Abstract:
Under-cabinet lighting systems and methods include lighting fixtures are capable of being hidden from view by a decorative molding forming a part of the cabinetry. Such decorative molding also serves the dual purpose of a wiring raceway and a physical support for the lighting fixture. The lighting fixture includes a mounting clip which is especially adapted to be engaged removably with the wiring channel of the molding at a desired location along the length thereof. The mounting clip may be integrally provided with a component of the lighting fixture or may be provided as a separate structure which is removeably attached thereto. At the location of the lighting fixture the wiring may be extended into engagement with knife contacts of the fixture which pierce the insulation of the wiring and establish electrical contact with the bulb. In such a manner, hidden under-cabinet lighting fixtures may be provided which are relatively easy to install as a component part of the cabinetry.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a division of commonly owned copending U.S. application Ser. No. 11/132,435, filed on May 19, 2005 which is hereby incorporated in its entirety by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to under-cabinet lighting systems which provide task lighting to a work surface (e.g., countertops). 
       BACKGROUND AND SUMMARY OF THE INVENTION 
       [0003]    Under-cabinet lighting is a well known and popular option for homeowners to provide task lighting directly onto countertops and like work surfaces. Under-cabinet lighting therefore minimizes shadowing of the task surface (e.g., countertops) that may otherwise occur if only overhead lighting systems were installed. 
         [0004]    The art is replete with various proposals to provide lighting fixtures under cabinetry. For example, U.S. Pat. No. 5,829,864 to Scanlan describes a system having a decorative strip in which holes are provided for receiving lights. U.S. Pat. No. 6,089,884 to Klaus describes a classic track lighting system applied to the underside of the cabinetry in which lighting fixtures are connected to the electrical power by means of an electrically conductive track. U.S. Pat. No. 6,814,462 to Fiene discloses an under-cabinet lighting system wherein the wiring is routed to the fixtures by means of access holes drilled physically through the cabinet side panels. 
         [0005]    While the proposals in the prior art are suitable for their intended purpose, improvements are still needed. For example, it would especially be desirable if under-cabinet lighting fixtures could be provided which are hidden from view by means of a decorative molding forming a part of the cabinetry. It would also be especially desirable if the decorative molding served the dual purpose of a wiring raceway and a physical support means for the lighting fixture. It is therefore towards fulfilling such needs that the present invention is directed. 
         [0006]    Broadly, the present invention relates to under-cabinet lighting systems, kits and methods whereby under-cabinet lighting fixtures are capable of being hidden from view by means of a decorative molding forming a part of the cabinetry. Such decorative molding also serves the dual purpose of a wiring raceway and a physical support means for the lighting fixture. In especially preferred embodiments, the present invention is in the form of lighting systems, kits and methods which permit the tool-less mounting of undercabinet lighting fixtures to a decorative molding forming part of the cabinetry. 
         [0007]    In especially preferred embodiments, the under-counter lighting systems of the present invention comprise an electrically non-conductive decorative molding (e.g., preferably formed of the same material as the cabinetry to which it is attached) and a lighting fixture. The decorative molding has a face that is decorative and a rear side which is provided with a longitudinally extending channel for receiving electrical wiring. The lighting fixture includes clips which are especially adapted to be engaged removably with the channel at a desired location along the length thereof. 
         [0008]    According to one embodiment of the invention, at the location of the lighting fixture, the wiring may be extended into engagement with knife contacts of the fixture which pierce the insulation of the wiring and establish electrical contact with the bulb. In such a manner, hidden under-cabinet lighting fixtures may be provided which are relatively easy to install as a component part of the cabinetry. 
         [0009]    According to another embodiment of the invention, the lighting fixture may include electrical connection terminals for receiving plug terminals of connection wiring. The connection wiring may thus be positioned in the channel of the decorative molding. 
         [0010]    The fixture mounting clips adapted to be engaged removeably with the channel at a desired location along the length thereof may be formed as an integral component of the lighting fixture or may be removeably attached to the lighting fixture. Removable attachment of the mounting clips to the lighting fixture according to the present invention therefore allows a variety of conventional and commercially available lighting fixtures to be adapted for use as under cabinet lighting in association with the decorative molding. 
