein the geometry of the hinge moieties is altered to provide a rearward and downward mating translation of the trim extrusion followed by the front-downward rotation. The mounting extrusion moiety slot opens forwardly and slightly upwardly to receive a rearwardly-projecting bead/knuckle of the trim extrusion moiety. The trim extrusion moiety rear portion has an upwardly open serrated screw slot to receive a screw through (e.g. through a pre-drilled hole in the mounting extrusion). The mounting extrusion includes a forwardly open slot to receive a projection of the rear end of the tray. The tray projection may be inserted into the slot and the tray rotated front-downward into position (or may simply be downwardly installed and shifted rearward to engage projection and slot). Forward of the trim extrusion hinge moiety, the trim extrusion includes an upwardly open serrated screw slot for receiving screws to secure a forward projecting portion of the light tray(s).

When all the trim members are put in place,FIG. 5further shows light blocking plates234(e.g., formed of sheets of spring steel or cold-rolled steel with pre-formed bend creases positioned across the gaps). In the particular embodiment, along the upper surface of the web204, there is a forward barb236which accommodates a lower edge of the light blocking plate234. An opposite portion of the light blocking plate is captured by a recess near the rear edge208. The light blocking plates234and connector plates84may extend symmetrically across the junctions between their associated extrusions. Exemplary end-to-end lengths of such plates234and84may be of any appropriate size (e.g., from an exemplary 20 mm to an exemplary 200 mm).

FIG. 5further shows a channel structure250joining the web204to the inclined wall206. The structure250is defined by an aft wall252joining a leading edge of the web204to the inclined wall206and a forward wall254. The exemplary channel256between the walls252and254has a filleted/relieved opening/inlet and convoluted sides. The channel256serves for capturing fasteners260securing the wallboard62(FIG. 6).

Depending from the inclined wall206near the forward edge202are a plurality of walls270whose lower ends272are slightly vertically recessed above a flat surface274extending rearwardly from the edge202. This vertical recessing and the channels276between the walls and a gap278aft of the trailing wall all provide volume for accommodating a skim coat280(FIG. 7) applied after the fastening of the wallboard62.FIG. 7also shows skim coat282extending into the channel178as discussed previously. Additional finishing steps may be as conventional in the dry walling art.FIG. 7further shows the light unit being installed via a downward translation in an initially angled condition followed by a back-down rotation. The exemplary light units and mounting extrusions have interfitting features300,302,304, and306for holding the light units in position. The exemplary feature300is a forwardly projecting sheetmetal foot captured in a recess302behind the hinge. The exemplary feature304is a depending vertical sheetmetal projection received in a vertically upwardly open channel306.

For manufacturing and shipping purposes, the extrusions may be formed in one or more standard lengths. One exemplary length is standard US 8-foot length. If shorter pieces are required to complete a given leg of a system, these may be cut from the stock material. Alternatively, smaller standard sizes may also be provided such as 4-foot and 6-foot or their SI/metric equivalent for countries outside the US. In the exemplary system, the length and nature of the individual lighting trays may be influenced by the particular bulbs desired to be used. Trays may be assembled end-to-end and, therefore, do not have to correspond to length of the extrusions. The selection of trays and their arrangement may be made to provide even lighting along the length of any given leg or to provide a desired variation in light along that leg. Trays may overlap junctions between extrusions.

Exemplary depths between the fixture forward edge and the mounting surface of the blocking member are approximately 6-18 inches with particular examples in the range of 8-13 inches. For example, an exemplary 8.625 inch length when used with 0.625 inch wallboard results in an 8-inch protrusion. Thus, nominal protrusions of 8, 10, and 12 inches might be made available in a given series of fixtures. SI/metric equivalents could also be provided.

FIGS. 9 and 9Ashow a given length of extrusion with light blocking and alignment members protruding from one end for mating with the adjacent opposite end of another such extrusion or corner piece.FIG. 9also shows sockets/receptacles96for mating with seamless-style fluorescent tubes98.

