Abstract:
An emergency lighting device adapted to be quickly and easily mounted and installed. In one embodiment, a mounting member of the device is first mounted to a desired structure and connected to an external power supply. Once mounted and completed, and emergency lighting assembly is secured to the mounting member. In certain embodiments, securing the emergency lighting assembly to the mounting member connects the device to the external power supply and energizes the device.

Description:
FIELD OF INVENTION 
     This invention relates to emergency lighting devices that may be quickly and easily mounted and installed. 
     BACKGROUND 
     Emergency lighting devices include circuitry that illuminate emergency lights during a power outage using a battery or similar power supply. 
     Because these lighting devices are relied on for emergency situations, they must be tested at the factory to ensure that they function properly. To test a typical emergency lighting device, it must be completely assembled with all of its components (including the back-up power supply) assembled and connected to one another. Next, the device&#39;s circuitry is wired to a testing unit and is tested to ensure that it will function properly during a power outage. After testing, the battery of a typical emergency lighting device must be disconnected from the device&#39;s circuitry. In typical devices, if the battery is not disconnected from the circuitry, the circuitry will remain energized and the battery&#39;s charge may drop below an acceptable level prior to installation. 
     Typical emergency lighting devices are difficult and time consuming to install and are not shipped in a condition ready for installation. Rather, the installer must disassemble the device, perform a number of steps, and then reassemble the device to mount and install it. Because the device is shipped with a disconnected battery, the installer must remove the device&#39;s housing and reconnect the battery to the circuitry. Additionally, the battery, circuitry and other components of the unit may obstruct portions of the housing that must be accessed for mounting and wiring the device. If so, the installer must remove those components, mount and wire a portion of the device, and then reinstall the components and replace the device&#39;s housing to complete installation. 
     Installation of a typical emergency lighting device may require: (1) removing the device from its packaging; (2) removing the device&#39;s cover; (3) disconnecting the wires connecting the device&#39;s lamps to its circuitry; (4) removing the device&#39;s battery; (5) knocking out mounting holes; (6) mounting the device to the desired structure; (7) reinstalling the battery; (8) reconnecting the wires connecting the device&#39;s lamps to its circuitry; and (9) reinstalling the device&#39;s cover. 
     SUMMARY 
     Unlike typical emergency lighting devices, assembly and installation of emergency lighting devices of the present invention proceeds in a relatively quick and uncomplicated manner. Installation of devices of the present invention may be done without disassembling the device or removing any components from it. Rather, emergency lighting devices of the present invention are installed simply by mounting a mounting member to a desired structure (such as a wall, ceiling, or pole), connecting a power source line to the mounting member, and then securing an emergency lighting assembly (including at least a portion of the device&#39;s circuitry, an emergency power supply, and connections for at least one light) to the mounting member. Because it is the mounting member, and not the lighting assembly, that is first mounted and connected to the external power source, the installer does not need to disassemble, remove or disconnect various components, reconnect various components or reassemble the device. Also, because the external power source may be connected without opening the housing of the lighting assembly (as discussed further below), the device can similarly be connected to the wiring or other devices necessary to test the emergency lighting devices without having to disassemble the device to access its internal components. 
     Additionally, the present invention may be shipped from the factory with the battery already physically (but not electrically) connected to the circuitry of the device without the battery losing its charge prior to installation. Consequently, the installer may install the emergency lighting device without opening its housing to reconnect the battery. 
     This invention includes a mounting member and an emergency lighting assembly. The emergency lighting assembly may include one or more lights, a battery and at least a portion of an electrical circuit. In some embodiments the portion of the electrical circuit is incomplete. By leaving a portion of the electrical circuit “open” or incomplete, the battery may remain connected to the portion of the electrical circuit in the emergency lighting assembly after leaving the factory without substantially depleting its charge. Securing the emergency lighting assembly to the mounting member completes assembly of the circuitry by connecting a jumper (associated with the mounting member) to close the circuit. 