         [0011]    A removable mounting clip is provided so as to removeably attach a lighting fixture to a wiring channel formed in a rear surface of decorative cabinet molding. According to a particularly preferred embodiment, the mounting clip comprises attachment means for attaching the mounting clip to the lighting fixture, and upper and lower engagement clip fingers projecting rearwardly of said attachment means and adapted to being removeably inserted into the wiring channel of the decorative cabinet molding. 
         [0012]    The attachment means may be in the form of a base member of the lighting fixture wherein the upper and lower engagement clip fingers are integral with the base member or may be provided as a part of a separately removable mounting clip structure. If provided as a separate removable structure, the attachment means most preferably comprises upper and lower fixture mounting arms for removable engagement with the lighting fixture. The terminal ends of the upper and lower fixture mounting arms may include engagement claws adapted to be engaged with the lighting fixture. Such mounting claws preferably define a sloped lower surface to allow the engagement arms to resiliently spread when forced onto the lighting fixture during installation of the mounting clips thereto. In order to facilitate removal of the mounting clip from the lighting fixture, the engagement claw of the lower fixture mounting arm may define a slot to allow insertion of a removal tool. 
         [0013]    According to another aspect of the invention, the mounting clip may be in the form of a one-piece (unitary) structure which comprises a clip wall, wherein the upper and lower engagement clip fingers are integrally joined to the clip wall and project rearwardly therefrom, and wherein the upper and lower fixture mounting arms are integrally joined to the clip wall and project forwardly therefrom. 
         [0014]    These and other aspects and advantages will become more apparent after careful consideration is given to the following detailed description of the preferred exemplary embodiments thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS 
         [0015]    Reference will hereinafter be made to the accompanying drawings, wherein like reference numerals throughout the various FIGURES denote like structural elements, and wherein; 
           [0016]      FIG. 1  is an underneath perspective view of cabinetry on which one preferred embodiment of an under-cabinet lighting system in accordance with the present invention has been installed; 
           [0017]      FIG. 2  is an underneath perspective view showing the lighting fixture depicted in  FIG. 1  coupled operatively to the decorative molding; 
           [0018]      FIG. 3  is an exploded perspective view of one preferred embodiment of a lighting fixture according to the present invention; 
           [0019]      FIG. 4  is a rear perspective view of the lighting fixture according to the present invention depicted in  FIG. 3 ; 
           [0020]      FIGS. 5A and 5B  are each side elevation views showing the manner in which the lighting fixture of  FIG. 3  may be coupled to the decorative molding; 
           [0021]      FIGS. 6A and 6B  show the manner in which the bulb unit associated with the lighting fixture of  FIG. 3  may be electrically connected to a pair of wires; 
           [0022]      FIG. 7  is an underneath perspective view of cabinetry on which another preferred embodiment of an under-cabinet lighting system in accordance with the present invention has been installed; 
           [0023]      FIG. 8  is an enlarged top perspective view of the lighting fixture depicted in  FIG. 7  together with removable mounting clips to attach the fixture to the decorative molding; 
           [0024]      FIG. 9  is an enlarged end elevational view of the lighting fixture and mounting clips depicted in  FIG. 8 ; and 
           [0025]      FIGS. 10 and 11  are respectively rear and front perspective views of a preferred fixture mounting clips of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0026]    A presently preferred embodiment of an under-cabinet lighting system  10  in accordance with the present invention is depicted in accompanying  FIGS. 1 and 2 . In this regard, the lighting system  10  is generally comprised of a lighting fixture  12  and a decorative molding  14  attached to the forward and side edges at the bottom of cabinetry C (see  FIG. 1 ). The cabinetry is, in and of itself, conventional in that it is formed of a suitable cabinetry material (e.g., wood, composite laminates and/or molded plastics materials) with cabinetry doors CD which visibly hide internal storage shelves (not shown). 
         [0027]    The decorative molding  14  is most preferably formed of the same material as the cabinetry C. As shown in  FIG. 1 , the decorative molding  14  has a visible face  14 - 1  that is decorative and a non-decorative rear surface  14 - 2  which is provided with a longitudinally extending channel  16  for receiving electrical wires EW. As will be explained in greater detail below, the lighting fixture  12  is physically attached to the channel  16  and electrically connected to a pair electrical wires EW positioned therewithin. 
