Abstract:
Apparatus and method for joining and aligning fixture modules in an end-to-end relationship, utilizing paired interlocking connectors. The apparatus and method are particularly suited for connecting fluorescent light modules which are suspended from a wall or ceiling, with minimal end-to-end distance between the ends of the fluorescent light tubes in adjacent modules. The connectors are placed at the ends of the modules, with a body portion of each connector adjacent a module end. Tapered tabs, joined to at least one body portion of each pair of connectors, are insertable through tapered openings in the body portion of the other connector in the pair to connect the two modules to each other. The tabs and openings are adapted for interconnection in at least two positions, including a first position for supporting an end of one of the modules while the module is hung and while electrical connections are made between the modules, and a second position where the tabs are fully inserted through the body portion of the adjacent connector to interlock the connectors. The tapered sides of the tabs and the openings aid in aligning the modules as the tabs are inserted through the openings. Each connector may be constructed from a single piece of a suitable material.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to the field of modular fixtures for architectural applications, and in particular to connectors for connecting a series of modules to form an elongated fixture. The invention is particularly useful for assembling elongated light fixtures such as are used in suspended, indirect lighting applications.  
         BACKGROUND OF THE INVENTION  
         [0002]    There are a number of architectural settings in which arrays of interconnected modular fixtures are installed. For example, arrays of modular light fixtures can be suspended from a ceiling or otherwise supported, such as by mounting on a wall, in a linear, circular, polygonal, or other geometric array. However, installation of such arrays generally requires that the individual modules of the fixture be physically connected to each other in a precise alignment, both to ensure structural stability of the array and to create an esthetically pleasing appearance.  
           [0003]    Installation and alignment of many existing types of suspended arrays require considerable time and labor to ensure proper and precise three-dimensional alignment. In particular, it is typically necessary to support both ends of an initial module while it is being suspended from a wall or ceiling or other support structure, and also while it is being physically connected to an adjacent module. In this regard, one worker typically holds the initial module while another worker attaches hangers at each end of the module. For subsequent modules, the modules are attached by a hanger at one end and to a previously hung module at the other end. For example, one worker may hold the module while another worker attaches the hanger. While the first worker continues to hold the unsupported end, the other worker can then carefully align the module with the previously hung module and use fasteners or the like to interconnect the modules. Installation procedures may be even more complex and time-consuming when additional parts must be positioned within or between fixtures. In the case of light fixtures and other electrical fixtures, for example, it is also necessary to make electrical connections between the fixtures. These operations may have to be conducted in physically cramped and awkward work spaces, where it is difficult to position mechanical parts. It will thus be appreciated installation and alignment is generally time-consuming, labor intensive and expensive.  
           [0004]    In some settings, it is desirable to have arrays of modular fixtures for fluorescent light tubes in which the tubes can be mounted in a manner which minimizes the distance between the ends of tubes in adjacent fixtures to provide a pleasing appearance, more uniform illumination, and/or efficient use of available space for mounting fixtures. For example, fluorescent bulbs are typically available in predetermined lengths, for example, four feet. A designer or client may desire to provide a fixture having a cumulative length of sixteen feet. If such a fixture was assembled using four modules with conventional fixtures having connectors between modules that occupy, perhaps, two or more inches, the resulting fixture could be half a foot or more larger than the desired length. Additionally, at each connection, a dark spot will appear, thereby damaging the illusion of a continuous, customized fixture. It is therefore desirable to minimize the length of connections. However, decreasing the space between the modules and, consequently, the ends of the bulbs, can result in decreased working space for making mechanical and electrical connections between the modules.  
         SUMMARY OF THE INVENTION  
         [0005]    It is an object of the present invention to provide a system and method which allow connection and alignment of modules into fixtures with reduced labor requirements.  
           [0006]    It is another object of the present invention to provide a system and method for connecting fluorescent light modules end to end in fixtures with decreased space between the ends of the fluorescent tubes in adjacent modules.  
           [0007]    It is yet another object of the present invention to provide a connector and a method for installing modules rapidly and easily in precise three-dimensional alignment.  
