Abstract:
A light assembly combined into a unitary structure with a liquid circulation fitting, such as a water return fitting, for use underwater or above water in a pool, tub, spa, fountain, or similar large liquid container. The combination is well suited for use as a combined underwater light and return water fitting in pools, tubs, or spas, and especially in above-ground pools, and as a combined ornamental light and fountain jet. The unitary structure eliminates the need for more than one hole in the pool wall and thereby simplifies installation and decreases the chance of leaks. The structure provides for both water and air cooling if the light is installed underwater. Furthermore, the structure is connectable to water supply lines of various sizes, and includes a directionally adjustable port to control water returning to the pool or container.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates generally to lights and water or other liquid circulation fittings used in pools or other liquid containers. More particularly, the invention relates to underwater or above-water pool lights and is especially well suited for installation in above-ground pools, vinyl liner pools, ornamental fountains, tubs and spas. 
     An underwater pool light generally requires that a hole be made in the wall of the pool for installation. This increases the chance of leaks and sometimes requires extra reinforcing of the pool wall. 
     A return water inlet fitting also requires that a hole in the wall of the pool for its installation and connection to a circulation pump. This also increases the chance of leaks. 
     Many available pool lights cannot be used in vinyl liner pools because their mounting may require a niche in the pool wall. Other underwater lights cannot be used in vinyl liner pools because of their large size and weight. 
     Another common difficulty is that some underwater lights must be removed and completely disassembled just to replace a bulb, adding to their inconvenience and requiring experienced personnel for maintenance. Other lights have no means of cooling or may have just one, less than adequate, method of cooling, resulting in reduced bulb life and increased maintenance costs. 
     Another drawback of some underwater lights is their use of clear covers or lenses, providing no directional control over the light output. These lights have a tendency to illuminate not just the pool but also the surrounding area. The resulting glare is both an inconvenience and a safety hazard. 
     It will be appreciated from the foregoing that there has long been a need for improvement in the field of lights for pools and other large containers of liquids, and specifically in the field of underwater pool lights. In particular, there has been a need for a pool light that does not require an additional opening to be made in the wall of a pool, thereby reducing installation cost and the chance of leaks. Ideally the light should provide for adequate cooling, should be easy to maintain, safe to operate, and able to direct the flow of water to aid a pool skimmer in collecting debris. The present invention satisfies all these requirements. 
     SUMMARY OF THE INVENTION 
     The present invention resides in a combination of a light assembly and a liquid circulation fitting formed as a unitary structure. Briefly, and in general terms, the invention includes a light assembly for installation in a liquid container, and a liquid circulation fitting through which liquid flows to or from the container. 
     More specifically, in one preferred embodiment of the invention, the liquid circulation fitting is a return water inlet fitting formed integrally as a unitary structure with a light assembly to be installed in a single opening in the wall of a pool, tub or spa, and is connected to a water circulation pump that returns circulating water from the pump. 
     The unitary structure of the invention includes means for cooling the light assembly, thereby extending its life by reducing possible damage due to overheating. Cooling the light assembly is effected by means for circulating water around it and means for circulating air within it. Venting for the air circulation is provided through vents in an electrical junction box external to the pool but coupled to the light assembly. 
     The means for circulating water around the light assembly has a water line fitting for coupling the circulation pump to an opening in the return water inlet fitting, and a directionally adjustable port surrounding the light assembly. The means for circulating water around the light assembly is sealed from the light assembly with a water tight seal. The directionally adjustable port permits the water to emerge into the pool in any desired direction, and provides the capability to control the return flow into the pool in a manner that aids a pool skimmer in collecting debris. This directionally adjustable port includes a rotatable annular element surrounding the light assembly, having a plurality of openings through which water emerges in the desired direction. 
     The water line fitting is designed to accommodate any of a plurality of water line sizes. However, the water return inlet fitting is designed to have a water passage with a cross-sectional area larger than that of the water line, to minimize flow restriction. 
     In the unitary structure of the invention the means for circulating air within the light assembly includes a cavity within the light assembly coupled to a cavity formed by the electrical junction box, these coupled cavities being sealed from the means for circulating water around the light assembly. The electrical junction box has a plurality of exit vents through which heated air can escape to the exterior of the pool wall. 
     The light assembly itself has a light source and a lens that is attached to a face of the assembly. The light source is preferably a low-voltage, high-output quartz halogen bulb. Alternatively, optical fibers can be used to transmit light from a remote source into the structure. The lens serves both to direct light into the pool and to form a watertight light assembly. 
     The unitary structure also includes means for preventing rotation of the light assembly with respect to the return water inlet fitting, and means for releasably securing the light assembly within the unitary structure. These features allow the light assembly to al removal or rotation of the light assembly, so that light is dispersed only in a preferred direction. 
     The unitary structure also includes means for adjustably mounting the device in pools having walls of various thicknesses. Therefore, the structure of the invention can be installed conveniently in existing openings used for water return inlet fittings. 