         [0028]    The various component parts of the light fixture  10  in accordance with the present invention are depicted more clearly in the exploded view of accompanying  FIG. 3  and the rear perspective view of accompanying  FIG. 4 . As shown, the light fixture  10  includes a base member  20  sized and configured to receive therein a bulb unit  30  which is itself comprised of a bulb base  32 , an electrical contact unit  34  and a standard bulb  36 . The base member  20  and bulb unit  30  are housed within an opaque low profile upper shell  40  and a lower transparent or translucent lens  50 . A metal or metallized reflector  60  is positioned between the upper shell  40  and the bulb unit  30  so as to reflect light from the bulb  36  downwardly through the lens  50 . The upper shell  40  includes a number of elongate vent slots  42  to allow heat generated by operation of the bulb  36  to escape to the ambient environment. 
         [0029]    The base member  20  includes a mounting clip comprised of an elongate upper engagement clip finger  22  and a pair of laterally spaced-apart lower engagement clip fingers  24   a ,  24   b  extending rearwardly therefrom. As is seen in  FIGS. 5A and 5B , the lower engagement clip fingers  24   a ,  24   b  are positioned below the upper engagement clip finger  22  as viewed in side elevation. In addition, the upper engagement clip finger  22  has a cross-sectional profile which is conformably shaped to an upper region of the channel  16 , while the lower engagement clip fingers  24   a ,  24   b  are conformably shaped to a lower region of the channel  16 . Collectively therefore, the upper and lower engagement clip fingers  22 ,  24   a ,  24   b  are capable of being inserted forcibly into the channel  16  so as to couple the lighting fixture  12  to the decorative molding  14 . Moreover, the upper and lower engagement clip fingers  22 ,  24   a ,  24   b  will provide essentially a “three-point” cantilever support for lighting fixture  12  thereby ensuring that it is mounted stably to the molding  14 . 
         [0030]    As depicted in  FIGS. 5A and 5B , the lighting fixture  12  may installed by simply forcibly inserting the upper engagement clip finger  22  and lower engagement fingers  24   a ,  24   b  into the conformably shaped channel  16  formed in the rear surface  14 - 2  of the decorative molding  14 . In this regard, the upper clip finger  22  includes an enlarged head portion  22   a  and a relatively narrow neck portion  22   b  joining the head portion  22   a  integrally to the rear of the base member  20 . The relatively narrow neck portion  22   b  and the plastics material from which it is formed (and preferably the plastics material from which the entirety of the base member  20 , the upper engagement clip finger  22  and the lower clip fingers  24   a ,  24   b , are formed) thereby provides a resilient connection to allow the head portion to be moved slightly during installation as will be discussed in greater detail below. 
         [0031]    The base member  20  also includes an upper recessed shoulder  22   c  extending lengthwise in opposition to the rear surface  14 - 2  of the molding  14 . The recessed shoulder  22   c  thereby is conformably shaped to the rearwardly projecting molding shoulder  14 - 3  formed on the molding  14 . It will also be observed in  FIGS. 5A and 5B  that the upper shell  40  of the fixture  10  is separated from (i.e., is not flush with) the lower surface of the cabinetry C to thereby define a space  43  which allows heat to dissipate during fixture use. 
         [0032]    It will of course be appreciated that, for clarity of presentation, the electrical wires EW are not visible in the channel  16  shown in  FIGS. 5A and 5B . Instead, the manner in which the electrical wires EW are electrically connected to the lighting fixture  12  will be discussed in greater detail below with reference to accompanying  FIGS. 6A and 6B . 
         [0033]    In the preferred embodiment of the engagement clip finger  22  depicted in  FIGS. 4 ,  5 A and  5 B, the head portion  22   a  thereof is triangularly shaped in cross-section so as to conform to the general triangular shape of the upper region of channel  16 . Thus, as the head portion  22   a  is forced into the channel (i.e., in the direction of arrow A 1  in  FIG. 5A ), the sloped surface of the head portion will serve as a cam of sorts to yieldably force the neck portion  22   b  downwardly to an extent whereby the entire head portion may be positioned within the channel  16 . Once positioned within the channel  16 , however, the resilient nature of the integral neck portion  22   b  will cause the head portion  22   a  to return to its normal state whereby it is seated within the conformably shaped upper portion of the channel  16  as shown in  FIG. 5B . Meanwhile, the pair of engagement fingers  24   a ,  24   b  will be positioned in engagement with the lower portion of the channel  16 . 