           [0008]    It is still another object of the present invention to provide a mechanism which supports the fixtures and free both hands of a worker to make electrical connections.  
           [0009]    It is a further object of the present invention to provide a connector and a method for connecting modules utilizing fewer parts and that is less labor intensive than conventional installations.  
           [0010]    It is still a further object of the present invention to provide a connector for modular fixtures which can be easily and inexpensively manufactured from readily available and inexpensive materials, and a method for manufacturing such a connector.  
           [0011]    These and other objectives are addressed by the connector system of the present invention.  
           [0012]    The present invention is directed to connecting and aligning modules of modular fixtures, which may be suspended in an abutted end-to-end configuration from above or from a vertical wall. The present invention simplifies installation of fixtures, with decreased labor requirements relative to previous installation methods. In accordance with the present invention, connectors are mountable to fixtures, preferably substantially inside of and at the ends of the fixture modules.  
           [0013]    The fixtures may be electrical fixtures, and more particularly, they may be fluorescent light fixtures. In this regard, connectors are adapted and mountable to the fixtures in a manner that allows fluorescent light tubes in adjacent modules to be aligned end-to-end, with minimal space between the tubes. In addition to using the available space more efficiently for mounting the fixtures, this arrangement of the light tubes eliminates dark spots which detract from the appearance of the fixture array and could decrease the uniformity of the illumination of the space in which the fixtures are mounted.  
           [0014]    In accordance with the present invention, when modules are installed in an end-to-end configuration with the end of one module adjacent the end of another module, the connectors at those ends interlock with each other so as to cause the fixtures to be aligned with each other. To achieve this interlocking and self-aligning relationship, at least one of each pair of connectors (e.g., mating connectors of adjacent modules) includes at least one tab member, and at least the other of the two paired connectors includes at least one opening, preferably with a wide central portion and tapered sides. Each tab member also preferably tapers from a wide portion adjacent a joint between the tab member and a body portion of the connector to a narrower portion which is distal from the joint, and each tab member can be positioned to extend outward from the end of the module to which it is mounted. Preferably, the tab member(s) is deployable from a first position where the tab member is flush with the body portion (e.g., for shipping and handling) and a second position where it extends from the body portion for engaging the connector of an adjacent module.  
           [0015]    The tab member(s) and the opening(s) are sized and positioned such that an extended tab member of one connector can be inserted through an opening of another connector to engage the connectors in at least two interlocking positions. In one interlocking position, the two connectors are close enough to each other to allow a worker to access the ends of both fixtures easily during installation of the fixtures, such as for making electrical connections, and provide adequate work space for moving the connected wires to a position where they will be invisible when installation is complete. Additionally, in this first interlocking position, one end of a module being installed can be supported by a previously hung module while the other end is suspended, thereby simplifying installation and reducing labor requirements. To facilitate engagement of the tab with the opening in the first position, the tab member may terminate in a hook distal from the joint between the tab and the body portion of the connector to which it is joined.  
           [0016]    In the second position, the connectors are engaged such that the ends of the two fixtures abut each other, and the electrical wires are inside the fixtures and hidden from view. In a preferred embodiment, the tab member and the opening are sized and positioned such that the tapered sides of the tab member engage the tapered sides of the opening into which the tab is inserted as the two connectors are moved toward each other from the first position to the second position, and the wider portion of the tab member adjacent the joint is simultaneously and progressively guided to the widest portion of the corresponding tapered opening. The tabs and openings are also positioned such that, when connectors are in the second position, the fixtures to which the connectors are mounted are also aligned with each other. The connections between modules are thus self-aligning, as well as convenient to use and compact.  
           [0017]    Preferably, each connector associated with each module end includes both a tab and an opening. More preferably, the connectors are identical, and the openings and tabs are positioned such that any two of the connectors can be paired, with one connector rotated 180 degrees relative to the other such that each tab member corresponds with an opening in the other connector in the pair. That is, the connectors are preferably of identical construction and are capable of mating engagement when arranged in mirror-image pairs. In this manner, construction is simplified and it is unnecessary to arrange modules in male-female series for assembly.  