     To install emergency lighting devices of this invention, the installer first mounts the mounting member to any desired surface, such as a wall, ceiling, pole or other building structure. Next, the installer connects an external power source to a power supply line connector associated with the mounting member. As discussed above, the mounting member may include a jumper adapted to complete and close the electrical circuit and electrically connect the battery in the emergency lighting assembly when it is secured to the mounting member. After the mounting member is mounted and the external power source is connected, the installer may complete assembly by mechanically securing the emergency lighting assembly to the mounting member. In some embodiments, a plurality of resilient arms secure the emergency lighting assembly to the mounting member. Securing the emergency lighting assembly to the mounting member also electrically connects the external power source to the unit to monitor that power source and recharge the battery. 
    
    
     
       DESCRIPTION OF DRAWINGS 
         FIG. 1  shows a perspective view of an emergency lighting device according to a first embodiment of the present invention. 
         FIG. 2  shows a perspective view of an emergency lighting device according to a second embodiment of the present invention. 
         FIG. 3  shows an exploded view of the emergency lighting device shown in  FIG. 1 . 
         FIG. 4  shows a perspective view of a portion of the emergency lighting device shown in  FIG. 3 . 
         FIG. 5  shows a perspective view of another portion of the emergency lighting device shown in  FIG. 3 . 
         FIG. 6  shows a perspective view of the circuit board shown in  FIG. 5 . 
         FIG. 7  shows schematically a portion of the circuitry of the emergency lighting device shown in  FIG. 3 . 
         FIG. 8  shows schematically a portion of the circuitry of an emergency lighting device in accordance with alternate embodiments of the invention, shown in an open configuration. 
         FIG. 9  shows schematically the portion of the circuitry shown in  FIG. 8 , shown in a closed configuration. 
         FIG. 10  shows a schematic wiring diagram of an emergency lighting device in accordance with alternate embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  shows an emergency lighting device  10  of the present invention. Emergency lighting device  10  includes a mounting member  12  and an emergency lighting assembly  14 . Mounting member  12  is adapted to be mounted to any suitable or desirable structure, such as a wall, a ceiling, or a pole, typically by passing screws through any of numerous locations for such screws molded into mounting member  12  (e.g.  22  shown in  FIG. 3 ). The emergency lighting assembly  14  is adapted to be mechanically secured to the mounting member  12 . 
     With respect to electrically connecting mounting member  12  to emergency lighting assembly  14 , the building&#39;s power cable is first routed through one of the openings  24  in mounting member  12  and attached to a terminal  28  on mounting member  12 . Next, mechanically securing the emergency lighting assembly  14  to the mounting member  12 , as discussed below, completes the electrical connections of the emergency lighting device  10  because edge finger contacts  34  and  46  of terminals  28  and  40  respectively receive contacts  36  and  48  on assembly  14 , thereby connecting the external power source and completing assembly of the device&#39;s circuitry with an electrical jumper  38 . 
     To mechanically secure the emergency lighting assembly  14  to the mounting member  12 , the assembly  14  may be placed over the mounting member  12  such that a plurality of protrusions  16  engage a plurality of corresponding receivers  18 . In the embodiment shown in  FIG. 3 , the plurality of protrusions  16  extend from the mounting member  12  and the receivers  18  are associated with the emergency lighting assembly  14 . 
     As shown in  FIGS. 4 and 5 , protrusions  16  includes a lip  82 , and receiver  18  includes a resilient arm  84  such that inserting protrusions  16  into receivers  18  engage the resilient arms  84  with the lips  82  to secure the emergency lighting assembly  14  to the mounting member  12 . Resilient arms  84  may include a tab  86 , which facilitates using a fingernail, flathead screwdriver or other suitable device to disengage resilient arm  84  from lip  82 , permitting the removal of the emergency lighting assembly  14  from the mounting member  12 . 
       FIG. 4  shows in more detail the mounting member  12  of the emergency lighting device  10  shown in  FIG. 1 . Mounting member  12  may include frangible regions  22 , which close the fastener openings so that passageways completely penetrating mounting member  12  are created only where the screws or fasteners are actually used. 
     As shown in  FIG. 2 , removal of a frangible region  22  may form a keyhole slot in the mounting member  12 . Fastener openings and frangible regions may be formed in any other suitable or desirable shape, the removal of which forms an aperture to receive a fastener  90  to secure mounting member  12  to the desired structure. 