         [0034]    The exact cross-sectional profile of the channel  16  and the upper engagement clip finger  22  is not critical. Thus, virtually any conceivable cross-sectional profiles thereof may be envisioned which permit secure but removable mating of the upper engagement clip finger  22  within the channel  16  so as to positionally mount the lighting fixture  12  to the decorative molding  14 . Thus, the cross-sectional profiles of the channel  16  and engagement clip finger  22  may be embodied in uniform or nonuniform convexly curved profiles, L-shaped profiles, C-shaped profiles and the like, to name just a few. It will therefore be realized that the generally triangular cross-sectional profile of the channel  16  and engagement clip finger  22  as depicted in the accompanying drawings represent a presently preferred embodiment of the invention which is non-limiting with respect thereto. 
         [0035]    The manner in which electrical connection is established with the lighting fixture  12  of the present invention will be further understood by reference to  FIGS. 6A and 6B . It will be appreciated in this regard that the electrical wires EW will be routed in the channel  16  from a main source of electrical energy (not shown), such as a transformer, junction box, and/or electrical distribution panel, as may be required by the particular installation. At each location where it is desired to install a lighting fixture  12  in accordance with the present invention, the electrician will form a generally U-shaped wiring loop  70  which will allow the electrical wires EW to enter the base member  22  via wiring access openings  26   a ,  26   b  (see  FIG. 4 ). 
         [0036]    It will be appreciated that forming the wiring loop  70  will create a lengthwise portion of the wiring channel  16  in which the electrical wires EW are not present. Moreover, it will be appreciated that such lengthwise portion is immediately adjacent the rear of the base member  20  at a desired installation location along the rear side  14 - 2  of the decorative molding  14 . Thus, the electrical wires EW of the loop  70  will enter the base member  20  through the wiring access openings  26   a ,  26   b  laterally adjacent the terminal ends of the engagement clip finger  22 . In such a manner, the electrical wires EW will not present an impediment to the engagement clip finger  22  being forced into engagement with the wiring channel  16  as described previously. 
         [0037]    The electrical contact unit  34  includes a pair of knife contacts  34 - 1 ,  34 - 2  which are electrically connected to the bulb  36  via lead wires  34 - 3 ,  34 - 4 , respectively, when it is operatively inserted into the unit  34 . As can be seen from  FIGS. 6A and 6B , a portion of the wiring loop  70  may be forced downwardly into a wire cradle  34 - 5  of the contact unit  34  so as to cause the knife contacts  34 - 1 ,  34 - 2  to pierce through the electrical insulation coating of the electrical wires EW and make contact with the electrically conductive wire thereof. In such a manner, electrical communication is established with the bulb  36  so it can be illuminated when the electrical wiring is energized (e.g., by means of a switch, not shown). 
         [0038]    The systems of the present invention may take many forms. For example, according to one embodiment of the invention, a kit may be provided comprised of the lighting fixture  10  and the decorative molding  14  matching the cabinetry purchased by the consumer. Alternatively, the cabinetry C itself may be provided as part of the system kit along with the lighting fixture  10  and the molding  14 . The molding  14  may be sold in nominal lengths for the contractor to cut on site, or may be in pre-cut lengths with appropriately mitered corners for the contractor to install onto the bottom edges of the cabinetry once the latter has been mounted. Thereafter, an electrician may route the electrical wiring  14  in the channel  16  and will provide a number of wiring loops  70  corresponding to the location along the length of the molding  14  where installation of fixture  10  is desired. 
         [0039]    With the upper shell  40  removed from the base member  20 , the electrician will thus place the wiring loop  70  within the wiring access openings  26   a ,  26   b  of the base member  20  and position the wires in the wiring cradle  34 - 5  of the contact unit  34  as described above so the electrical wires EW make electrical contact with the knife contacts  34 - 1 ,  34 - 2 . Thereafter, the upper shell  40  may simply be snapped into engagement with the base member  20 . The entire fixture  10  now electrically connected to the electrical wiring EW may thus be mounted to the molding  14  by forcibly inserting the engagement clip finger  22  and engagement fingers  24   a ,  24   b  as described previously. 
