Abstract:
A mounting platform for a lighting fixture comprising a substantially flat plate and an integral cutting guide. The integral cutting guide includes an aperture formed through the substantially flat plate and a flange formed around a perimeter of the aperture. The flange and the substantially flat plate preferably intersect in a curve and the flange forms an angle of less than (90) degrees with respect to the bottom surface. The mounting platform also includes elongated slots for securing the mounting platform to a ceiling support member. The elongated slots are preferably of a sufficient length to allow the mounting platform to be secured to the ceiling support member to allow placement of the integral cutting guide between the ceiling support member and a second ceiling support member wherein the span between the ceiling support member and the second ceiling support member is in the range of (16 to 24) inches.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to lighting fixtures and in particular to installation of downlights. 
       BACKGROUND ART 
       [0002]    Lighting fixtures, such as recessed or semi-recessed lights, are commonly installed with the assistance of mounting bars. In a new construction setting (i.e. where the ceiling is in a “rough state” allowing for easy access to install electrical, mechanical, plumbing elements, etc.), the lighting fixtures can be installed between the ceiling support members, such as rafters, joist or other similar structures, prior to installing the ceiling. This allows for accurate placement of the light fixtures, but not necessarily accurately cut finish holes. This method is also undesirable because it requires the contractor to purchase and install lighting fixtures well ahead of the intended finish date for the structure. 
         [0003]    Recessed lighting fixtures may also be installed after a ceiling structure is completed, reducing the time between the contractor&#39;s purchases and the completion of the project. This method typically involves using a lighting fixture that has a mounting structure integral to the light fixture, which eliminates the need for using mounting bars. Installation of this type of recessed fixtures requires a specific size hole, directly related to the diameter of the fixture, to be cut through the ceiling material. The fixture is then inserted into the hole and secured to the ceiling material using the provided integral mounting structure. 
         [0004]    Typically, a template, guide or measuring device is required to outline the correct size hole required for the lighting fixture. This requires additional labor and effort to conduct precise measurements to locate and cut an accurately sized hole. When installing the fixtures according to the pre-determined lighting layout, the placement of the fixtures is also entirely dependent on the various measurements of the installer after installation of the ceiling. Therefore, accurate placement of the fixtures is not always achieved, and obstructions behind the ceiling may prevent installation of the light fixture in a desired location. 
         [0005]    Another method for installing a recessed lighting fixture is through the use of a mounting plate. As with new construction installations, the mounting plate is installed prior to the installation of the ceiling material. The plate does not use bar hangers for the method of attachment, but is fastened directly to the narrow flat edge of a ceiling support member that is parallel to the floor. The ceiling is then installed covering the mounting plate. After the ceiling material is completed, the contractor locates the mounting plates and cuts holes in the ceiling using the installed mounting plate as the guide for locating and cutting his hole. The wiring is then completed and recessed lighting fixture is inserted into the hole and secured into place. This method reduces the time between the contractor&#39;s purchases and the completion of the project, but without many of the drawbacks of conventional remodeling installations. 
         [0006]    However, conventional mounting plates include numerous drawbacks. For example, conventional mounting plates are not designed to simultaneously address various construction styles. For example, the same mounting plate cannot be used with ceiling support members that are 16″ apart and with ceiling support members that are 24″ apart. Furthermore, in conventional mounting plate designs, the outside vertical surface of the cylindrical return is required to be used as the cutting guide, causing the plate to be pushed back away from the rear side of the ceiling material when covered by the ceiling material. Accordingly, the plate may not be in the correct position during installation, increasing the possibility of cutting a hole that is oversized, out of round, or both. 
         [0007]    Accordingly, it is desirable to have one mounting platform that addresses all construction styles, allows for a more accurate layout, and reduces the potential for making oversized holes that would cause final installation problems with both the remodel type recessed lighting fixture and the finish trim. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention is a mounting platform for a lighting fixture comprising a substantially flat plate and an integral cutting guide. The integral cutting guide includes an aperture formed through the substantially flat plate and a flange formed around a perimeter of the aperture. In one embodiment, the flange and the substantially flat plate intersect in a curve and the flange forms an angle of less than 90 degrees, and preferably approximately 30 degrees, with respect to the bottom surface. 