     As shown in  FIG. 4 , mounting member  12  may also include a plurality of frangible portions  24  which, when removed, create entry portals: for a conduit containing power lines  26  from an external power source; for pendant mounting of the mounting member  12 ; or for entry points for wires to connect emergency lighting device  10  to remote emergency lights. In embodiments where remote emergency lights are desired, these lights may be electrically connected through the portals to the circuitry  20  of the emergency lighting device  10  such that the circuitry  20  can control the remote lights.  FIG. 10  shows a schematic wiring diagram including wiring  102  for an remote light  104 . In the embodiment shown in  FIG. 10 , the remote light  104  is wired to the same terminal block  40  as loop of wire  42 . However, in other embodiments, remote light  104  may be connected to the device&#39;s circuitry  20  in any suitable manner. 
     The external power source  26  may be connected to a connector  28  associated with the mounting member  12 . In the embodiment shown in  FIG. 4 , the connector is a terminal block  28 , however, any desired or suitable connector may be used. As shown in  FIG. 4 , terminal block  28  is secured to the mounting member  12  by a number of resilient clips  30  extending from the mounting member  12  which engage terminal block  28  when it is inserted into the resilient clips  30 . However, terminal block  28  may be secured to mounting member  12  in any suitable or desirable fashion, including brackets, screws, nuts and bolts, adhesives, or any other desired device or material. 
     As shown in  FIG. 4 , terminal block  28  includes two screw contacts  32  and two edge finger contacts  34  for receiving and connecting power line  26 . Edge finger contacts  34  are adapted to electrically connect power lines  26  with the circuitry  20  of the emergency lighting assembly  14  shown in  FIG. 3 . When emergency lighting assembly  14  is secured to mounting member  12 , the edge finger contacts  34  engage contacts  36 . Contacts  36  (shown in  FIG. 6 ) extend from circuit board  70 , such that when edge finger contacts  34  engage contacts  36 , electrical circuit  20  is coupled to the external power source  26 . 
     In the embodiment shown in  FIG. 4 , mounting member  12  also includes an electrical jumper  38 . Jumper  38  includes a terminal block  40  and a loop of wire  42 . Loop of wire  42  is secured to terminal block  40  by screw contacts  44  in a similar manner as power lines  26  are secured to terminal block  28 . Also in a similar manner to terminal block  28 , securing emergency lighting assembly  14  to mounting member  12  engages edge finger contacts  46  on terminal block  40  with contacts  48  extending from circuit board  70  (shown in  FIG. 6 ) and associated with electrical circuit  20 . Electrically connecting jumper  38  to electrical circuit  20  in this manner completes assembly of electrical circuit  20 , which is discussed in further detail below. 
     In the embodiment shown in  FIG. 4 , mounting member  12  is substantially planar, however, it may be formed in any suitable shape as desired. A number of slotted ridges  92  allow the various wires associated with mounting member  12  to be secured to retain the wires in unobtrusive locations and orientations. As shown in  FIG. 3 , mounting member  12  may also have surface features  50  which correspond with portions of emergency lighting assembly  14  to facilitate aligning emergency lighting assembly  14  with mounting member  12  to secure one to another. 
     In the embodiment shown in  FIG. 3 , the emergency lighting assembly  14  includes lights  52 , housing  54  (which includes cover member  56  and back member  58 ), a battery  60 , and unassembled electrical circuit  20 . 
     Lights  52  are mounted on cover member  56 . In the embodiment shown in  FIG. 3 , lights may be rotated or positioned in multiple orientations. 
     When housing  54  is assembled, which includes cover member  56  and back member  58 , the housing  54  substantially encloses battery  60  and circuitry  20 . Cover member  56  may be removably secured to back member  58 . As shown in  FIGS. 3 and 5 , a pair of hooks  62  engage a pair of protrusions (not shown) on an inner surface of the cover member  56 , and a pair of paddle shaped resilient arms  64  extending from the back member  58  engage a pair of apertures  66  formed in the cover member  56 . The cover member  56  may be removed from the back member  58  by pressing in the paddle shaped resilient arms  64  and pivoting the cover member  56  off of the back member  58 . In other embodiments, cover member  56  may be secured to back member  58  in any other suitable manner, such as by tabs, snap locks, press fit structures or any other suitable mechanism. 
     In still other embodiments that do not require the housing  54  to be opened to mount and install emergency lighting device  10 , cover member  56  may be non-removable from the back member  58 . 
     Housing  54 , which includes cover member  56  and back member  58 , may be formed in a variety of different sizes, shapes and configurations to accommodate any necessary or desired components. For example, for embodiments using multiple batteries, back member  58  may be formed with an increased depth to accommodate the batteries  60 .  FIG. 2  shows a housing  54  with increased depth. 
     In the embodiment shown in  FIG. 3 , an outer edge  68  of back member  58  substantially defines an oval shape and cover member  56  substantially defines at least a partial egg shape. When assembled, housing  54  fits over mounting member  12  to conceal most of member  12 . 
       FIG. 5  shows in more detail a portion of the emergency lighting assembly  14  of the emergency lighting device  10  shown in  FIG. 3 . In  FIG. 5 , the unassembled electrical circuit  20  is associated with a circuit board  70 , which is mounted on back member  58 . Because the unassembled electrical circuit  20  has not been completed, battery  60  may be connected to the circuitry  20  without losing its charge. Securing the emergency lighting assembly  14  to mounting member  12  completes the assembly of electrical circuit  20 . When emergency lighting assembly  14  is secured to mounting member  12 , edge finger contacts  46  of jumper  38  engage contacts  48  extending from circuit board  70  to electrically connect and engage a connector  48  in a sliding manner. As shown schematically in  FIG. 7 , contacts  48  are electrically connected to a first portion  94  and a second portion  96  of the electrical circuit  20  such that when jumper  38  is connected to contacts  48  the first portion  94  is electrically connected to the second portion  96  by jumper  38 . 
     In the embodiment shown in  FIG. 5 , battery  60  is a rechargeable battery electrically connected to electrical circuit  20 . However, battery  60  may be any suitable device capable of storing power to provide to lights  52  during power outages. Suitable batteries  60  may include rechargeable batteries, dry cell batteries, lead acid batteries, other types of batteries, or any other suitable storage device presently existing or made available in the future. 
     Battery  60  is supported by shelf member  76 . Shelf member may be formed in any suitable shape and dimension to accommodate whatever number and size of batteries  60  desired. Shelf member  76  extends from back member  58 . To further secure battery  60  to back member  58  a strap  78  may be installed over battery  60 . The strap may be formed from any suitable material. In some embodiments hook and loop fasteners may be used as straps  78 . In other embodiments, where a stronger hold is desired between battery  60  and back member  58 , such as when emergency lighting device  10  is intended for ceiling mounting, a metal strap may be used. The strap  78  may be secured to back member  58  by a pair of fasteners engaged in holes  80 . 
     The above description of the drawings is intended to describe the embodiments shown in the drawings. As will be appreciated by those skilled in the art, this invention can be practiced in numerous alternative embodiments in addition to those shown in the drawings and described above without departing from the spirit of this invention or the scope of the following claims. 
     For example, in various embodiments of this invention, the emergency lighting device  10  may be formed from any suitable material, including light weight materials such as polycarbonate plastic, ABS plastic, sheet metal, or any other suitable material. 
     In some embodiments, the emergency lighting device  10  may also include an illuminated or non-illuminated EXIT sign for indicating emergency exits in buildings. 
     In alternative embodiments of this invention, connectors  28  and  36  are not terminal blocks. Rather, connectors  28  and  36  may be any suitable alternative structure for coupling the external power source  26  to the circuitry  20  of the emergency lighting assembly  14 . 
     Also in alternative embodiments, jumper  38  may be replaced with any suitable alternative devices. For instance, a single pole, single throw switch connected to the circuit  20  and mounted on the emergency lighting assembly  14  could be actuated by structure on member  12  when assembly  14  is mounted on member  12 . Alternatively, a double pole, single throw switch could be used to simultaneously connect the batter  20  to the circuit and close the portion of the circuit closed as described above by jumper  38 .  FIGS. 8 and 9  show a switch  74  associated with first and second portions of the electrical circuit  94  and  96  respectively. In the embodiment shown schematically in  FIGS. 8 and 9 , securing the lighting assembly to the mounting member causes a portion of the mounting member  98  to depress a plunger  100  on switch  74  to electrically connect first and second portions of the electrical circuit  94  and  96 .