         [0040]    Another preferred embodiment of an under-cabinet lighting system  100  in accordance with the present invention is depicted in accompanying  FIGS. 7-9 . In this regard, the lighting system  100  is generally comprised of a lighting fixture  112  in combination with the decorative molding  14  which was described previously as being attached to the forward and side edges at the bottom of cabinetry C. In this regard, the lighting fixture  112  is depicted as being of a type having an elongate transparent or translucent lens  112 - 1  which covers a conventional fluorescent tube lamp (not shown), and a generally rectangular base  112 - 2  which houses the fixture&#39;s circuitry. Electrical plugs  116  are attached to respective receptacles  112 - 3  of the fixture so as to supply electrical energy thereto via wires  117  and to allow the fixture  112  to be interconnected in series with other similar fixtures. A pair of fixture mounting clips  114  is removeably attached to the base  112 - 2  so as to mount the fixture  112  to the rear surface  14 - 2  of the decorative molding  14  in a manner to be described further below. 
         [0041]    As is perhaps best shown in  FIG. 9 , the mounting clips  114  according to the present invention include rearwardly projecting upper and lower clip fingers  120 ,  122  and forwarding projecting fixture mounting arms  124 ,  126  each attached to a clip wall  128 . The clip fingers  120 ,  122  are vertically separated from one another by a distance essentially corresponding to the widthwise vertical dimension of the channel  16  formed in the decorative molding  14 . The fixture mounting arms  124 ,  126  are similarly vertically separated from one another by a dimension to allow the base  112 - 2  of the fixture  112  to be received therebetween. 
         [0042]    The upper clip finger  120  includes an enlarged generally triangular head portion  120 - 1  which is conformably shaped to an upper region of the cross-sectional profile of the channel  16 . As discussed previously, however, the enlarged head portion  120 - 1  may take virtually any geometric shape in conformance to the particular cross-sectional profile that may be selected for the channel  16 . The lower clip finger  122  on the other hand is conformably shaped to a lower region of the channel  16 . Collectively therefore, the upper and lower clip fingers  120 ,  122  are capable of being inserted forcibly into the channel  16  so as to couple the lighting fixture  112  to the decorative molding  14 . Moreover, the upper and lower clip fingers  120 ,  122  and the clip wail  128  will provide essentially a “three-point” cantilever support for lighting fixture  112  thereby ensuring that it is mounted stably to the molding  14 . That is, the fingers  120 ,  122  will each engage respective upper and lower regions of the channel  16  while the clip wall  128  will bear against the rear surface  14 - 2  of the decorative molding  14 . 
         [0043]    The fixture mounting arms  124 ,  126  each terminate in an engagement claw  124 - 1 ,  126 - 1  adapted to engage with upper and lower raised shoulders  112 - 2   a ,  112 - 2   b , respectively of the fixture base  112 - 2 . In addition, the engagement claws  124 - 1 ,  126 - 1  each include a sloped lower surface  124 - 2 ,  126 - 2  which serves as a cam of sorts to allow the arms  124 ,  126  to spread slightly when forced onto the base  112 - 2  of the fixture  112  during installation of the mounting clips  114  thereto (i.e., when forced in a direction of arrow A 1  in  FIG. 9 ). The resilient nature of the mounting arms  124 ,  126  will therefore allow them to return to a normal condition once the base  112 - 2  of the fixture  112  has been received therebetween so that the claws  124 - 1  and  126 - 1  thereof engage with the shoulders  112 - a  and  112 - 2   b , respectively. 
         [0044]    As is particularly shown in  FIGS. 10-11 , the preferred mounting clip  114  is most preferably a unitary (one-piece) structure molded from a resilient plastics material. In this regard, a number of raised ribs  130  may be provided so as to structurally strengthen the clip fingers  120  and/or  122  (it being understood that only the ribs  130  associated with finger  122  are visible in  FIG. 10 ). In addition, a recessed window  132  is formed in the claw  126 - 1  of the lower mounting arm  126  so as to allow a tool (e.g., a flat-bladed screw driver) to be inserted to assist in spreading the mounting arm  126  and thereby permit the fixture  112  to be removed from the clip  114 . An integrally molded raised stop surface  132 - 1  is provided so as to prevent over-insertion of the tool in the window  132 . 
         [0045]    While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.