     Another embodiment of the invention includes multiple lenses through which light passes on its way to the pool, and around which liquid is circulated. 
     It will be appreciated from the foregoing that the present invention represents a significant advance in the field of underwater light fittings for pools, tubs, or spas. In particular, the invention provides an underwater light without the need for an additional hole in the pool wall. In addition the invention provides multiple means of cooling the light assembly, thereby extending the bulb life. The device of the invention is especially suitable for mounting on above ground pool walls, and is adjustable to fit walls of various thicknesses. Further, the device of the invention is also easier to retrofit in existing installations that already include a liquid circulation fitting. In one preferred form of the invention, the water circulated around the bulb for cooling purposes can be adjustably directed to aid the skimmer in collecting debris. Other aspects and advantages of the invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an elevational view of the underwater return light fitting embodying the invention; 
     FIG. 2 is a rear view of the light assembly, showing a flattened portion that prevents rotation; and 
     FIG. 3 is a front view of a rotatable annular element surrounding the light assembly, showing a plurality of openings through which water emerges; 
     FIG. 4 is an elevational view, partly in section, of an alternate embodiment of the invention as used in an ornamental fountain; and 
     FIG. is an elevational view of yet another embodiment of the invention, having multiple lens elements. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As shown in the drawings for purposes of illustration, the present invention is concerned with improvements in the field of light assemblies and liquid circulation fittings. Prior to this invention light assemblies used in liquid containers required a hole in the container wall for the fitting, or to make connection to a power supply. The liquid circulation fitting required another opening to be made in the container wall for its installation and connection for circulation. This need for at least two openings in the container wall increased the possibility of leaks. One preferred embodiment of the invention is concerned with underwater pool lights and water return fittings. 
     In accordance with the present invention, and as shown by way of example in FIG. 1, a return water inlet fitting 5 for connection to a circulation pump to return circulating water from the pump, and a light assembly 10 for installation beneath the water level in a pool, tub, or spa, are combined in a unitary structure 15. The light assembly 10 is mounted inside the return water inlet fitting at the pool wall. 
     More specifically, the return water inlet fitting 5 is generally cylindrical in shape, but is tapered from its front end 16 to a smaller diameter along a central portion of its length to the rear end 18, and has an opening at each end. An external flange 20 is formed integrally with the fitting at its larger diameter end. This flange 20 provides a surface for mounting and securing the underwater return light fitting to the pool wall. The return fitting 5, when installed, is located for the most part behind the pool wall, and has an integral water line slip fitting 25, having portions of different external diameters to accommodate water lines of various sizes. As shown in FIG. 1, the slip fitting 25 extends obliquely from the water return fitting 5, specifically from its tapered central portion. 
     The light assembly 10 has a generally cylindrical body, with a flared conical portion at one (front) end 30, and an end flange 35 adapted to sealably engage a lens 40. The assembly 10 also has a rear end 45 and an externally threaded end portion 50 for engaging a lock nut 55 to which an electrical junction box 60 is attached. The light assembly 10 encloses a bulb 65, socket 70, and an electrical connector 75, while forming an air chamber 80 for cooling the bulb. The electrical junction box 60 has vents 85 to the exterior of the pool for releasing hot air. 
     For mounting in a pool wall, the larger diameter end of the return water inlet fitting 5 is internally threaded, as indicated at 16, to receive a securing ring 90. The ring 90 has a hollow cylindrical body 95, externally threaded at one end 100 to engage the return fitting 5, and having an external flange 105 at its other end. Flange 20 is mounted against the exterior of the pool wall and flange 105 against the interior of the pool wall. Around the opening in the pool wall a gasket 110 is placed between the vinyl liner and the pool wall, and another gasket 112 is held in place against the outside of the pool wall and around the opening as the securing ring 90 is tightened onto the threaded end of the fitting 16, using thumb tabs 115 formed on the flange 105 of the securing ring. This action secures the return water inlet fitting 5 in the opening. 
     The light assembly 10 is also generally cylindrical, with a flared portion at the front end 30 to accommodate the halogen bulb 65, and having an integral external flange 35. Four radial tabs 67 are evenly spaced around the flared portion of the light assembly 10, and abut the securing ring 90 at a rounded edge 113 where the flange 105 joins the securing ring 90. The abutment of these tabs against the flange 105 fixes the distance between the flange 105 or the securing ring 90 and the flange 35 at the front end of the light assembly 10. The lens 40 has an annular slot 120 formed around its perimeter and sized to fit over the flange 35 for ultrasonic welding in place. The lens cover 41 snaps in place around the outer diameter of the lens 40. The halogen bulb 65 fits in the socket 70 located centrally within the front end 30 of the light assembly. An end portion of the rear end 45 of the body 125, is externally threaded, as shown in FIG. 2, but has flattened, i.e. noncircular and therefore nonthreaded region 130 that engages a corresponding region of the opening formed by the internal flange 135 at the end 18 of the return fitting body 5. As best shown in FIG. 2, the flattened region 130 prevents rotation of the light assembly 10 with respect to the return fitting 5. The lock nut 55 engages the externally threaded portion 50 of the light assembly 10 adjacent to the return water inlet fitting 5 to secure the light assembly 10 to the return fitting. 