         [0009]    The mounting platform may also include elongated slots for securing the mounting platform to a ceiling support member. In one embodiment, the platform may include a first elongated slot positioned proximal to the left edge of the mounting platform and a second elongated slot positioned proximal to the right edge of the mounting platform. The elongated slots are preferably of a sufficient length to allow the mounting platform to be secured to the ceiling support member to allow placement of the integral cutting guide between the ceiling support member and a second ceiling support member wherein the span between the ceiling support member and the second ceiling support member is up to about 24 inches. 
         [0010]    At least one slit may also be positioned proximal to the perimeter of the integral cutting guide and extending in a radial direction from a center of the integral cutting guide. In one embodiment, the mounting platform includes a first slit located proximal to a portion of the integral cutting guide closest to a top edge of the mounting platform, a second slit located proximal to a portion of the integral cutting guide closest to a bottom edge of the mounting platform, a third slit located proximal to a portion of the integral cutting guide closest to a right edge of the mounting platform, and a fourth slit located proximal to a portion of the integral cutting guide closest to a left edge of the mounting platform. 
         [0011]    The mounting platform may also include a first notch in a top edge of the mounting platform, a second notch in a bottom edge of the mounting platform, a third notch in a right edge of the mounting platform, a fourth notch in a left edge of the mounting platform. In one aspect, the first and second notches are in line with a center of the integral cutting guide along a longitudinal axis of the mounting platform, and the third and fourth notches are in line with a center of the integral cutting guide along a lateral axis of the mounting platform. 
         [0012]    In another aspect, the present invention may also include a method for forming a mounting platform for a lighting fixture from a substantially flat plate having an upper surface and a bottom surface. The method includes forming an aperture in the substantially flat plate, and bending a portion of the plate at the perimeter of the aperture more than 90 degrees with respect to the bottom surface to form a flange, wherein the flange and the substantially flat plate intersect in a curve. The method may also include forming at least a first elongated slot proximal to the right edge of the mounting platform and forming at least a second elongated slot proximal to the right edge of the mounting platform, where each of the at least one first and second elongated slots are of a sufficient length to allow the mounting platform to be secured to a ceiling support member and to allow placement of the integral cutting guide between the ceiling support member and a second ceiling support member wherein the span between the ceiling support member and the second ceiling support member up to about 24 inches. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  shows one embodiment of a mounting platform according to the present invention; 
           [0014]      FIGS. 2 and 2A  show a cross section of one embodiment of the mounting platform in  FIG. 1 ; and 
           [0015]      FIG. 3  shows one embodiment of a mounting platform installed on a ceiling support member according to the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    The present invention is a mounting platform  10  for use in the installation of lighting fixtures that serves both as a location mark for electrical rough-in and as a hole locator for drywall installation. As shown in  FIG. 1 , the mounting platform is preferably rectangular. For purposes of description in this patent, the fours edges of the mounting platform in this embodiment are referred to herein as a top edge  12 , a bottom edge  14 , a left edge  16 , and a right edge  18 . In one embodiment, the mounting platform  10  has a length of 16.5 inches and a width of 8 inches. The mounting platform  10  is also preferably constructed from a single plate of sheet metal. It should be understood, however, that the mounting platform may alternatively be formed in other shapes, have different lengths of widths, and constructed using other materials without departing from the present invention. 
         [0017]    The mounting platform  10  includes an integral cutting guide  20 . In one embodiment, the cutting guide  20  is an aperture in the mounting platform. As most recessed lighting fixtures require a circular hole for installation, the aperture is preferably circular in shape and has a diameter that is chosen based on the size of the lighting fixture to be installed. For example, as shown in  FIG. 1 , the cutting guide may have a diameter of 4.375 inches. Of course, both the size and/or shape of the cutting guide may be changed based on the associated lighting fixture. 