In either of the exemplary systems, interior350(FIG. 10) or exterior352(FIG. 11) corners may be provided to join one mounting extrusion and trim extrusion pair to another such pair. These may be formed of the same as-extruded stock used for the mounting extrusions and trim extrusions. The two pieces may be secured to each other such as via screws and may be mitered to form the associated interior or exterior corner. Exemplary interior corners are 90 degree corners and exemplary exterior corners are 270 degree corners. However, other angles may be appropriate for other angles of wall intersections. The corner members may be attached to the adjacent extrusion pairs via similar mounting plates as are used to span the junctions of end-to-end pairs. For example, to form a 90 degree corner member, two pieces of the combined extrusion with opposite 45 degree cuts may be mated along those cuts and secured to each other. This securing may be via adhesive, welding, or brackets received in the channels of the extrusion (e.g., bent metal, brackets, or the like). Yet alternative embodiments of the corner pieces involve a single-piece extrusion replacing the mated two extrusion pieces. The single-piece extrusion might be extruded into the overall profile of a mated extrusion pair. Individual pieces could then be cut from this single piece extrusion and assembled to form the corner members.

The exemplary system may have a number of utilitarian advantages. One advantage is economy of contractors. For example, different contractors may serve different purposes. There may be a structural contractor who installs the building framing and the blocking members, a sheetrocking/plastering contractor for installing the sheetrock, a lighting installer, and an electrician (if not also the lighting installer). The exemplary system allows the lighting installer to install before the sheetrocker has done any work. This is distinguished, for example, from a situation wherein the sheetrocker must apply some sheetrock before the fixtures are installed and some sheetrock after the fixtures are installed. With the blocking member (or other structure) in place, the lighting installer (if different) may install at least the key structural portions of the lighting system. Thereafter, the sheetrocker may install the sheetrock, including the applying of the joint compound, depending on the situation, painting may then occur. The lighting trays may be installed and wired thereafter allowing them to avoid damage or contamination. This may, for example, allow use of spray paint without need to protect the light sources.

A second embodiment400(FIG. 12) differs from the first embodiment in terms of the underside of the cove structure presented. In this embodiment, the sheetrock62ends at the blocking member and the lighting system provides a smooth underside402flush with the underside of the sheetrock62. In this embodiment, the rear portion of the mounting extrusion is positioned downwardly protruding from the underside of the blocking member by slightly less than the thickness of the sheetrock. Construction of the mounting extrusions and the trim extrusions is otherwise similar to the first embodiment except that the trim extrusion is characterized by a single bottom web having a smooth underside and extending essentially the full depth of the fixture (e.g., the stepped interaction is eliminated). When installed, the underside of the web of the trim extrusion is flush with the underside of the wallboard62.

FIG. 13shows gear trays420having receptacles422slightly diagonally offset from each other so that the associated conventional fluorescent tubes424are slightly diagonal and, thereby, interleave at their adjacent ends to avoid dark spots. It can be seen that the gear trays may span junctions between extrusions.FIG. 13Aalso shows a combination alignment and light-blocking clip440which may be formed as a sheetmetal assembly interfitting adjacent ends of the adjacent extrusions.FIG. 13Aalso shows a reveal spacer442secured abutting the end faces of the extrusions along one end. The exemplary reveal spacer is fastened (e.g., screwed) to one of the two adjacent pair of extrusions so as to create a predetermined minimum space between adjacent fixtures (or a fixture and a corner). By creating this minimum spacing (e.g., 1-5 mm) slight variations in spacing caused by alignment issues are not as perceptible as if one endeavored to butt the extrusions directly end-to-end.

FIGS. 17 and 18show respective interior and exterior corner assemblies for use with theFIG. 12fixture.

One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, various elements may be combined or further separated. Additionally, a variety of structural shapes and cooperating features of the extrusion are possible. Various other manufacturing techniques and materials may be used. Multiple bulb and multiple reflector embodiments are also possible. Architectural/design considerations may influence any particular implementation, giving rise to the possibility of mounting on non-vertical surfaces and mounting in non-horizontally extending arrays. Accordingly, other embodiments are within the scope of the following claims.