     The lock nut 55 includes an integral cylindrical flange 140 that serves to secure the electrical junction box 60 in place. The electrical junction box 60 has a cylindrical flange 145 that fits over the rear end 45 of the light assembly 10. 
     A rotatable annular element 150 fits over the opening between the flange 35 on the front end 30 of the light assembly 10 and the flange 105 on the securing ring 90. An internal flange 155 in the element 150 fits behind the flange 35 of the light assembly 10. The annular element 150 also has a rear annular bearing surface 157 that engages a corresponding bearing surface on the flange 105 of the securing ring 90. When the lock nut 55 is tightened to secure the light assembly 10 to the return water inlet fitting 10, the annular element 150 is secured between flanges 35 and 105, but rotation is permitted because the element is sized to fit rotatably in the fixed axial distance between flanges 105 and 35. As shown in FIG. 3, there are a plurality of spaced openings 160 around the perimeter of the rotatable annular element 150, which act to direct the flow of water in a desired direction. Cooling is provided to the light through the openings 160 even when water is not being circulated by the pump. 
     Water from the pump flows through the water line fitting 25, around the light assembly 10, and through the openings 160 in the rotatable annular element 150. The light assembly body 125 also includes two integral external annular ridges 170, together defining an annular space to accommodate an O-ring seal 175, which, when the light assembly 10 is installed in the return fitting 5, engages the wall 180 of the return fitting 5 and prevents water from entering the electrical junction box 60 or leaking from the fitting 5. 
     To install the underwater return light fitting, the return water inlet fitting 5 is secured to the pool wall, the rotatable annular element 150 is placed around the return water inlet fitting 5, and the light assembly 10 is placed through the center of the rotatable annular element 150 and into the return water inlet fitting 5 with the lens 40 facing into the pool with the tabs 113 abutting the securing ring 90. The lock nut 55 is then secured in place, securing the light assembly but allowing the annular element 150 to rotate. Finally electrical connections 75 are made and the electrical junction box 60 is snapped into place. Instead of having a halogen bulb housed in the structure of the invention, the light source may include a bundle of optical fibers for coupling light from a remote location into the structure. This arrangement simplifies the structure to some degree and alleviates the cooling requirements, but requires that a separate housing be provided for a remote light source. 
     As shown in FIG. 4, the device of the invention may be conveniently formed as a combined water and light source in a fountain. Many of the features shown in FIG. 4 are common to those shown in FIG. 1 and like reference numerals have been used wherever appropriate. The principal differences are that the device of FIG. 4 is usually oriented vertically, is mounted on cylindrical pedestal 200, and includes a water outlet fitting 202 that is designed to fit over the light assembly 10 and provide multiple jets of liquid, indicated at 204, emerging from the device at selected angles. Typically, the device of FIG. 4 will be installed almost completely submerged under water, the surface of which is indicated at 206. 
     For some applications of the invention, the water outlet fitting 202 (FIG. 4), or the annular element 150 (FIG. 1), may be self rotating, i.e. the jets may be angled to provide a tangential component that rotates the fitting. In a spa application, this provides additional therapeutic action, and in the fountain application the rotating jets provide a different desired visual effect. 
     FIG. 5 shows yet another embodiment of the invention, in which the light assembly, indicated at 10&#39;, is not surrounded by circulating water. Instead, the light assembly 10&#39; is positioned in a lamp cavity 208, which is well to the rear of an opening 210 through liquid will flow. A lens assembly 212 seals the lamp cavity 208, and a water line 214 supplies water to a body 216, part of which surrounds the lens assembly 12. The lens assembly includes multiple lens surfaces that are integrated into the assembly and provide a desired light pattern, which emerges through the opening 10 with the circulated water. 
     It will be appreciated from the foregoing that the present invention represents a significant advance in the field of light fittings for pools and other large open liquid containers. In particular, the invention combines an underwater pool light with a return water inlet fitting as a unitary structure. Therefore, no additional opening is required to install the light in the pool wall leakage is less likely. Moreover, the circulating water in the return water inlet fitting can be used to cool the light and thereby increase the life of the bulb. It will also be appreciated that, although a specific embodiment of the invention has been described in detail for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. It will be understood, for example, that the principles described in relation to an illustrative underwater pool light and return fitting could also be applied to other large liquid containers having need for both a light assembly and a liquid circulation fitting. The circulation fitting may be returning liquid to the container, or drawing liquid from the container, such as through a pool skimmer. Moreover, the combined light and circulation fitting may be located below or above the surface of the liquid in the container. Accordingly, the invention is not to be limited except as by the appended claims.