         [0018]    As shown in  FIGS. 2 and 2A , the interior edge of the integral cutting guide  20  is formed as a smooth rolled edge  22  arranged to face opposite the drywall or other ceiling material (after platform installation), thereby allowing the platform  10  to sit flush against the rear side (i.e., the side facing into the plenum) of the ceiling material. In one embodiment shown in  FIG. 2A , the smooth rolled edge  22  is preferably constructed by bending a portion of the interior edge of the integral cutting beyond 90°. Preferably, the bent portion of the interior edge creates a flange  56  that forms approximately a 30° angle between the flange  56  and the bottom surface  58  of the mounting platform. In one embodiment, the distance, in a direction perpendicular to the bottom surface  58 , from the end of the flange  56  to the bottom surface  58  is 0.18 inches and the curved edge formed at the intersection between the flange  56  and the bottom surface  56  preferably has a radius of curvature of approximately 0.03 inches. As a result, the integral cutting guide  20  helps to avoid inaccurate hole cutting when using the mounting platform. 
         [0019]    The mounting platform  10  also includes means for securing the mounting platform to a ceiling support member (or joist). Essentially, the securing means is one or more guides used in combination with one or more mechanical fasteners to properly locate the platform  10  relative to a ceiling support member. The securing means is preferably positioned to address various distances between ceiling support members. For example, in one embodiment, the securing means may be positioned to accommodate spans between ceiling support members up to 24 inches apart. As a result, there are no “dead spots” that could undesirably complicate the installation of a recessed lighting fixture in any typical application. 
         [0020]    Referring back to  FIG. 1 , the securing means may include three elongated slots  24 ,  26 , and  28  positioned proximal to the left side of the mounting platform  10  and three elongated slots  30 ,  32 , and  34  positioned proximal to the right side of the mounting platform. The elongated slots  24 ,  26 ,  28 ,  30 ,  32 , and  34  are each shaped so as to allow a fastener, such as a nail or screw, to be inserted through the slot and into a ceiling support member, thereby securing the platform  10  against the ceiling support member. In one embodiment, each of the elongated slots may each be 3.25 inches in length along longitudinal axis A and approximately 0.20 inches in width. The center elongated slots  26  and  32  on each side may be positioned closer to the interior of the mounting platform than slots  24 ,  28 ,  30 , and  34 , allowing a portion of the center slots  26  and  32  to overlap with the other slots. In one embodiment, elongated slots  24 ,  28 ,  30 , and  34  are formed 1.375 inches from the edge while elongated slots  26  and  32  are formed 2 inches from the edge. 
         [0021]    Although the securing means are depicted as elongated slots proximal to the sides of the platform  10  to properly locate the platform relative to the ceiling support members, the number of slots and the shape of the slots may be changed as long as the mounting platform provides a way for a user to secure the platform to various widths of ceiling support members. For example, the mounting platform may include only a single elongated slot proximal to each of the left and right edges or more than three elongated slots. Alternatively, the mounting platform may also include numerous holes, rather than slots, positioned at various locations along each side of the mounting platform. In another alternative, the securing means may include markings on the platform rather than apertures to indicate desired placement for the one or more fasteners. These markings may also be simple ink markings or dimples embossed in the platform or a combination thereof. 
         [0022]    In order to simplify installation, the mounting platform  10  may also include four slits  36 ,  38 ,  40 , and  42  located near the cutting guide  20 . The four slits are preferably located at 0°, 90°, 180°, &amp; 270° (where 0° is defined as the portion of the cutting guide closest to the top edge of the mounting platform) around the cutting guide. Each slit preferably begins just outside the radius of the cutting guide and extends radially away from the center of the cutting guide. 