           [0018]    One aspect of the present invention involves a self-aligning engagement structure. The structure includes a body portion having at least one opening sized and shaped to accommodate a tapered tab connector from a connector on an adjacent fixture. The body portion may also include a tapered tab connector, as described above, joined to the body portion at a joint. Preferably, the wide portion of the opening and the joint between the tab member and the body portion located on opposite sides of a centerline of the assembled fixture. If the engagement structure is used for connecting light fixtures, the body portion preferably is adapted for enclosing electrical wires running between fixtures and for passing a power line into a module to which the connector is mounted. The body portion may also be adapted for supporting the fixture, such as by suspension from above or from a wall. The tab member preferably terminates in a hook for engaging an opening of an adjacent connector.  
           [0019]    Another aspect of the present invention involves a method for making interlocking connectors for interconnecting modules of a modular fixture. The method includes the steps of providing a workpiece such as a flat sheet of metal, dimensioning the workpiece so as to allow the workpiece to be mounted to an end of one of the modules, bending the workpiece to form an end wall and a support section on opposite sides of a bend, and forming a tab connector on the end wall. The end wall may also include a tapered opening for receiving a tab connector of an adjacent module. The steps of dimensioning the workpiece and forming the tab connector involve, for example, cutting the workpiece such as by laser cutting or high precision punching. In the case where the fixture is a fluorescent light fixture, the method may further involve the steps of forming a support contour in the support section for engaging an end portion of a fluorescent light tube and forming a pass-through in the end wall and/or support section for passing electrical wires between adjacent modules. A separate or integral hanger attachment may be provided in connection with the interlocking connector for use in hanging the fixture. By virtue of such construction, the connector can be formed in large part from a single workpiece, thereby simplifying construction and reducing costs.  
           [0020]    In yet another aspect, the present invention comprises a system for connecting and aligning fixture modules in an end-to-end relationship. In the system, there are at least two modules, each having a first end and a second end, and two connectors. The first connector includes a first body portion adapted for mounting at the first end of a first module and at least one tab member adapted for extension from the body portion beyond the first end of a module to which it is mounted. The second connector includes a second body portion adapted for mounting at the second end of the second module, with at least one tapered opening positioned to receive an extended tab member of the first connector. When the connectors are mounted to modules and interlocked with each other, the modules are forced into an aligned, butting relationship. The connectors may also be adapted to accommodate fasteners, such as screws or bolts, for securing adjacent connectors to each other to provide structural integrity for the fixture array.  
           [0021]    According to a still further aspect of the present invention, a method is provided for installing modules to form a fixture. The method includes the steps of: providing first and second modules, the first module having a tab connector on an end thereof and the second connector having an opening on an end thereof; connecting one of the modules to a support structure; inserting the tab connector of the first module into the opening of the second module to engage the modules in a first interlocking position where relative longitudinal motion between the modules is constrained (e.g., the modules resist moving apart); with the modules engaged in the first position, connecting the other of the modules to a support structure and/or running electrical wires between the modules; and progressively receiving the tab within the opening such that the modules are engaged in a second position wherein the modules are in an aligned abutting relationship. This two position process allows the modules to be preliminarily engaged for support, for example, while one of the modules is being hung or electrical connections are being made, thereby reducing the complexity or labor requirements of installation, and allows for simple alignment of the modules. 
       
    
    
     DESCRIPTION OF THE DRAWINGS  
       [0022]    The present invention can be understood with reference to the following drawings, wherein:  
         [0023]    [0023]FIG. 1 is a perspective view of a linear modular light fixture suspended from a ceiling by sections of flexible cable, with the modules connected in accordance with the present invention;  
         [0024]    [0024]FIG. 2 is a perspective view of a connector in accordance with one embodiment of the present invention;  
         [0025]    [0025]FIG. 3 is a plan view of a piece of sheet metal having cut edges and openings, suitable for making the embodiment shown in FIG. 2;  
         [0026]    [0026]FIG. 4 is a perspective view showing a connector of the present invention which has been inserted into the end of a module;  
         [0027]    [0027]FIG. 5( a ) is a perspective view from below showing one module which has been suspended in position with a connector according to the present invention mounted at the end of the module and showing an adjacent module, prior to connection with the first module, with a second connector according to the present invention mounted at the end adjacent the first module;  
         [0028]    [0028]FIG. 5( b ) is a partial cutaway side view of the modules shown in FIG. 5( a ), with connector tabs of the adjacent connectors engaged in accordance with the present invention;  
         [0029]    [0029]FIG. 5( c ) is a top perspective view of the modules shown in FIGS.  5 ( a ) and  5 ( b ), with the modules aligned and connected to each other in accordance with the present invention;  
         [0030]    [0030]FIG. 6( a ) is a perspective view of connector in accordance with another embodiment of the present invention; and  
         [0031]    [0031]FIG. 6( b ) is a perspective view of another connector in accordance with yet another embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0032]    The present invention relates to supported modular fixtures for use in architectural applications. These fixtures may be supported in any manner known to those skilled in the art, including suspension from above or from the side. In accordance with the present invention, the fixture modules  10  and  12  may be light fixture modules in a linear array, as shown in FIG. 1. Although only two modules  10  and  12  are shown in FIG. 1, any number of modules may be connected end-to-end, depending on the needs for a particular architectural setting. Alternatively, two or more modules may be arrayed in any geometric relationship. However, the preferred modules of the present invention are in physical contact with adjacent modules, with the modules mechanically connected to and aligned with each other, such that the outer surfaces present a substantially continuous appearance.  
         [0033]    Any suspension device known in the art may be utilized. Preferred suspension devices include aircraft cable  14 , as shown in FIG. 1, and rigid stems. Although not shown, one or more electrical cables may be used to provide power to modules  10  and  12 , and the cable or cables wires may be incorporated into one or more of the support devices  14 . For simplicity, the following discussion describes modules which are suspended from above, such as from a ceiling or other structural element. However, other means of support may be utilized, such as support from below on pedestals or from the side.  
         [0034]    In accordance with one embodiment of the present invention, modules are joined by connectors, one of which is shown generally as  100  in FIG. 2. Connector  100  has a substantially planar wall member  102 , a substantially planar fixture support member  104 , and a substantially planar light tube support member  106 . Fixture support member  104  is joined to wall member  102  and fixture support member  104  such that wall member  106  and fixture support member  104  are maintained in a substantially parallel relationship to each other and perpendicular to fixture support member  104 . Outer edges  108 ,  110 , and  112  of light tube support member  104  and wall member  106  are contoured for friction fitting inside a module, such as module  10  or  12  in FIG. 1.  
         [0035]    Tab member  114  is attached to wall member  102  at joint  116 . Although shown as substantially coplanar with wall member  102 , tab member  114  can be extended substantially perpendicularly from wall member  102  in a direction away from fixture support member  104  and light tube support member  106 . In this manner, the tab member  114  can be maintained flush with the wall member  102  for convenient shipping and handling and then deployed to an extended position (e.g., by hand or using a screwdriver or other tool) for engaging a connector of an adjacent module. Tab member  114  is widest adjacent joint  116  and wall member  102  and tapers to a smaller width distal from the joint. Preferably, tab member  114  terminates in a hooked end  115 . It will be appreciated that the axis of the joint  116  must be carefully positioned to provide proper alignment of the connected module.  
         [0036]    Connector  100  is also adapted to accommodate several types of hardware which may be necessary for proper functioning of the fixtures. Openings  118  and  120  accommodate wiring for receptacles for the ends of fluorescent light tubes. These receptacles may be of a type well known in the art for supporting and making electrical contact with metal prongs at the ends fluorescent light tubes. An insert may be fitted into opening  122  for securing connector  100  to the end of a cable, stem, or other suspension device.  
         [0037]    Opening  124  in wall member  102  is adapted for insertion therethrough of a tab member  114  of an adjacent connector, as will be discussed below. In this regard, opening  124  has a section  126  with dimensions closely matched to the dimensions of the widest portion of tab member  114 . Section  126  and joint  116  are located on opposite sides of a center (generally indicated by line  127 ) and, more preferably, are positioned symmetrically with respect to the center of wall member  102 , for reasons which will become apparent below. The size of opening  124  decreases with increasing distance from section  126 . Opening  128  aids in attachment of a hanging device, such as  14 . Opening  130  is adapted to accommodate electrical wires and cables. Openings  132 , 134 ,  136 ,  138 , and  140  are sized and positioned to accommodate fasteners, such as screws or bolts.  
         [0038]    In a preferred embodiment, connectors, such as  100 , can be manufactured from sheet metal, as shown in FIG. 3. A flat work piece  200  is cut from the sheet metal, with edges  108 ,  110 , and  112  shaped and sized for fitting into fixture  10  or  12 . The outline of tab member  114  and joint  116  between tab member  114  and wall member  102  are defined by cutting openings  142 ,  144 , and  146 . Opening  124  is cut to accommodate a tab from another connector. Openings  118  and  120  are cut into piece  200 , with shapes appropriate for the wiring of particular light tube receptacles to be used with the fixture.  
         [0039]    Openings  130  and  148  are cut to accommodate electrical cables and wires which may be need to connect modules. As shown, opening  148  defines the outline of a removable plug  150  which is attached to the fixture support member  104  at joint  152 . Plug  150  may be easily removed subsequently, if necessary, by bending plug  150  back and forth or otherwise severing the connection at joint  152 . Screw holes  132  and  140  are cut at appropriate locations for subsequent use in attaching the connector  100  to another connector, as described below.  
         [0040]    The openings, edges, and other features of work piece  200  may be cut in any order or simultaneously, by any means known in the art. Preferably, a laser cutting device or high precision punching device is utilized to enhance the precision and accuracy of the cutting process and thus the fit between the connector and module housing, as well as the resulting alignment of the modules. After cutting is complete, manufacturing of connector  100  is completed by bending piece  200  along lines A-A and B-B so that wall member  102 , fixture support member  104 , and light tube support member  106  are arranged as shown in FIG. 3.  
         [0041]    As shown in FIG. 4, connector  100  is then inserted into a module, such as module  12 , with wall member  102  aligned with the end  202  of module  12 . Connector  100  may be secured in position in module  12  by any suitable method, such as by friction fitting, welding, or attachment to a support/positioning device within module  12 . Tab member  114  may be left as cut, temporarily. However, it should be noted that, prior to connecting module  10  to module  12 , tab  114  is bent away from wall member  102  to obtain the orientation shown in FIG. 2. Receptacles for the ends of light tubes and wiring are also installed, using the openings described above with reference to FIGS. 2 and 3. For simplicity, the modules in FIGS. 4 and 5 are shown without fluorescent light tubes and without receptacles for mounting the tubes.  
         [0042]    The first module of a fixture is generally hung at both ends thereof. Thereafter, the connector of the present invention allows modules to be hung with a single support device at each connection between modules, as illustrated in FIGS. 2 and 5. In FIG. 5( a ), a first module  10  has been suspended in position, with a threaded insert  302  mounted in opening  122 , and hanger  14  supporting the end where a first connector  100   a  has been installed. The other end of module  10  is supported in a similar manner by another hanger  14  as shown in FIG. 2. The end of second module  12  which is adjacent module  10  and connector  100   a,  has been fitted with a second connector  100   b.  Each of modules  10  and  12  has been prewired with wires for providing electricity to illuminate fluorescent tubes which can be installed in the modules. Wire ends  304  have been left loose and hang from connectors  100   a  and  100   b.  Tabs  114   a  and  114   b  have been bent outward away from their respective modules  10  and  12 . Tab  114   a  is approximately lined up with opening  124   b,  and tab  114   b  is approximately lined up with opening  124   a.    
         [0043]    Referring now to FIGS.  5 ( a ) and  5 ( b ), installation of second module  12  is continued by moving the modules toward each other as indicated by the dashed arrows in FIG. 5( a ). Hooked end  115   a  of tab  114   a  is inserted into opening  124   b,  and hooked end  115   a  is engaged with wall member  102   b  of connector  12 . Also, hooked end  115   b  of tab  114   b  is inserted into opening  124   a  and engaged with wall member  102   a.  The engaged hooked ends  115   a  and  115   b  support module  12  temporarily and resist pulling apart of the modules, allowing a single worker to use both hands for connection of wire ends  304  and suspension of the other end of module  12 . In this regard, it is noted that, in this position, one of the tabs will rest against an upper end of the associated opening and the other tab will rest against a lower end of the associated opening to resist accidental detachment due to either upwardly directed or downwardly directed jarring forces or vibrations. After wire ends  304  have been connected, they can be pushed upwards into the space  306  defined between fixture support members  104   a  and  104   b,  light tube support members  106   a  and  106   b,  and the adjacent ends of modules  10  and  12 . In this position, the other end of module  12  can be hung by a single worker while the module is supported by the connection with the previously hung module  10 .  
         [0044]    Next, the connectors are moved toward each other until wall members  102   a  and  102   b  are butted against each other. Because wall members  102   a  and  102   b  are aligned with the ends of modules  10  and  12 , respectively, the module ends are also butted against each other, as illustrated in FIG. 5( c ). The tapered sides of tabs  114   a  and  114   b,  in combination with the tapered sides of openings  124   a  and  124   b,  cause the connectors  100   a  and  100   b  and the modules  10  and  12  to progressively line up with each other as the connectors are moved toward each other. Connectors  100   a  and  100   b  are then secured to each other with suitable fasteners, such as bolts  308  extending through openings  132   a  and  140   b,  and through  140   a  and  132   b,  respectively, and secured with nuts  310 .  
         [0045]    It should be noted that the widest portions of the tabs  114   a  and  114   b  and of the openings  124   a  and  124   b  are sized so that each tab fits closely in the widest portion of the corresponding opening, thereby achieving secure attachment and vertical alignment. The joints  116   a  and  116   b  and the openings  124   a  and  124   b  are also positioned on the wall members  102   a  and  102   b  such that insertion of each tab in the corresponding opening on the adjacent connector will align the modules horizontally as desired. In a preferred embodiment, tab  114  and opening  124  (referring to FIGS. 2 and 3) are positioned such that they are symmetrically disposed on opposing sides of the center of wall member  102  such that the connectors can be of identical construction and interlock in an aligned relationship. Further, as illustrated in FIG. 5, connector  100   b  is identical to first connector  100   a,  but rotated 180 degrees (i.e., deployed in mirror image fashion) so that the two wall members  102   a  and  102   b  can be butted against each other. However, the connectors need not be identical, as long as the corresponding joints and openings match up with each to align the attached fixtures.  
         [0046]    It should be appreciated that shape of each connector may be dictated, in part, by the shape of the fixture module in which it is mounted. Further, connectors in accordance with the present invention may have different configurations of tabs and openings. For example, connector  400  in FIG. 6 a  has a tab member  414 , a joint  416 , and an opening  424  for interlocking and alignment with a mating connector. Similarly, in connector  500 , shown in FIG. 6 b,  tab member  514  has been formed to extend into a larger opening  546  from joint  516 . A portion  524  of opening  546  is tapered to receive a tab member from an adjacent connector. It should be noted that each connector may include more than one tab member and/or more than one opening for receiving tab members. However, for proper alignment of the fixtures, the corresponding joints and openings should match up with each other.  
         [0047]    The fixtures illustrated and described herein are fluorescent light fixtures, although the present invention could be used with other types of fixtures. It is contemplated that the illustrated fixtures may be open on top, as shown in FIGS. 4 and 5( c ), or that the fixtures have top covers. Alternatively, the fixtures may be open at the bottom or open at both the top and the bottom. After installation of the illustrated modular fixtures has been completed, fluorescent bulbs can be inserted into the receptacles in the modules.  
         [0048]    It should be noted that the other configurations of portions and members of the connectors are possible. However, it is preferred that the connectors are configured so they are functional to aid in supporting the fixtures to which they are mounted and light tubes used in the fixtures, as well as to provide for interlocking, self-aligning connections between modules. The connectors can be formed from any suitable material. Also, the connectors can be mounted to the modules by any suitable method known in the art.  
         [0049]    While specific embodiments of this invention have been disclosed, it is expected that those skilled in the art can and will design alternate embodiments of this invention that fall within the scope of the appended claims.