         [0023]    Each slit  36 ,  38 ,  40 , and  42  is preferably shaped so as to provide retention of the end of a typical tape measure. In one embodiment, each slit may be 0.825 inches in length and 0.04 inches in width. Accordingly, the four slits  36 ,  38 ,  40  and  42  allow for an accurate center-to-center measurement between various mounting platforms to be obtained without an additional person holding the tape measure in place. 
         [0024]    As shown in  FIG. 1 , the mounting platform  10  may also include four notches  44 ,  46 ,  48 , and  50 , each positioned along one of the four sides of the mounting platform  12 ,  14 ,  16 , and  18 , respectively. The notches  44 ,  46 ,  48 , and  50  are preferably triangular in shape, with the center of each of the notch being aligned with the center of the integral cutting guide  20 . In one embodiment, each triangular notch is approximately 0.376 inches in width and extends approximately 0.188 inches in depth from the edge of the mounting platform. During installation, the notches may be used to keep multiple mounting platforms in-line with each other by using a string, chalk line, laser or other similar measuring devices for alignment. Although the notches are shown as being triangular, they may be also be of any other shape that provide aid in alignment. 
         [0025]    As shown in  FIG. 1 , the mounting platform also preferably includes integral measurement guides  52  and  54  along the left and right sides of the mounting platform. As shown in  FIG. 1 , the integral measurements are preferably in inches. However, the integral measurements may alternatively be in metric denominations or any other unit of measurement, or any combination of different units of measurement. These measurements may be stamped into the platform or printed on the surface of the platform or applied by appliance. 
         [0026]    In the embodiment shown in  FIG. 1 , the integral measurement guides  52  and  54  indicate the distance from the center of the integral cutting guide opening along the longitudinal axis A of the mounting platform  10 . The integral measurement guides facilitate consistent placement of the platform with respect to the ceiling support members, without the need for additional measuring tools or measurements. The integral measurement guides may also be used to aid in determining that the platform is positioned 90° from the joist. Of course, it is understood that while the illustrated mounting platform includes two guides, the mounting platform may also include only a single guide. 
         [0027]    Finally, the mounting platform  10  may also include markings to identify the face of the mounting platform plate that should be directed toward the room for proper orientation during installation. Such markings help to ensure that the mounting plate is installed with the cutting guide  20  in the proper orientation. As shown in  FIG. 1 , these markings  60  may simply be comprised of the words “Room Side” printed or on embossed in the upper surface  62  of the mounting platform. The words “Ceiling Side” may then be printed on the bottom surface of the mounting platform. Of course, the markings may be any other type of designation such as symbols or colors. 
         [0028]    In use, as shown in  FIG. 3 , the mounting platform  10  is preferably installed on a ceiling support member  64  prior to the installation of the ceiling material (not shown). To properly orient the platform  10 , the integral measurement guides and notches are used as described above to help align and position the mounting platform. Fasteners, such as nails or screws, are used to secure the mounting platform  10  to a ceiling support member  64 . Preferably, one fastener is placed in an elongated slot near the right edge of the platform and a second fastener is placed in an elongated slot near the left edge and directly across from the first fastener. 
         [0029]    Preferably, once all the mounting platforms for a given ceiling are secured, the ceiling material is installed. Due to the design of the integral cutting guide  20 , the mounting platform  10  sits flush with the top side of the ceiling material This allows the integral cutting guide to remain in the proper position, which will allow for an optimized opening during installation of the fixture. 
         [0030]    The user then locates the mounting plates and cuts the holes in the ceiling by using the installed mounting plate as the guide for locating and cutting his hole. The smooth shape of the integral cutting edge  20  results in more surface area of the guide in contact with the cutting device, such as a rotary cutting tool. The integral cutting edge  20  is also shaped such that the cutting tool follows the inside of the cutting guide, resulting in a more accurate cut. 
         [0031]    After cutting a hole in the ceiling, the wiring is completed and the recessed lighting fixture is inserted into the hole and secured into place. The lamp and finish trim can then be installed completing the installation. 
         [0032]    While various embodiments of the application have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of this invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalent.